Bosch Rexroth IndraDyn L Project Planning Manual
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Bosch Rexroth IndraDyn L Project Planning Manual

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

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Summary of Contents for Bosch Rexroth IndraDyn L

  • Page 1 The Drive & Control Company Rexroth IndraDyn L Ironless Linear Motors MCL Project Planning Manual Edition 05 R911330592...
  • Page 2 © 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.

  • Page 3: Table Of Contents

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG I/193 Rexroth IndraDyn L Ironless Linear Motors MCL Table of Contents Table of Contents Page Rexroth MCL - Product presentation................7 Fields of application ironless linear motors..................... 7 Construction ironless linear motors......................8 Comparison ironless with ferreous linear motors..................8 Power spectrum of MCL motors......................
  • Page 4 II/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Table of Contents Page 4.3.2 Data sheet MCS015.......................... 30 4.3.3 Motor characteristic curve frame size 015..................31 Technical data - frame size MCL020....................32 4.4.1 Data sheet MCP020.......................... 32 4.4.2...
  • Page 5 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG III/193 Rexroth IndraDyn L Ironless Linear Motors MCL Table of Contents 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 Hall unit adapter box SHL03.1......................81 7.2.1...
  • Page 6 IV/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Table of Contents 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...
  • Page 7 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG V/193 Rexroth IndraDyn L Ironless Linear Motors MCL Table of Contents 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............................
  • Page 8 VI/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Table of Contents Page 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...

  • Page 9: Rexroth Mcl - Product Presentation

    ● 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/...

  • Page 10: Construction Ironless Linear Motors

    8/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Rexroth MCL - Product presentation Construction ironless linear motors Ironless linear motors MCL consist of the components primary and secondary part and have an optional Hall unit .

  • Page 11: Power Spectrum Of Mcl Motors

    New solutions due to practice-oriented combination of motor technique with digital intelligent drive controllers with ironless linear direct drive technique are available. The spectrum of ironless linear drive technique of Bosch Rexroth realized drives with feed forces of 10 N up to 3,300 N, acceleration up to 250 m/s²...

  • Page 12: About This Documentation

    Additional documentation To plan the drive-systems with MCL motors, it is possible that you need addi‐ tional documentation referring the used devices. Rexroth provides the com‐ plete product documentation in PDF format in the following Bosch Rexroth media directory: http://www.boschrexroth.com/various/utilities/mediadirectory/index.jsp...

  • Page 13: Standards

    Internet: http://www.din.de/beuth E-Mail:postmaster@beuth.de 1.5.4 Additional components Documentation for external systems which are connected to Bosch Rexroth components are not included in the scope of delivery and must be ordered directly from the corresponding manufacturers. 1.5.5 Your feedback Your experiences are an essential part of the process of improving both the product and the documentation.
  • Page 14 12/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL...

  • Page 15: Important Instructions On Use

    2.1.2 Areas of use and application Coreless linear motors MCL of the IndraDyn L series by Bosch Rexroth are determined to be used as linear servo drive motors. There are drive controllers with different ratings, different DC bus voltages and different interfaces to allow application-specific use of the motors.

  • Page 16: Inappropriate Use

    14/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Important instructions on use Inappropriate use Any use of the motors outside of the fields of application mentioned above or under operating conditions and technical data other than those specified in this documentation is considered to be "inappropriate use".

  • Page 17: Safety Instructions For Electric Drives And Controls

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 15/193 Rexroth IndraDyn L Ironless Linear Motors MCL Safety Instructions for Electric Drives and Controls Safety Instructions for Electric Drives and Controls Definitions of Terms Application Documentation Application documentation comprises the entire documentation used to in‐...

  • Page 18: General Information

    You must follow these safety instructions. ● Bosch Rexroth is not liable for damages resulting from failure to observe the safety instructions. ●...

  • Page 19: Hazards By Improper Use

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 17/193 Rexroth IndraDyn L Ironless Linear Motors MCL Safety Instructions for Electric Drives and Controls gy". If this is not the case, they are excluded. Functional safety is a safe‐ ty concept in which measures of risk reduction for personal safety de‐...

  • Page 20: Instructions With Regard To Specific Dangers

    18/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Safety Instructions for Electric Drives and Controls ● Risk of burns by hot housing surfaces! ● Risk of injury by improper handling! Injury by crushing, shearing, cutting, hitting! ●...

  • Page 21: Protective Extra-Low Voltage As Protection Against Electric Shock

    Protective extra-low voltage is used to allow connecting devices with basic in‐ sulation to extra-low voltage circuits. On components of an electric drive and control system provided by Bosch Rexroth, all connections and terminals with voltages up to 50 volts are PELV ("Protective Extra-Low Voltage") systems.

  • Page 22: Protection Against Dangerous Movements

    If extra-low voltage circuits of devices containing voltages and circuits of more than 50 volts (e.g., the mains connection) are connected to Bosch Rexroth products, the connected extra-low voltage circuits must comply with the requirements for PELV ("Protective Extra-Low Voltage").

  • Page 23: Protection Against Magnetic And Electromagnetic Fields During Operation And Mounting

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 21/193 Rexroth IndraDyn L Ironless Linear Motors MCL Safety Instructions for Electric Drives and Controls ment works. Do not operate the machine if the emergency stopping switch is not working. ● Prevent unintended start-up. Isolate the drive power connection by means of OFF switches/OFF buttons or use a safe starting lockout.

  • Page 24: Protection Against Contact With Hot Parts

    22/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Safety Instructions for Electric Drives and Controls 3.3.5 Protection against contact with hot parts Hot surfaces of components of the electric drive and control system. Risk of burns! ●...

  • Page 25: Protection Against Pressurized Systems

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 23/193 Rexroth IndraDyn L Ironless Linear Motors MCL Safety Instructions for Electric Drives and Controls ● When replacing the battery/batteries, do not damage the electrical parts installed in the devices. ● Only use the battery types specified for the product.
  • Page 26 24/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Safety Instructions for Electric Drives and Controls WARNING In case of non-compliance with this safety instruction, death or serious injury could occur. CAUTION In case of non-compliance with this safety instruction, minor or moderate in‐...

