Schaeffler SpindleSense User manual

Schaeffler SpindleSense
User manual

Schaeffler Technologies BA 61 1
Page
Contents
About the user manual Symbols ................................................................................... 3
Legal guidelines ....................................................................... 3
General safety guidelines Usage for the intended purpose ................................................ 4
Usage not for the intended purpose .......................................... 4
Ambient conditions................................................................... 4
Electromagnetic compatibility ................................................... 5
Qualified personnel .................................................................. 5
Safety regulations..................................................................... 6
Scope of delivery Damage during transit............................................................... 7
Defects..................................................................................... 7
Description Design...................................................................................... 8
Measurement principle ............................................................. 9
Functional scope ...................................................................... 9
Coordinate system .................................................................... 10
Setup software
Service Setup Tool (SST)
Logging in and user levels......................................................... 11
General settings and alarm status ............................................. 13
Connection to the sensor ring.................................................... 14
Assistants ................................................................................ 15
Data acquisition ....................................................................... 19
Configuration............................................................................ 20
Log ........................................................................................... 26
Transport and storage ................................................................................................ 27
Mounting Demands on the adjacent construction ..................................... 27
Cleanliness............................................................................... 27
Mechanical mounting ............................................................... 28
Connection of the sensor ring.................................................... 31

2 BA 61 Schaeffler Technologies
Page
Contents
Commissioning Connecting the sensor ring to a Windows PC .............................. 32
Installation of the setup software SST ........................................ 32
Selection of the sensor ring ....................................................... 32
Selection of the user level.......................................................... 34
Configuration of the sensor ring ................................................. 34
Operation Permissible indirect process materials....................................... 35
Operating temperature .............................................................. 35
Troubleshooting and
rectification
Essential guidelines .................................................................. 36
Reading out fault information .................................................... 36
Fault correction ......................................................................... 36
Dismounting Mechanical dismounting ........................................................... 37
Cleaning.................................................................................... 37
Decommissioning ................................................................................................. 38
Disposal ................................................................................................. 38
Technical data and
accessories
Interfaces.................................................................................. 39
Voltage supply .......................................................................... 42
Connection cable....................................................................... 43
Approval and tests .................................................................... 44

Schaeffler Technologies BA 61 3
Schaeffler SpindleSense
About the user manual This user manual describes the Schaeffler SpindleSense system.
The associated setup software “Service Setup Tool” (SST) is
described in the following version: 3.45.02972M.
Symbols The warning and hazard symbols are defined in accordance with
ANSI Z535.6–2011.
WARNING
In case of non-compliance, death or serious injury may occur. 
NOTICE
In case of non-compliance, damage or malfunctions in the product or
the adjacent construction may occur.

Legal guidelines The information in this manual reflects the status as of
December 2019.
Unauthorised modifications to or improper use of the device are
not permitted. Schaeffler accepts no liability in these cases.

4 BA 61 Schaeffler Technologies
Schaeffler SpindleSense
General safety guidelines
Usage for
the intended purpose
Schaeffler SpindleSense is intended for installation in machine
tools. The system measures displacements of the shaft relative to
the housing. With appropriate parametrisation, critical machine
conditions can also be detected and overload messages can be
output.
Usage not for
the intended purpose
Any use involving a safety-related application of the measurement
values is excluded. The safety of the machine tool, ambient systems
and of persons must be taken into account.
Application areas in which the use of Schaeffler SpindleSense is
not permitted:
■ explosive environments (ATEX)
■ nuclear power
■ aerospace
■ rail
■ military
■ medical equipment.
Ambient conditions Air pressure:
■ The permissible ambient pressure is 700 hPa up to 1050 hPa.
Temperature:
■ The permissible ambient temperature is 0 °C up to +80 °C.
Protection type in accordance with ISO 20653:
■ The sensor and interface unit are designed in accordance with
the protection type IP65.
Excluded ambient conditions:
■ Magnetically or electrically conductive dusts or particles.

Schaeffler Technologies BA 61 5
Electromagnetic compatibility The connection cable for the sensor ring is shielded. Cable shielding
is already provided on one side of the sensor ring housing in
the delivered condition. There must be no electrically conductive
connection between the cable shielding and the housing of
the customer’s control system. The shielding concept must be
observed,
Figure 19 , page 31.
Extensive tests have been carried out to verify electromagnetic
compatibility (EMC), see table , page 44.
Qualified personnel Schaeffler SpindleSense may only be mounted, commissioned,
operated and maintained by qualified personnel. The scope of
competence, area of responsibility and monitoring of personnel
must be precisely regulated by the site operator.
A person defined as qualified personnel:
■ is authorised to perform mounting of the bearing and
electronic components
■ has all the necessary knowledge
■ is familiar with the safety guidelines
■ has read and understood this manual.
Work on electrical devices Work on electrical devices may only be carried out by a trained
electrician.
An electrician is in a position, on the basis of his technical training,
knowledge and experience as well as his knowledge of the appropri-
ate regulations, to assess the work assigned to him and recognise
possible hazards.

