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LINEAR MOTION CONTROLSMotion Controls CMC Spiral Bevel Gearbox RLS51 limit switch provides extreme end of travel limits for each actuator system and a datum reference point for position

Trang 1

71

80

90SN

90LN

100L

112M

132S

132M

160M

160L

180M

180L

200L

D

11 14 19 24 24 28 28 38 38 42 42 48 48 55

E

23 30 40 50 50 60 60 80 80 110 110 110 110 110

F

4 5 6 8 8 8 8 10 10 12 12 14 14 16

G

8.5 11 15.5 20 20 24 24 33 33 37 37 42.5 42.5 49

D1

11 14 19 24 24 28 28 38 38 42 42 48 48 55

E1

23 30 40 50 50 60 60 80 80 110 110 110 110 110

FI

4 5 6 8 8 8 8 10 10 12 12 14 14 16

G1

8.5 11 15.5 20 20 24 24 33 33 37 37 42.5 42.5 49

ED2

10 20 25 32 32 50 50 70 70 100 100 100 100 100

ED3

16 5 32 40 40 5 5 5 5 5 5 5 5 5

EB3

1.5 1.5 1.5 1.5 1.5 3 3 3 3 5 5 5 5 5

ED

10 20 25 32 32 50 50 70 70 100 100 100 100 100

ED1

16 5 32 40 40 5 5 5 5 5 5 5 5 5

63S 71 80 90SN 90LN 100L 112M 132S 132M 160M 160L 180M 180L 200L

DH

M4 x 10 M5 x 12.5 M6 x 16 M8 x 19 M8 x 19 M10 x 22 M10 x 22 M12 x 28 M12 x 28 M16 x 36 M16 x 36 M16 x 36 M16 x 36 M20 x 42

DH1

M4 x 10 M5 x 12.5 M6 x 16 M8 x 19 M8 x 19 M10 x 22 M10 x 22 M12 x 28 M12 x 28 M16 x 36 M16 x 36 M16 x 36 M16 x 36 M20 x 42

63 71 80 90SN 90LN 100L 112M 132S 132M 160M 160L 180M 180L 200L

M

115 130 165 165 165 215 215 265 265 300 300 300 300 350

N

95 110 130 130 130 180 180 230 230 250 250 250 250 300

P

140 160 200 200 200 250 250 300 300 350 350 350 350 400

S

10 10 12 12 12 15 15 15 15 19 19 19 19 19

T

3 3.5 3.5 3.5 3.5 4 4 4 4 5 5 5 5 5

LA

7 7 12 12 12 12 12 12 12 13 13 15 15 19

M

75 85 100 115 115 130 130 165 165 215 215

-N

60 70 80 95 95 110 110 130 130 180 180

-P

90 105 120 140 140 160 164 200 200 250 250

-S

M5 M6 M6 M8 M8 M8 M8 M10 M10 M12 M12

-T

2.5 2.5 3 3 3 3.5 3.5 3.5 3.5 4 4

-LA

7 9 9 9 9 12.5 13 14 14 13 13

Typ.