  • Page 27: Technical Data

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 25/193 Rexroth IndraDyn L Ironless Linear Motors MCL Technical data Technical data Explanations about technical data 4.1.1 Introduction All relevant technical motor data as well as the functional principle of this mo‐ tors are given on the following pages in terms of tables and characteristic curves.
  • Page 28 26/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Technical data To avoid damaged winding in standstill operation, limit the cur‐ rent or the operation duration. ① When using the motor in this operating range, observe the notes under chapter 11.8 "Operation at or near motor stand‐...

  • Page 29: Description Of Specified Sizes

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 27/193 Rexroth IndraDyn L Ironless Linear Motors MCL Technical data 4.1.3 Description of specified sizes Maximum force F Maximum feed force of the motor at maximum current I . Unit [N]. Continuous nominal force F Available continuous nominal force of the motor up to v at nominal current .
  • Page 30 28/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Technical data Primary part mass m Mass of primary part Unit [kg]. Secondary part mass m Mass of secondary part Unit [kg]. Relative duty factor Relative duty factor ED in %, relating on the specified maximum and con‐...

  • Page 31: General Technical Data

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 29/193 Rexroth IndraDyn L Ironless Linear Motors MCL Technical data General technical data For the sake of clarity, the following table contains data which is applicable to all motor frame sizes. In this context, however, the comments on the individu‐...

  • Page 32: Technical Data - Frame Size Mcl015

    30/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Technical data Technical data - frame size MCL015 4.3.1 Data sheet MCP015 Technical data specified in Tab. 4-2 are only valid in combination with secondary parts MCS015-3S-____-NNNN. Parameter...

  • Page 33: Motor Characteristic Curve Frame Size 015

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 31/193 Rexroth IndraDyn L Ironless Linear Motors MCL Technical data 4.3.3 Motor characteristic curve frame size 015 Fig. 4-4: Motor characteristic curve MCP015A-L040 at 48 V Fig. 4-5: Motor characteristic curve MCP015B-L040 at 48 V...

  • Page 34: Technical Data - Frame Size Mcl020

    32/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Technical data Technical data - frame size MCL020 4.4.1 Data sheet MCP020 Technical data specified in Tab. 4-4 are only valid in combination with secondary parts MCS020-3S-____-NNNN. Parameter...

  • Page 35: Motor Characteristic Curves Frame Size 020

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 33/193 Rexroth IndraDyn L Ironless Linear Motors MCL Technical data 4.4.3 Motor characteristic curves frame size 020 Fig. 4-6: Motor characteristic curves MCP020B at 300 V Fig. 4-7: Motor characteristic curves MCP020C at 300 V...
  • Page 36 34/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Technical data Fig. 4-8: Motor characteristic curves MCP020D at 300 V...

  • Page 37: Technical Data - Frame Size Mcl030

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 35/193 Rexroth IndraDyn L Ironless Linear Motors MCL Technical data Technical Data - frame size MCL030 4.5.1 Data sheet MCP030 Technical data specified in Tab. 4-6 are only valid in combination with secondary parts MCS030-3S-____-NNNN. Parameter...

  • Page 38: Motor Characteristic Curve Frame Size 030

    36/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Technical data 4.5.3 Motor characteristic curve frame size 030 Fig. 4-9: Motor characteristic curve MCP030B at 300 V Fig. 4-10: Motor characteristic curve MCP030C at 300 V...
  • Page 39 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 37/193 Rexroth IndraDyn L Ironless Linear Motors MCL Technical data Fig. 4-11: Motor characteristic curve MCP030D at 300 V...

  • Page 40: Technical Data - Frame Size Mcl040

    38/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Technical data Technical data - frame size MCL040 4.6.1 Data sheet MCP040 Technical data specified in Tab. 4-8 Tab. 4-9are only valid in combination with secondary parts MCS040-3S-____-NNNN.

  • Page 41: Data Sheet Mcs040

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 39/193 Rexroth IndraDyn L Ironless Linear Motors MCL Technical data Parameter Symbol Unit MCP040 Frame lengths Winding V070 V300 V070 V300 Maximum velocity at F m/min Fmax Nominal velocity m/min Force constant 63.1 38.9 66.2 39.1...

  • Page 42: Motor Characteristic Curves Frame Size 040

    40/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Technical data 4.6.3 Motor characteristic curves frame size 040 Fig. 4-12: Motor characteristic curve MCP040B at 300 V Fig. 4-13: Motor characteristic curve MCP040C at 300 V...
  • Page 43 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 41/193 Rexroth IndraDyn L Ironless Linear Motors MCL Technical data Fig. 4-14: Motor characteristic curve MCP040E at 300 V Fig. 4-15: Motor characteristic curve MCP040G at 300 V...

  • Page 44: Technical Data - Frame Size Mcl070

    42/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Technical data Technical data - frame size MCL070 4.7.1 Data sheet MCP070 Technical data specified in Tab. 4-11 Tab. 4-12are only valid in combination with secondary parts MCS070-3S-____-NNNN.

  • Page 45: Data Sheet Mcs070

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 43/193 Rexroth IndraDyn L Ironless Linear Motors MCL Technical data Parameter Symbol Unit MCP070 Frame lengths Winding V050 V300 V050 V230 Maximum velocity at F m/min Fmax Nominal velocity m/min Force constant 93.0 47.5 92.2 52.9...

  • Page 46: Motor Characteristic Curve Frame Size 070

    44/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Technical data 4.7.3 Motor characteristic curve frame size 070 Fig. 4-16: Motor characteristic curve MCP070C at 300 V Fig. 4-17: Motor characteristic curve MCP070D at 300 V...
  • Page 47 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 45/193 Rexroth IndraDyn L Ironless Linear Motors MCL Technical data Fig. 4-18: Motor characteristic curve MCP070F at 300 V Fig. 4-19: Motor characteristic curve MCP070M at 300 V...
  • Page 48 46/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL...

