Bosch Rexroth NYCe 4000 Design Manual
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Bosch Rexroth NYCe 4000 Design Manual

Bosch Rexroth NYCe 4000 Design Manual

Linear motion system
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NYCe 4000
Linear motion system
LMS Design Guide
Reference
R911386072
Edition 07

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Summary of Contents for Bosch Rexroth NYCe 4000

  • Page 1 NYCe 4000 Linear motion system LMS Design Guide Reference Edition 07 R911386072...
  • Page 2 Copyright © Bosch Rexroth AG 2021 All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

  • Page 3: Table Of Contents

    Introduction............................22 4.2.2 Position accuracy..........................22 4.2.3 Carrier..............................22 4.2.4 Motion profile and airgap........................22 4.2.5 Number of carriers and overall system layout................... 23 Friction force............................23 Drive size calculations.......................... 24 Curved track geometry......................... 24 R911386072_Edition 07 Bosch Rexroth AG...
  • Page 4 4.8.8 Track stiffness........................... 39 Electrical implementation..................... 41 Introduction............................41 Wiring shielding and grounding......................41 5.2.1 Introduction............................41 5.2.2 Wiring and shielding.......................... 41 5.2.3 Grounding............................43 Safety........................... 45 Introduction............................45 Mechanical safety..........................45 Electrical safety............................. 45 Bosch Rexroth AG R911386072_Edition 07...

  • Page 5: Introduction

    This manual is intended for system design engineers who want to integrate an LMS in their application. This manual guides the system designer through the design and selection process. Bosch Rexroth always intends to make life easier for the application engineer. However, the main focus is to provide maximum flexibility based on the type of applications that can be realized with a Linear Motion System.

  • Page 6: What Is In This Manual

    IEEE Institute of Electrical and Electronics Engineers Linear Motion System Motion Control Unit NY4112 MCU with 2 IEEE802.3 (ethernet) connections Requires Software LMS 47VRS NY4114 MCU with 3 IEEE802.3 (ethernet) connections Requires Software LMS 50VRS Bosch Rexroth AG R911386072_Edition 07...

  • Page 7: References

    Planning Manual, order number R911338962 (for the Control units). ● IndraControl XM21, XM22 Operating Instructions, order number R911340667. ● Motion Logic System IndraMotion Control hardware IndraControl L. ● HMI/Industrial PC Box PC IndraControl VPB. ● Cam Roller Guides, R310EN 2101 (2004-09). R911386072_Edition 07 Bosch Rexroth AG...
  • Page 8 4/47 NYCe 4000 Linear motion system LMS Design Guide Bosch Rexroth AG R911386072_Edition 07...

  • Page 9: Linear Motion System Overview

    PLC. If CM is executed on a node, the LMS application, implemented as an Embedded Application, executes on a node or on a PLC. Note that CM and the Embedded Application do not have to run on the same node. R911386072_Edition 07 Bosch Rexroth AG...
  • Page 10 1024 * pole pitch Carrier length min 192 mm (MR sensor) min 144 mm (Hall sensor) max 25 m carrier length must be a multiple of 24 mm Tracks in an LMS Coils in an LMS Bosch Rexroth AG R911386072_Edition 07...
  • Page 11 Linear Motion System overview Description Maximum Coils in a track Coils controlled by one NY4074 with NY4120/10 Coils controlled by one NY4079 with IndraDrives Nodes daisy-chained connected Tab. 2-2: LMS maximum configuration specification (CM on a node) R911386072_Edition 07 Bosch Rexroth AG...
  • Page 12 8/47 NYCe 4000 Linear motion system LMS Design Guide Bosch Rexroth AG R911386072_Edition 07...

  • Page 13: Hardware Overview And Specifications

    Mechanical construction coil, carrier, magnets and Hall sensors carrier movement guiding system MR sensor MR sensor carrier magnetic magnets scale coil coil (fixed) construction frame Fig. 3-2: Mechanical construction coil, carrier, magnets and MR sensors R911386072_Edition 07 Bosch Rexroth AG...

  • Page 14: Complete Lms Including Control Components

    These restrictions may limit the maximum obtainable acceleration and velocity of the carrier(s). If the application requires higher accelerations or velocities, you must choose the IndraDrive solution supported with the NY4079 system housing. Bosch Rexroth AG R911386072_Edition 07...
  • Page 15 IndraDrive. No DC power supply is required for IndraDrives, because IndraDrives are directly connected to the mains power supply. See Rexroth IndraDrive Supply Units, Power Sections HMV, HMS, HMD, HCS02, HCS03 Project and Planning Manual. R911386072_Edition 07 Bosch Rexroth AG...