6 BA 61 Schaeffler Technologies
Schaeffler SpindleSense
Safety regulations This section contains important safety regulations relating to work-
ing with Schaeffler SpindleSense. Further guidelines can be found in
the individual chapters of this user manual.
General handling Schaeffler SpindleSense is a sensitive measuring system.
Shocks and compressive loads can damage the components,
render the system unusable or result in erroneous output values.
Shocks, such as those that occur due to falling, and other
impermissible mechanical loads must therefore be avoided.
Magnetisation of the measurement rings may distort the measure-
ment results and should therefore be avoided.
The maximum permissible residual magnetism for the measurement
rings is 2 A/cm.
Conversion Unauthorised modifications to the components of Schaeffler
SpindleSense, including the supplied connection cable, may affect
the safety and function of the system and are not permitted.
Modifications are only permissible in consultation with Schaeffler.
If unauthorised modifications and conversions are carried out or
unauthorised components are used, Schaeffler cannot accept any
liability for the resulting negative consequences.
Safe handling of
information interfaces
This product has the following information interfaces:
■ CAN bus
■ USB interface via CAN-USB adapter
■ digital alarm and error output
■ speed signal input (HTL-compatible).
The product can be connected to other devices, components and
internal or external networks (for example the Internet) via any
information interface. Devices connected via information interfaces
(for example data carriers) may contain malware or perform
detrimental functions undetected. The use of such information
interfaces may damage this product or your company infrastructure
(for example the IT infrastructure). In addition, the data security of
your company may be impaired.
Before using our product and its information interfaces,
familiarise yourself with:
■ the safety precautions offered by the product and
its information interfaces
■ the security specifications of your company
(for example in relation to IT security).
Before commissioning, clarify with your responsible contact person
whether and which safety precautions must be taken when using
the product and its information interfaces.

Schaeffler Technologies BA 61 7
Scope of delivery The scope of delivery of Schaeffler SpindleSense includes:
■ sensor unit, comprising sensor ring with connection cable and
provisional plug, radial measurement ring and
axial measurement ring
■ safety guidelines.
The enclosed safety guidelines include the following link to this user
manual (BA 61), which is always available in its current version:
https://www.schaeffler.de/std/1F36
Damage during transit Any damage during transit must be reported as a complaint to
the carrier:
 Check the delivery immediately upon arrival for any damage
during transit.
 Report any damage during transit promptly as a complaint to
the carrier.
Defects Any defects must be reported promptly as a complaint:
 Check the product immediately upon delivery for visible defects.
 Report any defects promptly as a complaint to Schaeffler.
 Sensor unit
 Safety guidelines
Figure 1
Scope of delivery
Schaeffler SpindleSense
+120 °C
+248 °F
+120 °C
+248 °F
DC24 V
DC24
В
EMC
ЭMC
https://www.schaeffler.de/std/1F36
SchaefflerTechnologiesAG & Co. KG
Georg-Schäfer-Straße30
97421Schweinfurt· Deutschland
www.schaeffler.de
spindlesense@schaeffler.com
©Schaeffler TechnologiesAG &Co. KG
MATNR095184570-0000/ BA 66 / 0M-0M / 2020031 / Printed in Germany by kraus
1
2
0016667200166672

8 BA 61 Schaeffler Technologies
Schaeffler SpindleSense
Description Schaeffler SpindleSense is a compact measuring system for use in
machine tools. It measures displacements of the shaft relative to
the housing.
When used in combination with FAG spindle bearings, the option of
overload detection is also available. In this case, Schaeffler
Application Engineering must adapt the evaluation algorithm to
the specific application and parameterise the evaluation software,
in order that the design characteristics of the respective machine
tool and spindle can be taken into account. The prompt detection of
an overload on the main spindle can prevent or reduce damage.
Design The sensor unit comprises a sensor ring and both an axial and
a radial measurement ring.
The sensor ring has the following integral components:
■ 3 axially and 3 radially arranged eddy current displacement
sensors
■ evaluation unit (hardware and software)
■ connection cable for data exchange and voltage supply.
Materials
 Sensor unit
Sensor unit components:
 Sensor ring
 Radial measurement ring
 Axial measurement ring
Figure 2
Sensor unit
1
2
3
4
0010AB260010AB26
 Eddy current displacement sensors
 Evaluation unit
 Connection cable
Figure 3
Sensor ring
(image without module support or
potting material)
1
1
1
3
2
0010ABC50010ABC5
Components Material
Sensor ring, measurement rings 100Cr6
Potting material Epoxy resin
Cable sheath for connection cable Polyurethane