  • Page 49: Dimension Sheets

    For the installation of the motors into the machine structure, Bosch Rexroth specifies a defined installation height with tolerances. Thus, the specified size and tolerances of the air gap are maintained inevitably – even if individual...

  • Page 50: Frame Size Mcl015

    48/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets 5.1.2 Frame size MCL015 Motor width Frame size Motor height A MCP B* MCS C* 51 mm 13.5 mm 14.8 mm Tolerance details see motor dimension sheet Tab.

  • Page 51: Frame Size Mcl020

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 49/193 Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets 5.1.3 Frame size MCL020 ... 070 Motor width Frame size Motor height A MCP B* MCS C* 52.0 mm 20.5 mm 20.8 mm 67.0 mm 24.7 mm 25.0 mm...

  • Page 52: Parallelism And Symmetry Of Machine Parts

    50/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets 5.1.4 Parallelism and symmetry of machine parts Before primary and secondary part can be mounted, align the parts of the machine. Especially the machine slide is to be brought into a defined position to the machine bed.
  • Page 53 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 51/193 Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets...

  • Page 54: Dimension Sheets Mcl015

    52/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets Dimension sheets MCL015 Fig. 5-2: Dimension sheet primary part MCP015...
  • Page 55 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 53/193 Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets Fig. 5-3: Dimension sheet secondary part MCP015...

  • Page 56: Dimension Sheets Mcl020

    54/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets Dimension sheets MCL020 Fig. 5-4: Dimension sheet primary part MCP020...
  • Page 57 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 55/193 Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets Fig. 5-5: Dimension sheet secondary part MCS020...

  • Page 58: Dimension Sheets Mcl030

    56/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets Dimension sheets MCL030 Fig. 5-6: Dimension sheet primary part MCP030...
  • Page 59 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 57/193 Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets Fig. 5-7: Dimension sheet secondary part MCS030...

  • Page 60: Dimension Sheets Mcl040

    58/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets Dimension sheets MCL040 Fig. 5-8: Dimension sheet primary part MCP040...
  • Page 61 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 59/193 Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets Fig. 5-9: Dimension sheet secondary part MCS040...

  • Page 62: Dimension Sheets Mcl070

    60/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets Dimension sheets MCL070 Fig. 5-10: Dimension sheet primary part MCP040...
  • Page 63 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 61/193 Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets Fig. 5-11: Dimension sheet secondary part MCS070...
  • Page 64 62/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL...

  • Page 65: Type Codes

    General information The type code describes the deliverable motor variants. It is the basis for se‐ lecting and ordering products from Bosch Rexroth. This applies to new prod‐ ucts as well as to spare parts and repairs.. In the following, a type code example is given, where a stipulation of the sin‐...
  • Page 66 The cable output direction of the Hall unit is performed to the same front side as for the power connection. The necessary length measuring system is not in the scope of delivery of Bosch Rexroth and has to be provided and mounted by the machine manu‐ facturer himself. Electrical connection Short-text columns 1920 All primary parts are provided with a flexible and shielded connection cable.

  • Page 67: Type Code Secondary Part Mcs

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 65/193 Rexroth IndraDyn L Ironless Linear Motors MCL Type codes 6.1.3 Type code secondary part MCS General Information Fig. 6-2: Example of type code MCS040 secondary part Product Short-text columns 123 MCS is the name of an ironless linear motor secondary part product group.

  • Page 68: Type Code Frame Size 015

    66/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Type codes Type code frame size 015 Fig. 6-3: Type code MCP015 primary part...
  • Page 69 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 67/193 Rexroth IndraDyn L Ironless Linear Motors MCL Type codes Fig. 6-4: Type code MCS015 secondary part...

  • Page 70: Type Code Frame Size 020

    68/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Type codes Type code frame size 020 Fig. 6-5: Type code MCP020 primary part...
  • Page 71 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 69/193 Rexroth IndraDyn L Ironless Linear Motors MCL Type codes Fig. 6-6: Type code MCS020 secondary part...

  • Page 72: Type Code Frame Size 030

    70/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Type codes Type code frame size 030 Fig. 6-7: Type code MCP030 primary part...
  • Page 73 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 71/193 Rexroth IndraDyn L Ironless Linear Motors MCL Type codes Fig. 6-8: Type code MCS030 secondary part...

  • Page 74: Type Code Frame Size 040

    72/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Type codes Type code frame size 040 Fig. 6-9: Type code MCP040 primary part...
  • Page 75 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 73/193 Rexroth IndraDyn L Ironless Linear Motors MCL Type codes Fig. 6-10: Type code MCS040 secondary part...

  • Page 76: Type Code Frame Size 070

    74/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Type codes Type code frame size 070 Fig. 6-11: Type code MCP070 primary part...
  • Page 77 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 75/193 Rexroth IndraDyn L Ironless Linear Motors MCL Type codes Fig. 6-12: Type code MCS070 secondary part...
  • Page 78 76/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL...

  • Page 79: Accessories And Options

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 77/193 Rexroth IndraDyn L Ironless Linear Motors MCL Accessories and options Accessories and options Hall unit 7.1.1 General information To drive synchronous motors, an absolute position information regarding pole pair or pole pair width is necessary to recognize the position of the perma‐...
  • Page 80 20 V. The voltage supply must ensure a current consumption of the Hall unit of minimum 40 mA. Fig. 7-1: Signal curve of an analog Hall unit Bosch Rexroth controllers use a voltage supply of 12 V for analog Hall units.
  • Page 81 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 79/193 Rexroth IndraDyn L Ironless Linear Motors MCL Accessories and options Hall unit digital Digital Hall units for MCL from Rexroth create three rectangular signals, which are phase-delayed by 120°. The signals of an open-collector-switch are provided on the lines according to Fig. 7-2. The voltage supply is 3 ... 24 V.