  • Page 16: Specifications Lms Components

    NY4150/10 SERCOS Master module. Specifications LMS components 3.3.1 Coils The coils are installed on the track at a mutual distance of the length of the magnet plate. This makes it possible to realize carrier movements along the Bosch Rexroth AG R911386072_Edition 07...
  • Page 17 4.8.7 "Magnet plate and coil mounting" on page 36 for the mounting height specifications related to air gap between coil and magnet plate. The component dimensions of coils and magnet plate should not be considered for determining the air gap. R911386072_Edition 07 Bosch Rexroth AG...
  • Page 18 Different aspects must be considered for both configurations. If you consider the implementation of parallel-wired coils, always contact Bosch Rexroth. If coils are wired in parallel, make sure that the length of the connection cables is identical. Bosch Rexroth AG R911386072_Edition 07...

  • Page 19: Carrier With Magnet Plates

    (MR) in the sensors on an MR sensor based track. The MR elements measure the magnetic field direction of a dedicated magnetic scale attached to the carrier. Carrier positioning is more accurate with the MR sensor system than with the Hall sensor system. R911386072_Edition 07 Bosch Rexroth AG...

  • Page 20: Sensors

    Absolute accuracy +/-22 µm Repeatable accuracy +/-5 µm Tab. 3-4: Attainable position accuracy using MR sensors MR sensors cannot be used in the curve of a track. Bosch Rexroth AG R911386072_Edition 07...

  • Page 21: Specifications Control Components

    The NY4074 system housing supports up to 2 NY4120/10 PWM drive modules for LMS. Each drive module can control 2 LMS coils. ● NYM04.1-2PW-LMSN-NY4120/10, order number R911320447. See NYCe 4000 Hardware System Manual for more information. R911386072_Edition 07 Bosch Rexroth AG...

  • Page 22: Sercos Iii Master Module

    Release Bulletin, for minimum requirements, recommended configuration, network requirements, and supported operating systems. The available Bosch Rexroth PCs are the PR4 series and the VPB40.4. The PR4 has three main types PR41, PR42 and PR43 series, for specifications see IndraControl PR4 and VR4 Control Operating instructions, R911384699.

  • Page 23: Plc

    19/47 Hardware overview and specifications 3.4.6 Bosch Rexroth has PLCs available, such as the MLC L45, MLC L65, and the XM21, XM22 and XM42 series. These PLCs support the Carrier Management functions. All PLC programming languages according to the IEC 61131-3 standard are supported on these PLCs.
  • Page 24 20/47 NYCe 4000 Linear motion system LMS Design Guide Bosch Rexroth AG R911386072_Edition 07...

  • Page 25: Hardware Components Selection

    NY4079 with NY4150 module and IndraDrives) Drive sizing calculations performed with the final choice of the guiding system for the carrier Mechanical track design Contact Bosch Rexroth to review the design Fig. 4-1: Track design flowchart R911386072_Edition 07 Bosch Rexroth AG...

  • Page 26: System Specifications And Requirements

    With increasing air gap distance the available force constant, back EMF constant and drive force (continuous Bosch Rexroth AG R911386072_Edition 07...

  • Page 27: Number Of Carriers And Overall System Layout

    ● Orientation of the carriers and whether the track is curved or straight. R911386072_Edition 07 Bosch Rexroth AG...

  • Page 28: Drive Size Calculations

    Drive size calculations A Drive Sizing tool is available from Bosch Rexroth that can be used to select the coil type, magnet plate type and the drives. Input information for the drive sizing calculations are the parameters described in the previous chapters.
  • Page 29 Fig. 4-3: Large carrier in a curve If the carrier moves out of the sensor detection range before the end of the magnet plate is reached, the LMS software reports a "sensor inactive error" R911386072_Edition 07 Bosch Rexroth AG...

  • Page 30: Coil Size

    4.1 "Introduction" on page 21, in the paragraph "Carriers", 3 types of magnet material is available. If SmCo vacuum magnets are used, an additional 10% margin for drive currents and magnet forces is required. Bosch Rexroth AG R911386072_Edition 07...

  • Page 31: Magnet Plates

    MR sensors. However, Hall sensors have the least demanding mounting tolerances and are more cost efficient. Therefore, in general, Hall sensors are the best choice if they meet the system accuracy requirements. R911386072_Edition 07 Bosch Rexroth AG...

  • Page 32: Guiding System

    LMS has an elevator or a ferry track, the friction will be significantly higher at this interruption (so more drive force is required here) and the position accuracy at this interruption is undefined. Bosch Rexroth AG R911386072_Edition 07...

  • Page 33: Mechanical Design Rules

    Therefore, it is advised to make holes in the carrier or in the roller block mounting plate. R911386072_Edition 07 Bosch Rexroth AG...

  • Page 34: Coil Placement

    ③), you must make sure that the overlap is at least in total 3 windings. If the system designer choses to change the orientation of one of the coils by 180°, it is important to be aware of the following issues. Bosch Rexroth AG R911386072_Edition 07...