Schaeffler Technologies BA 61 9
Measurement principle The displacement sensors measure the axial and radial displace-
ment between the sensor ring fixed in the housing and the
measurement rings located on the shaft with a resolution of approxi-
mately 1
␮ m. The displacements and tilting determined by this
method are output at a frequency of 1 kHz via CAN bus.
With appropriate parametrising, the evaluation unit integrated in
the sensor ring also calculates the load on the bearing. For this pur-
pose, the speed signal of the spindle must also be fed to the sensor
ring. The evaluation unit then identifies critical conditions within
2 ms and sends these to the machine controller via the CAN bus and
digital signal output.
The displacement is caused by axial loading, radial loading, tilting
and temperature. These influences must be taken into consideration
in the interpretation of the measurement results.
To ensure the displacement measurement is interpreted correctly,
it is essential that Schaeffler carry out a comprehensive analysis of
the application.
Functional scope Schaeffler SpindleSense is supplied as standard in a basic version
with displacement measurement (functional scope: C-A1).
When used in combination with FAG spindle bearings, the function
can be expanded to detect overloading of the spindle bearings.
This requires an application-specific configuration of the sensor ring
by Schaeffler.
Functional scope
 Housing
 Shaft
 Bearing
 Sensor ring
 Axial measurement ring
 Radial measurement ring
Figure 4
Displacement measurement
1
2
3 3 4
5
6
0016A1090016A109
Designation Description
C-A1 Output for measured displacements (axial and radial) and
tilting via CAN bus
Upgrade Alarm message output, if limiting values for load or
kinematics are exceeded

10 BA 61 Schaeffler Technologies
Schaeffler SpindleSense
Coordinate system A coordinate system is defined for the sensor ring in Schaeffler
SpindleSense.
Characteristics of the coordinate system:
■ right hand
■ origin:
radial and axial in the centre of the sensor ring
■ positive X direction:
from the sensor ring to the axial measurement ring
■ position of the z axis:
indicated by a marking on the sensor ring.
Coordinates in
displacement measurement
Displacements are measured and output in the coordinate system of
the sensor ring,
Figure 5 .
In the case of a displacement measurement, the output displace-
ments must be converted into the coordinate system of the machine
tool, taking account of the installation position of the sensor ring
in the machine tool.
 Sensor ring
 Radial measurement ring
 Axial measurement ring
 Marking: z axis
Figure 5
Coordinate system of
the sensor ring
1
2
3
4
Ry
Rz
x
y
z
001668B1001668B1

Schaeffler Technologies BA 61 11
Setup software
Service Setup Tool (SST)
The setup software “Service Setup Tool” (SST) facilitates extensive
communication between a Windows PC and the sensor ring for
commissioning and service. Schaeffler provides the software for
download, see section
Installation of the setup software SST ,
page 32.
Following setup, Schaeffler SpindleSense will then run in normal
operation without setup software SST.
Logging in and user levels The buttons for logging in and for selecting a user level are located at
the top right of the program window,
Figure 6 .
Logging in and out
Figure 6
Buttons for
logging in and user levels
Spindle manufacturer
0016DCEE0016DCEE
Button Function
[ Spindle Manufacturer ]
(name of the current
user level)
Display and change user level:
■ display current user level
■ the login window for the various user levels is
displayed when the button is clicked.
Log out of the current user level. After clicking
the button, the user is in the highest user level to
which no password is currently assigned.

12 BA 61 Schaeffler Technologies
Schaeffler SpindleSense
User levels There are five user levels for operating the setup software SST.
A user is always logged in to one of these user levels.
The scope of the available program functions and of the read and
write permissions is determined by the user level.
[
Normal User ] User level for machine users.
Permissions:
■ partial read access to parameter setting
■ configure user parameters.
No password entry is effective for this user level.
[
Machine Manufacturer ] User level for manufacturers of machines.
Permissions:
■ partial read access to parameter setting
■ configure machine parameters
■ configure user parameters
■ assign password for modification of machine parameters.
[
Spindle Manufacturer ] User level for manufacturers of spindles.
Permissions:
■ partial read access to parameter setting
■ configure spindle parameters
■ configure machine parameters
■ configure user parameters
■ assign password for modification of spindle parameters and
machine parameters.
[
Service ] Internal Schaeffler user level, contains the permissions required for
service activities.
[
Production ] Internal Schaeffler user level, contains the permissions required for
production and factory configuration.