  • Page 82: Hall Unit Assembly/Disassembly

    80/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Accessories and options 7.1.3 Hall unit assembly/disassembly The Hall unit is an ESD sensitive device. Before connecting the Hall unit, take appropriate measures for ESD protection (ESD = electrostatic discharge).

  • Page 83: Ordering Designation Separate Hall Unit

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 81/193 Rexroth IndraDyn L Ironless Linear Motors MCL Accessories and options 7.1.4 Ordering designation separate Hall unit Ordering designation Hall unit Primary part MCP ... Analog Digital no Hall unit available SUP-E01-A15-MCP020 SUP-E01-D15-MCP020 (R911335794) (R911335797) SUP-E01-A30-...
  • Page 84 82/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL...

  • Page 85: Connection Technique

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 83/193 Rexroth IndraDyn L Ironless Linear Motors MCL Connection technique Connection technique Power connection 8.1.1 Connection cable on primary part Primary parts of MCL motors are fitted with a flexible and totally shielded con‐ nection cable. This 1100 mm long connection cable is connected with the pri‐...
  • Page 86 84/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Connection technique Technical data power connection cable Cross section Cross section Connection cable Diameter Frame size Power wires Control wire Allowed bending radius[R]* (Bulk cable) [D in mm] [mm²]...

  • Page 87: Assembly Connection Cable On Primary Part

    . 8.1.2 Assembly connection cable on primary part Bosch Rexroth offers ready-made power cables to connect MCP primary part on Rexroth controllers. See also chapter 8.1.3 "Connection Power " on page Mount the connection cable on the flange socket (RLS1704) to connect the primary part with the power cable.

  • Page 88: Connection Power

    8.1.3 Connection Power Bosch Rexroth provides ready-made power cables available for motor con‐ nection. The cables RKL4800, RKL4801, RKL4802, RKL4803 and INK0650 are optimally adjusted to our products and their most different demands. Please observe that ready-made cables or cable systems of other manufacturers may not fulfill these demands completely.
  • Page 89 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 87/193 Rexroth IndraDyn L Ironless Linear Motors MCL Connection technique ① Rexroth drive controller ② Junction (terminal box) ① Temperature sensor and ground wire available only for frame size MCP020 ... 070. For MCP015 connect a separate protec‐...

  • Page 90: Installation Of Power Connection

    88/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Connection technique 8.1.4 Installation of power connection Installation method for motor sin‐ gle arrangement ① Drive controller ② Energy chain ① Junction (Connector or Terminal boxes) ① Motor Fig.
  • Page 91 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 89/193 Rexroth IndraDyn L Ironless Linear Motors MCL Connection technique Parallel arrangement, installation method separate power cables ① Drive controller ② Energy chain ① Junctions (Connector bzw. Terminal boxes) ① Motor 1 ① Motor 2 Fig. 8-6:...

  • Page 92: Sensors

    90/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Connection technique Sensors 8.2.1 Connection temperature sensor All primary parts - except frame size MCP015 - are equipped with a PTC tem‐ perature sensor KTY84-130. The temperature sensor is fixed within the motor winding and serves for winding temperature measuring.
  • Page 93 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 91/193 Rexroth IndraDyn L Ironless Linear Motors MCL Connection technique Connection cable Hall unit Cross section Motor frame size Diameter [D] Control wire Allowed bending radius[R]* [mm²] - for fix installation 5 x D MCP020 ... 070 4.2 ±0.1...

  • Page 94: Assembly Hall Unit Connection Cable

    92/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Connection technique 8.2.3 Assembly Hall unit connection cable Before the Hall unit can be connected to the SHL03.1 adapter box, the con‐ nection cable of the Hall unit must be assembled with a 9-pole D-sub connec‐...

  • Page 95: Connect Digital Hall Unit

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 93/193 Rexroth IndraDyn L Ironless Linear Motors MCL Connection technique 8.2.4 Connect digital Hall unit To connect a digital Hall unit in connection with an incremental length meas‐ uring system on a conroller of the IndraDrive Cs family, use the SHL03.1 adapter box.

  • Page 96: Connect Analog Hall Unit

    Also ob‐ serve the manufacturer's instruction of the length measuring system. To connect an incremental length measuring system on a Rexroth controller or on the adapter box SHL03.1, Bosch Rexroth provides two connection ca‐ bles.
  • Page 97 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 95/193 Rexroth IndraDyn L Ironless Linear Motors MCL Connection technique ● RKG0049 for connection of the length measuring system directly on the controller ● RKG0051 to connect the length measuring system on the SHL03.1 To use this connection cable, fit the connection cable on the incremental length measuring system with a compatible flange socket (RGS0006).
  • Page 98 96/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL...

  • Page 99: Application And Construction Instructions

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 97/193 Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions Application and construction instructions Mode of functioning The force generation for an ironless synchronous-linear motor, is the same as the torque generation at rotary synchronous motors. The ironless primary part (active part) has a winding;...

  • Page 100: Design Secondary Part

    98/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions ① Primary part carrier out of aluminum ② Form of molded motor winding in design I-form (MCP020 ... 070) ① Form of molded motor winding in design T-form (MCP015) Fig.

  • Page 101: Frame Size And Frame Length

    Application and construction instructions 9.2.3 Frame size and frame length For adjusting on different feed force requirements, Bosch Rexroth offers MCL motors in a modular system in different sizes and lengths. Frame sizes The designation of frame size is derived from the active height l and power of MCL.

  • Page 102: Setup Elevation And Ambient Conditions

    100/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions Setup elevation and ambient conditions The motor performance data specified are applicable for ● Ambient temperature 0 ... +40 °C ● Setup elevation of 0 m to 1,000 m above sea level.

  • Page 103: Ambient Conditions

    Deviating from class 3S2 of DIN EN 60721-3-3 Tab. 9-2: Operating conditions Unless otherwise specified, the values given are the values of the particular class. However, Bosch Rexroth reserves the right to adjust these values at any time based on future experiences or changed ambient factors.

  • Page 104: Degree Of Protection

    102/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions Degree of protection The design of MCL motors is according to protection mode according to DIN EN 60034-5. Motor component Degree of protection Primary part IP00 (Front face MCP020 ...