  • Page 35: Hall Sensor

    By optimizing the air gap, the position resolution is optimized. For applications in which the position resolution is not critical, the recommended air gap is 8 to 10 mm (thus fine tuning the air gap would only consume time). R911386072_Edition 07 Bosch Rexroth AG...
  • Page 36 12 mm on both sides, see fig. 4-9 "Hall sensor - magnet plate overlap" on page carrier magnet plate sensor sensor – magnet edge coil ≥ 12 mm ≥ 12 mm Fig. 4-9: Hall sensor - magnet plate overlap Bosch Rexroth AG R911386072_Edition 07...

  • Page 37: Mr Sensor And Magnetic Scale

    The magnetic scale of all carriers in the LMS must be positioned such that all are within a span of 2 mm. The positioning of the magnetic scale of carrier D can never fit within a 2 mm span, compared to carriers A, B, and C. R911386072_Edition 07 Bosch Rexroth AG...
  • Page 38 2 adjacent MR sensors distance between 2 adjacent MR sensors depends on the minimum bending radius of the connection cable plus cable diameter. The minimum bending radius is 29.5 mm, the cable diameter is 5.8 mm. Bosch Rexroth AG R911386072_Edition 07...

  • Page 39: Curved Track Coil And Sensor Placement

    The coil is placed parallel to this tangent line. This positioning is done for all coils and sensors along the curve. The tangent (red line) must be through the center of the coil. R911386072_Edition 07 Bosch Rexroth AG...

  • Page 40: Carrier Design

    MR sensor based track. 4.8.7 Magnet plate and coil mounting All magnet plates have a dowel pin hole and a slotted hole for a dowel pin for accurate positioning of the magnet plate. Bosch Rexroth AG R911386072_Edition 07...
  • Page 41 38. Note that the magnetic center line of the coil is not the mechanical center line of the coil. The dowel pin hole in the coil indicates the center of the active part of the coil. R911386072_Edition 07 Bosch Rexroth AG...
  • Page 42 If, for example, an air gap of 1.0 mm is desired using TM coils and magnet plates, the mounting height must be 40.5 mm. See the following table for an overview of the mounting heights per motor type and air gap. Bosch Rexroth AG R911386072_Edition 07...

  • Page 43: Track Stiffness

    The figure shows that the sensor brackets also have a certain stiffness. Make sure that the stiffness of the sensor brackets is such that the first natural frequency is much higher than the first natural frequency of the frame. R911386072_Edition 07 Bosch Rexroth AG...
  • Page 44 40/47 NYCe 4000 Linear motion system LMS Design Guide Bosch Rexroth AG R911386072_Edition 07...

  • Page 45: Electrical Implementation

    SF-UTP (shielded-foiled unshielded twisted pair) cables are also supported, but S-FTP cables are better. See fig. 5-1 "Network cable types (source: www.laborelec.com)" on page 42 for the different types of network cable. R911386072_Edition 07 Bosch Rexroth AG...
  • Page 46 Cable type Cable type without aluminum steel partitioning partitioning partitioning Unshielded Unshielded 200 mm 100 mm 50 mm power cable data cable Unshielded Shielded data 50 mm 20 mm 5 mm power cable cable Bosch Rexroth AG R911386072_Edition 07...

  • Page 47: Grounding

    If the machine consists of multiple frames, the frames must be properly connected with each other using a braid wire. See for more information NYCe 4000 Standard Housing & Accessories manual, chapter "Installation, Earthing, Shielding, EMC, Electrical Connections". R911386072_Edition 07 Bosch Rexroth AG...
  • Page 48 44/47 NYCe 4000 Linear motion system LMS Design Guide Bosch Rexroth AG R911386072_Edition 07...

  • Page 49: Safety

    Drive Voltage power supply is switched off. These measures ensure that the system has power to brake the carriers when an emergency situation occurs. R911386072_Edition 07 Bosch Rexroth AG...
  • Page 50 24V SYSTEM IndraDrive SAFETY TIMER power supply RELAY with STO 24V SYSTEM emergency stop button NY4079 system housing “STOP AXES” input safety switches COIL Fig. 6-2: IndraDrive Cs (with STO) safety circuit with emergency stop button Bosch Rexroth AG R911386072_Edition 07...
  • Page 51 NYCe 4000 Linear motion system LMS Design Guide 47/47 Notes...
  • Page 52 Bosch Rexroth AG P.O. Box 13 57 97803 Lohr a.Main, Germany Bgm.-Dr.-Nebel-Str. 2 97816 Lohr a.Main, Germany Phone +49 9352 18 0 Fax +49 9352 18 8400 www.boschrexroth.com/electrics *R911386072* R911386072 DOK-NY4000-LMS*DESIGN*-PR07-EN-E...

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