Schaeffler Technologies BA 61 13
General settings and
alarm status
The button for general settings and the alarm status indicator are
located at the top right of the program window,
Figure 7 .
Menu for general settings and
alarm status
Figure 7
Button for general settings and
alarm status
0016DD0C0016DD0C
Button Function
Opens the menu for general settings:
■ [ Scaling ]:
adjusting the font size
■ [ Language ]:
selection of language for setup software SST
■ [ Record storage location ]:
specification of the storage location for
the recording of measured values
■ [ License ]:
information about the licence
■ [ About ]:
information about the program version and current system.
Symbol Definition
Alarm status:
■ green = no alarm
■ red = alarm.

14 BA 61 Schaeffler Technologies
Schaeffler SpindleSense
Connection to the sensor ring The buttons for the connection to the sensor ring are located at
the top right of the program window,
Figure 8 .
Restart and connection status
Figure 8
Buttons for
connection to the sensor ring
0016DD1B0016DD1B
Button Function
Restart the sensor ring and subsequently update
the connection to the Windows PC.
Connection status between sensor ring and Windows PC:
■ green = connected
■ red = not connected.
The connection can be established or broken by clicking
the relevant button.

Schaeffler Technologies BA 61 15
Assistants The assistants are located under the [ Overview ]tab, Figure 9 .
The scope of the available assistants is determined by the user level.
The assistants are used to quickly configure the sensor ring by
importing parameter sets as well as to facilitate rapid viewing of
product information, set the zero position and update firmware.
Status
of the assistants
The assistants [ Production data ], [ Spindle parameters ], [ Machine
parameters
] and [ User parameters ] are intended for configuration
purposes. A status is displayed for these assistants.
Status
Symbol Definition
All requisite data are available in the sensor ring.
Not all requisite data are available in the sensor ring.
!
Figure 9
Assistants
in the setup software SST
0016DD2A0016DD2A

16 BA 61 Schaeffler Technologies
Schaeffler SpindleSense
[ Production data ] Assistant for reading in sensor calibration data and ring-specific
parameters.
This assistant can only be executed in the user level [ Production ]
and requires special authentication. If the status of the assistant is
not displayed with a green tick, please contact Schaeffler.
[ Spindle parameters ] Assistant for reading in spindle-specific parameters with the aid of
a BLOB file. The BLOB file will be made available to you by Schaeffler.
[
Machine parameters ] Assistant for reading in machine-specific parameters with the aid of
an INI file. If no INI file is available, one can be generated using
the setup software SST under the [ Configuration ] tab, see section
Procedure for configuration , page 34.
[
User parameters ] Assistant for reading in user-specific parameters with the aid of
an INI file. If no INI file is available, one can be generated using
the setup software SST under the [
Configuration ] tab, see section
Procedure for configuration , page 34.
[ Product information ] Display information regarding:
■ firmware of the sensor ring and sensors
■ internal Schaeffler codes
■ hardware version and sensor ring number
■ system temperature
■ active licenses.
[
Zero compensation ] In this assistant, the current measured values can be set as the zero
position. Displacements and loads will always be calculated on
the basis of this zero position.
[ Update firmware ] This assistant opens a window for updating the sensor ring firmware,
Figure 16 , page 25.

Schaeffler Technologies BA 61 17
Executing
the configuration assistants
The configuration assistants allow a new parameter set to be trans-
ferred from a configuration file (BLOB or INI file) to the sensor ring
and saved.
These assistants are executed in four steps. This is illustrated using
the assistant for machine parameters as an example, Figure 10 ,
page 18:
■ Step  :
– Display of the parameters stored in the sensor ring.
■ Step  :
– Loading of a parameter set from a configuration file into
the setup software SST.
■ Step  :
– Comparison of the parameter values stored in the sensor ring
with the new values in the configuration file.
– A parameter value is limited if a default threshold exists for
this parameter and the new value in the configuration file
exceeds this. In such cases, a warning symbol will be displayed
next to the parameter.
■ Step  :
– Depending on the user level, a password can be assigned for
the parameter set. Click on [ Next ] to save the new parameter
set in the sensor ring and complete the process.

18 BA 61 Schaeffler Technologies
Schaeffler SpindleSense
Figure 10
Assistant [ Machine parameters ]
(screenshots)
0016DD660016DD66