  • Page 105: Magnet Fields

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 103/193 Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions Magnet fields During operation of electro motors, electro-magnetic fields on live-parts and connection lines of these motors occur. The secondary parts of synchronous linear motors and rotors of synchronous kit motors equipped with permanent magnets are not shielded magnetically and create continuously a static mag‐...

  • Page 106: Noise Emission

    For shipping of open, non-magnetic shieldes permanent magnetic parts as air freight, limit values (according to IATA953) for magnetic flow density in all room directions must be kept. All rotors of Bosch Rexroth synchronous mo‐ tors belong to category I according to the following figure. Secondary parts of Bosch Rexroth linear motors belong to one of the three named categories, depending on their geometry and construction.
  • Page 107 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 105/193 Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions Total loss in W Short-circuit loss in W Current in motor cable in A Electrical resistance of the motor at 20°C in Ohm (see Chapter 4 ”Technical data)
  • Page 108 106/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions Fig. 9-8: Heating up and cooling down of an electrical machine Heating up ϑ Final over temperature in K ϑ Initial over temperature in K...

  • Page 109: Motor Temperature Monitoring

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 107/193 Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions Cooling down ϑ Final over temperature or shutdown temperature in K Time in min Thermal time constant in min (see motor data sheet) Fig. 9-11: Cooling down of an electrical machine 9.10...

  • Page 110: Feed Force At Reduced Covering Between Primary And Secondary Part

    108/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions Fig. 9-12: Characteristic temperature sensor KTY84-130 Temperature sensor KTY84-130 is a component that might be damaged by ESD! For this reason, the wires of the sensor are protected by a protective foil at the connection cable.
  • Page 111 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 109/193 Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions Fig. 9-13: Force reduction with partial coverage of primary and secondary part [mm] [mm] Motor version without Hall unit Installation position 1 MCL015 MCL020 ... 70...

  • Page 112: Requirements On The Machine Design

    110/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions 9.12 Requirements on the machine design 9.12.1 General Derived from design and properties of linear direct drives, the machine con‐ struction must meet various requirements. For example, the moved masses should be minimized whilst the rigidity is kept at a high level.
  • Page 113 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 111/193 Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions Fig. 9-14: Deformation of the machine base caused by the reactive force during the acceleration process Δs Deformation of displacement of the machine base in µm Mass in kg Acceleration in m/s²...

  • Page 114: Protection Of The Motor Installation Space

    112/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions 9.12.4 Protection of the motor installation space Due to protection mode IP00 of the motor components, the protection of the motor installation space need especial observance. To avoid that dirt comes into the air gap between primary and secondary part (e.g.

  • Page 115: Several Motors Per Axis

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 113/193 Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions ① Control unit ② Controller ① Linear scale Fig. 9-17: Controlling a linear motor with single arrangement of the motor com‐ ponents 9.13.2 Several motors per axis...
  • Page 116 114/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions Parallel arrangement The arrangement of two or more primary parts on one drive controller in con‐ junction with a linear scale is known as parallel arrangement.
  • Page 117 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 115/193 Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions Phase sequence Distance x Primary part pmin Primary part 1 Primary part 2 MCP015 4.5 mm V-W-U 53 mm U-V-W MCP020 63 mm V-W-U...
  • Page 118 116/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions Fig. 9-23: Option 1: Arrangement of primary parts behind each other with cable entries in opposite directions Phase sequence Distance x Primary part pmin...
  • Page 119 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 117/193 Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions Fig. 9-25: Option 2: Arrangement of primary parts behind each other with cable entries in opposite directions Phase sequence Distance x Primary part pmin...

  • Page 120: Arrangement Of Secondary Parts

    118/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions Double comb arrangement (Gantry) Within a Gantry arrangement – the primary parts in feed direction can be me‐ chanically coupled and arranged in the form of a double comb arrangement.

  • Page 121: Vertical Axis

    The linear scale serves for high-resolution position sensing and to determine the current speed. The necessary length measuring system is not in the scope of de‐ livery of Bosch Rexroth and has to be provided and mounted from the machine manufacturer himself (tab. 9-10 "Manufacturers of length measuring systems"...
  • Page 122 120/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions ● the maximum feed rate (model, signal period) ● the maximum travel (measuring length, model) ● if applicable, utilization of coolant lubricants (model) ●...

  • Page 123: Linear Guiding Systems

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 121/193 Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions Measuring system cables Ready-made cables of Rexroth are in preparation for the electrical connec‐ tion between the output of the linear scale and the input of the scale inter‐...

  • Page 124: Braking Systems And Holding Devices

    122/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions 9.17 Braking systems and holding devices The following systems can be used as braking systems and/or holding devi‐ ces for linear motors: ● External braking devices ●...

  • Page 125: Drive And Control Of Indradyn L Motors

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 123/193 Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions 9.20 Drive and control of IndraDyn L motors 9.20.1 General The following figures shows a complete linear direct drive, consisting of a synchronous linear motor, length scale system, drive controller and superor‐...

  • Page 126: Deactivation Upon Emergency Stopand In The Event Of A Malfunction

    124/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions 9.21 Deactivation upon EMERGENCY STOPand in the event of a malfunction 9.21.1 General The deactivation of an axis, equipped with an IndraDyn L motor, can be initi‐...

  • Page 127: Deactivation By A Master Control

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 125/193 Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions 9.21.3 Deactivation by a master control Deactivation by control functions Deactivation by the master control should be performed in the following steps: 1. The machine PLC or the machine I/O level reports the fault to the CNC control 2.
  • Page 128 126/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions ● either an uninterruptible power supply or ● additional DC bus capacities (capacitors), and /or ● mechanical braking facilities must be provided. Additional capacities in the DC bus represent an additional energy store that Determining the required addition‐...

  • Page 129: Short-Circuit Of Dc Bus

    9.21.6 Short-circuit of DC bus Most of the power supply modules of Bosch Rexroth permit the DC bus to be shortened when the power is switched off, which also establishes a short-cir‐ cuit between the motor phases. When the motor moves, this causes a brak‐...

  • Page 130: Velocity Resolution

    128/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction instructions Δx Drive-internal position resolution Linear scale system signal period (S-0-0116 Resolution of en‐ coder 1) Multiplication factor (S-0-0256, Multiplication 1) Fig. 9-34: Drive-internal position resolution The drive-internal position resolution is not identical to the reacha‐...

  • Page 131: Motor-Controller-Combinations

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 129/193 Rexroth IndraDyn L Ironless Linear Motors MCL Motor-controller-combinations Motor-controller-combinations 10.1 General information Technical data and figures of motor characteristic curves of the respective motors are shown in chapter chapter 4 "Technical data" on page Dimensioning and selection for separate motors results from the Gantry-arrangement .

  • Page 132: Motor-Controller-Combinations With Indradrive Cs

    130/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Motor-controller-combinations 10.3 Motor-controller-combinations with IndraDrive Cs HCS01.1E-Wxxxx-A-02-... HCS01.1E-Wxxxx-A-03-... 3x AC 110 ... 230 V / 1x AC 110 ... 230 V 3x AC 200 ... 230 V W003...

  • Page 133: Motor Dimensioning

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 131/193 Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning Motor dimensioning 11.1 General procedure The dimensioning and design of linear drives ist significantly defined by the application-related profiles of velocity, feed force and the thermal connection.

  • Page 134: Basic Formulae

    132/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning 11.2 Basic formulae 11.2.1 General movement equations The variables required for sizing and selecting the motor are calculated using the equations shown in the following. When linear direct drives are configured, the process-related feed forces and velocities are used directly and without conversion for selecting the drive.

  • Page 135: Feed Forces

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 133/193 Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning 11.2.2 Feed forces Fig. 11-3: Determining the feed forces Acceleration force in N Force due to weight in N Frictional force in N Additional frictional or base force in N (e.g. by seals of linear...
  • Page 136 134/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning For sizing calculations of linear motor drives, the moved mass of the motor component must be taken into account (in particular, if the slide masses are relatively small). The moved mass is only noted after successfull motor selection.
  • Page 137 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 135/193 Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning Resulting force in N Acceleration force in N Force due to weight in N Frictional force in N Fig. 11-6: Determining the resulting feed forces according to motion type and di‐...

  • Page 138: Average Velocity

    136/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning 11.2.3 Average velocity The average velocity is required for determining the mechanical continuous output of the drive. fig. 11-2 "General equations of motion" on page 132 shows the general way of determining the average velocity.

  • Page 139: Trapezoidal Velocity Profile

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 137/193 Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning 11.2.4 Trapezoidal velocity profile General information This mode of operation is characteristic for the most applications. After a con‐ stant acceleration phase, a motion with constant velocity up to the decelera‐...
  • Page 140 138/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning Acceleration in m/s² Final velocity in m/s Acceleration time in s Travel covered during acceleration in m Fig. 11-10: Constantly accelerated movement, initial velocity v = 0 (for trapezoidal...
  • Page 141 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 139/193 Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning Acceleration in m/s² Final velocity in m/s Initial velocity in m/s Acceleration time in s Travel covered during acceleration in m Fig. 11-11: Constantly accelerated movement, initial velocity v ≠...
  • Page 142 140/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning Acceleration in m/s² Final velocity in m/s Braking time in s Travel covered during acceleration in m Fig. 11-13: Constantly accelerated movement, initial velocity v = 0 (for trapezoidal...

  • Page 143: Triangle-Shaped Velocity Profile

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 141/193 Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning Acceleration in m/s² Initial velocity in m/s Final velocity in m/s Braking time in s Travel covered during acceleration in m Fig. 11-14: Constantly accelerated movement, initial velocity v ≠...

  • Page 144: Sinusoidal Velocity Profile

    142/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning Maximum velocity in m/s Acceleration in m/s² Total motion travel in m Positioning time in s Fig. 11-16: Determine triangular velocity profile 11.2.6 Sinusoidal velocity profile...
  • Page 145 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 143/193 Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning s(t) Chronological development of the path Radius r(t) Chronological path of velocity Time a(t) Acceleration ω Circular frequency Cycle duration Frequence Fig. 11-18: Calculation formula for motion profiles of an axis at sinusoidal velocity.
  • Page 146 144/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning Maximum acceleration in m/s² Maximum velocity in m/s Motion travel in one direction (or circle radius) in m Period in s Moved mass in kg Acceleration force in N...

  • Page 147: Duty Cycle And Feed Force

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 145/193 Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning 11.3 Duty cycle and feed force 11.3.1 General information The relative duty cycle ED specifies the duty cycle percentage of the load with respect to a total duty cycle time, including idle time. The thermal load capacity of the motor limits the duty cycle.

  • Page 148: Determining The Drive Power

    146/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning 11.4 Determining the drive power 11.4.1 General information To size the power supply module or the mains rating, you must determine the rated (continuous) and maximum power of the linear drive.

  • Page 149: Maximum Output

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 147/193 Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning 11.4.3 Maximum output The maximum output is also the sum of the mechanical and electrical maxi‐ mum output. It must be made available to the drive during acceleration and deceleration phase or for very high machining forces, for example.

  • Page 150: Power Loss

    148/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning 11.4.4 Power loss The power loss corresponds the electric continuous power loss of the motor. Electrical power loss of motor in W Effective force in N Rated force of the motor in N (see Chapter 4 ”Technical data”)

  • Page 151: Efficiency

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 149/193 Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning Final velocity = 0 If the regeneration energy that is determined according to Fig. 11-27 is negative, energy is not fed back. This means that energy must be supplied to the motor during the deceleration process.
  • Page 152 150/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning When the screw on surfaces of the motor components, especially the screw on surface of the primary part, is made of a badly heat- dissipating material (like plastics), it must be reckoned with a re‐...
  • Page 153 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 151/193 Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning Explanation of installation modes Mounting Schematic display Description method Installation mode A requires a good thermal connection of the motor to‐ gether with an additional cooling, e.g. by using a fan or by cooling the screw on surfaces.

  • Page 154: Operation At Or Near Motor Standstill

    152/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning 11.8 Operation at or near motor standstill In the case of motor operation within or near standstill observe special condi‐ tions. For means of simplification, this operation is indicated as standstill op‐...

  • Page 155: Handling, Transport And Storage

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 153/193 Rexroth IndraDyn L Ironless Linear Motors MCL Handling, transport and storage Handling, transport and storage 12.1 Identification of the motor components 12.1.1 Primary part An engraved type designation is on the primary part. ① Type designation (not for MCP015) ②...

  • Page 156: Secondary Part

    154/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Handling, transport and storage 12.1.2 Secondary part The type designation with serial number is at the bottom of the secondary part. ① Type designation ② Serial number Fig. 12-3: Position of type designation and serial number of secondary part Additionally, the secondary part has two identical type plates at delivery.

  • Page 157: Delivery Status And Packaging

    Rexroth (MNR R911278745). 12.3 Checking the motor components 12.3.1 Factory checks of the motor components The Bosch Rexroth linear motors undergo the following electrical checks at Electrical inspections the factory: ● HIgh voltage test according to DIN EN 60034-1 ●...

  • Page 158: Transport And Storage

    ⇒ Avoid repeated tests. ⇒ Observe the guidelines of DIN EN 60034-1 EMV radia interference suppres‐ The linear motor components of Bosch Rexroth have been subjected to an sion EMV type test and have been certified as complying EN 55011 Limit Class B, VDE 0875 Part 11 12.4...

  • Page 159: Notes About Storage

    For the sake of clarity, a few essential environmental factors of the aforemen‐ tioned classifications are presented below. Unless otherwise specified, the values given are the values of the particular class. However, Bosch Rexroth reserves the right to adjust these values at any time based on future experi‐...
  • Page 160 158/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Handling, transport and storage Allowed classes of ambient conditions during storage acc. to DIN EN 60721-3-1 Environmental factor Symbol Unit Value Air temperature °C -20 ... +60 Relative air humidity φ...

  • Page 161: Installation

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 159/193 Rexroth IndraDyn L Ironless Linear Motors MCL Installation Installation 13.1 Basic precondition Before you begin with the assembly, you must observe or check the following points: ● Observation of the necessary installation sizes (see chapter 5.1 "Instal‐...

  • Page 162: Installation Of Motor Components

    160/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Installation 13.3 Installation of motor components The order of installation of motor components is depending from the machine construction or the available space in the machine. Thereby, the arrangement of the motor components play a significant role.

  • Page 163: Fastening Secondary Part

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 161/193 Rexroth IndraDyn L Ironless Linear Motors MCL Installation Air gap Motor damage due to unsufficient air gap be‐ NOTICE tween primary and secondary part! After assembly, check the free movement of the motor components to each other immediately.
  • Page 164 162/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Installation Motor damage due to unsufficient air gap be‐ NOTICE tween primary and secondary part! Observe during fastening of the secondary parts according to variant 2 that the maximum screw-in depth specified in the table, is kept. In the case of de‐...

  • Page 165: Fastening The Primary Part

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 163/193 Rexroth IndraDyn L Ironless Linear Motors MCL Installation ● In certain cases, the secondary part cannot be screwed di‐ rectly with the machine, because additional materials like distance plates, heat-conductive paste etc. are between the secondary part and the machine.

  • Page 166: Electrical Connection

    164/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Installation Fig. 13-5: Tightening row of screws ● To fasten the primary parts, use all fastening points. ● The effect of liquid screw locking Loctite 243 is damaged due to loosening or re-tightening of the screws (e.g.

  • Page 167: Commissioning, Operation And Maintenance

    As a result, kit motors do not feature any data memory to pro‐ vide motor parameters, standard controller settings, etc. All parameters must be manually entered or loaded to the drive during commissioning. The start‐ up-program IndraWorks makes all motor parameters of Bosch Rexroth avail‐ able. Controller optimization The procedure used for optimizing the control loops (current, velocity and po‐...

  • Page 168: Tools

    166/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Commissioning, operation and maintenance ● Ensure safety for man and machine ● Properly install the motor ● Properly establish the power connection of the motor ● Correct connection of the length measuring system ●...
  • Page 169 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 167/193 Rexroth IndraDyn L Ironless Linear Motors MCL Commissioning, operation and maintenance Fig. 14-1: General start-up procedure at synchronous linear motors...

  • Page 170: Parameterization

    168/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Commissioning, operation and maintenance 14.4 Parameterization 14.4.1 General information IndraWorks allows entering or editing certain parameters and executing com‐ mands during commissioning by means of menu-driven dialogs and list rep‐...

  • Page 171: Entering Drive Limitations And Application-Related Parameters

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 169/193 Rexroth IndraDyn L Ironless Linear Motors MCL Commissioning, operation and maintenance Detailed information can be found in the project planning manual of the used drive controller and/or firmware ● Rexroth IndraDrive MPx-xx Parameter description, MNR R911328650 ●...

  • Page 172: Determining The Polarity Of The Linear Scale

    170/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Commissioning, operation and maintenance 14.5 Determining the polarity of the linear scale In order to avoid direct feedback in the velocity control loop, the effective di‐ rection of the motor force and the count direction of the linear scales must be the same.

  • Page 173: Commutation Adjustment

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 171/193 Rexroth IndraDyn L Ironless Linear Motors MCL Commissioning, operation and maintenance The encoder polarity is selected via the primary part (cable con‐ nection). The installation direction or the pole sequence of the secondary part does not have any influence on the selection of the sensor polarity.
  • Page 174 172/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Commissioning, operation and maintenance Fig. 14-4: Commutation adjustment method for ironless synchronous linear mo‐ tors Observe the following requirements for commutation adjustment: ⇒ Effective direction motor force = linear scale count direction ⇒...

  • Page 175: Sinusoidal Procedure

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 173/193 Rexroth IndraDyn L Ironless Linear Motors MCL Commissioning, operation and maintenance Motor connection The individual phases of the motor power connection must be assigned cor‐ rectly. Parameter verification To ensure a correct commutation adjustment, the following parameters...

  • Page 176: Measuring Procedure: Measuring The Reference Between Primary And Secondary Part

    174/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Commissioning, operation and maintenance With the aforementioned adjustments, the effective commutation offset (P-0-0521) is calculated automatically when switching into the operating mode. The drive is ready for power switch-on The procedure "Reference point - optimal commutation offset"...
  • Page 177 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 175/193 Rexroth IndraDyn L Ironless Linear Motors MCL Commissioning, operation and maintenance the power to be switched on nor the axes to be moved. Commutation adjust‐ ment need only be performed during the first-time commissioning. This procedure requires an absolute length measuring system.

  • Page 178: Setting And Optimizing The Control Loop

    176/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Commissioning, operation and maintenance in mm Primary part MCP020 24.1 MCP030 / 040 / 070 49.6 Tab. 14-5: Motor constant k for commutation adjustment Example on MCP040C for reference point ➀...
  • Page 179 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 177/193 Rexroth IndraDyn L Ironless Linear Motors MCL Commissioning, operation and maintenance Fig. 14-7: Setting and optimizing the control loop of synchronous linear drives. For more detailed information refer to ● Rexroth IndraDrive Firmware MPx-xx Funktionsbeschrei‐...
  • Page 180 178/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Commissioning, operation and maintenance is mainly in the frequency range from 400 to 800 Hz. It depends on the rigidi‐ ty of the mechanical system and the spatial expansion of the system.

  • Page 181: Parameterization And Optimization Of Gantry Axes

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 179/193 Rexroth IndraDyn L Ironless Linear Motors MCL Commissioning, operation and maintenance 14.7.2 Parameterization and optimization of Gantry axes General Information Prerequisites: ● The parameter settings of the axes are identical ● Parallelism of the guides of the Gantry axes ●...

  • Page 182: Estimating The Moved Mass Using A Velocity Ramp

    180/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Commissioning, operation and maintenance Velocity controller integral time (in‐ The following possibilities must be taken into account for the velocity control‐ tegral part) ler integral time (integral part):...
  • Page 183 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 181/193 Rexroth IndraDyn L Ironless Linear Motors MCL Commissioning, operation and maintenance Fig. 14-11: Oscillogram of velocity and force Moved axis mass in kg Continuous nominal force of the motor in N Force command value during acceleration in % Force command value during braking in % Δv...

  • Page 184: Maintenance And Check Of Motor Components

    182/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Commissioning, operation and maintenance 14.8 Maintenance and check of motor components 14.8.1 General information The motor components of IndraDyn L do not need any maintenance. Due to external influence, the motor components can be damaged during operation.

  • Page 185: Operation With Third-Party Controllers

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 183/193 Rexroth IndraDyn L Ironless Linear Motors MCL Commissioning, operation and maintenance 14.9 Operation with third-party controllers Rate of rise of voltage The electrical insulation system of the motor is subject to a higher dielectric load in converter mode than when it is operated with a merely sinusoidal source voltage.
  • Page 186 184/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Commissioning, operation and maintenance For ecological reasons, please refrain from returning the empty packages to Batteries and accumulators Batteries and accumulators can be labeled with this symbol. The symbol indicating "separate collection" for all batteries and accu‐...

  • Page 187: Service And Support

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 185/193 Rexroth IndraDyn L Ironless Linear Motors MCL Service and support Service and support Our worldwide service network provides an optimized and efficient support. Our experts offer you advice and assistance should you have any queries.
  • Page 188 186/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL...

  • Page 189: Index

    DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 187/193 Rexroth IndraDyn L Ironless Linear Motors MCL Index Index Requirements..........165 Tools............166 Acceleration............9 Commutation............77 Acceleration capability........110 Commutation adjustment......165, 171 Acceleration force..........110 Hall sensor procedure........173 Accessory............77 Measuring principle........174 Accessory delivery..........
  • Page 190 188/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Index Degree of protection........28, 29 Force reduction..........109 Delivery status..........155 Forces Design..............64 Reactive forces..........110 Detent force............8 Foreign bodies............ 97 Dimension sheets..........47 Frame length..........64, 99 MCP015............
  • Page 191 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 189/193 Rexroth IndraDyn L Ironless Linear Motors MCL Index Installation size..........159 Motor design Installation tolerances........25, 47 Primary part........... 97 Instructions on use..........13 Secondary part..........98 Appropriate use..........13 Motor dimensioning........... 131 Inappropriate use........... 14 Average velocity...........
  • Page 192 190/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Index Pole width ............27 Serial number MCS........... 154 Position accuracy........127, 128 Service hotline..........185 Position information..........77 Setting and optimizing the control loop..... 176 Position resolution........127, 128 Setup elevation..........
  • Page 193 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 191/193 Rexroth IndraDyn L Ironless Linear Motors MCL Index Travel velocity............. 27 Traverse path length........... 97 Type codes............63 Type designation MCP........153 Type designation MCS........154 Type plates..........153, 154 Velocity............9, 131 Velocity resolution........127, 128 Vertical axes............
  • Page 194 192/193 Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P Rexroth IndraDyn L Ironless Linear Motors MCL Notes...
  • Page 195 DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 193/193 Rexroth IndraDyn L Ironless Linear Motors MCL Notes...
  • Page 196 The Drive & Control Company Bosch Rexroth AG Electric Drives and Controls P.O. Box 13 57 97803 Lohr, Germany Bgm.-Dr.-Nebel-Str. 2 97816 Lohr, Germany Tel. +49 9352 18 0 +49 9352 18 8400 www.boschrexroth.com/electrics DOK-MOTOR*-MCL********-PR05-EN-P...

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