B3, B5, B3/B5, B14, B3/B14

Electric Motors

11 to 18

19 to 28

32 to 48

55

j6

j6

k6

m6

+0.008 -0.003 +0.009 -0.004 +0.018 +0.002 +0.030 +0.011

Shaft

British and European

,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,,

,,, ,,, ,,,

,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,, ,,,,,,

,,, ,,, ,,,

Shaft tapped DH1 x deep to

Shaft tapped

DH x deep to DIN 332 Form D

ØD

+0 G-0.2

+0 G-0.2

63

71

80

90SN

90LN

100L

112M

132S

132M

160M

160L

180M

180L

200L

A

100

112

125

140

140

160

190

216

216

254

254

279

279

318

B

80 90 100 100 125 140 140 140 178 210 254 241 279 305

C

40 45 50 56 56 63 70 89 89 108 108 121 121 133

H

63 71 80 90 90 100 112 132 132 160 160 180 180 200

K

7 7 10 10 10 12 12 12 12 15 15 15 15 M16

L

207 238 295 322 322 368 381 451 451 605 605 667 667 810

L2

264 257 315 342 342 397 410 490 490 644 644 706 706 855

AA

19 19 27 28 28 28 35 38 38 49 49 50 50 63

AB

119 131 157 165 165 184 218 242 242 304 304 329 329 386

BB

100 110 127 152 152 170 170 208 208 304 304 329 329 355

BC

10 10 13.5 38.5 13.5 15 15 53 15 69 25 63 25 25

HA

2 2 4 4 4 4 4 5 5 5 5 6 6 25

AC

126 140 158 178 178 199 215 255 255 314 314 358 358 410

AD

-132 140 140 154 167 188 188 240 240 260 260 280

HD

169 186 212 220 220 234 265 306 306 363 363 416 416 405

AE

68 91 102 110 110 123 133 155 155 196 196 216 216 235

EB

1.5 6.5 1.5 1.5 1.5 6 6 6 6 6 6 7 7 7

LL

44 42 75 100 100 32 35 25 25 25 25 40 40 38.5

KK

20 20 20 20 20 20 25 25 25 32 32 32 32 32

KK

1 x PG 13.5

1 x PG 13.5

1 x PG 13.5

1 x PG 13.5

1 x PG 13.5

2 x PG 13.5

2 x PG 16

2 x PG 21

2 x PG 21

2 x PG 29

2 x PG 29

2 x PG 29

2 x PG 29

2 x PG 29 + 1 PG 13.5

TBW

103 86 103 103 103 106 127 127 127 140 140 140 140 140

Terminal Box

Spec

European Spec TBH

103 86 103 103 103 106 127 127 127 140 140 140 140 140

Typ.

Trang 2

6.1.2 Anti-Rotation & Wear Monitoring

6.1.1 End of Travel Limit Switches

Inductive proximity sensors or electro-mechanical

roller plunger switches can be used as end of travel

limit switches These arrangements are typically

used as limits to stop the actuator or reverse the

drive motor.

Electro-mechanical roller plunger switches triggered

by a nut on the lifting screw which depresses the

plunger as it passes.

Inductive Proximity sensors trigger when the target

nut on the lifting screw passes the sensor The

sensor sends a signal to the control circuit.

Anti-Rotation Monitor - The inductive proximity sensor generates a series of pulses from the target discs mounted on the circumference of the nut The nut rotates at the same speed as the worm gear If the frequency of pulses is lower than a predetermined value or stops then the control system can inform the operator This can be used to indicate that the system is below speed or a jamming condition has occurred

The above arrangement is for a lifting screw in compression because as the gear wears the nut moves away from the gear and towards the sensor If an actuator were in tension the target ring for the sensor would be to the right of the sensor, as the nut would move towards the gear

The anti-rotation and wear monitor devices can be supplied together or as separate devices for Power Jacks machine screw actuators For installation purposes both devices can be accommodated either below the actuator base (as above) or in the actuator's shell cap Consult Power Jacks for details

Nut connects to worm

gear via dowel pins

This allows the nut to

rotate with the gear

and follow the lifting

screw as the thread in

the gear wears note

the nut is unloaded

Wear Monitor - Inductive

Proximity Sensor looks for the target ring on the nut As the gear set wears the nut and its target ring move closer to the sensor The sensor triggers when the ring

is in front of the sensor When trigger the control system indicates that the actuator should be inspected and refurbished

Electro-mechanical Limit Switches

Inductive Proximity Sensors

Anti-Rotation target discs

Wear monitor target ring

Actuator Base

Actuator Bottom Pipe

Trang 3

LINEAR MOTION CONTROLS

Motion Controls

CMC Spiral Bevel Gearbox RLS51 limit switch

provides extreme end

of travel limits for each

actuator system and a

datum reference point

for position control

PowerMAX 5000 frequency converter

with integral motion control card Two bookstyle units linked to sychronise a 2 axis system for speed and position control

Two mechanically linked Sym-metric actuator systems are electronically synchronised for speed and position control using the PowerMAX 5000 frequency converter with integral control card The PowerMAX 5000 controls the systems by controlling the motion of each motor comparing actual and required performance via a closed feedback loop This is provided by the encoders in each motor feeding back direct to the PowerMAX 5000 Each actuator system is referenced from a datum point signalled by the RLS-51 limit switch on each system The RLS-51 also provides end of travel limits that are installed for safety Each frequency converter has an integral motion control card, which are linked together and arranged in a master-slave relationship for control purposes.

This type of system is used where mechanical links to all linear motion components are not possible and where complete motion control is required for a specific process For example a platform lift where a series of precise positions are required along the actuators stroke where the platform must stop for a specified time with variable speeds at the end of each stroke and a certain number of cycles per complete operation All of which can be programmed into the unit with key user parameters accessible via the control keypad.

For advice on specifying the best solution for your application consult Power Jacks Ltd.

AC motor with integral

AC brake and encoder

Spacer couplings (self supporting)

Sym-metric translating screw actuators

mechanically linked in a two actuator

system

Trang 4

7.1.1 PowerMAX 5000 Frequency Converter

Advanced AC frequency converter with voltage vector control for extremely accurate motor control giving near servo performance from standard industrial AC induction motors

Plus Integral Motion Control Card Option Integral FieldBus Network Card Option

7.1.1.1 Features

Quick and Easy

to Program

The control panel provides a choice of language A "Quick Menu" guides the user quickly and safely through key parameters for a quick installation The panel simply clips in place and may be removed from the drive

at any time It also has a copy function so extra drives can be set-up in seconds

User-Friendly Control panel has a large display showing 4 measurements, menu group, menu item, parameter value and 3

operating conditions simultaneously It provides access to logically ordered and grouped menus of inverter parameters with values displayed in engineering units and plain English (or chosen language)

Fast Reaction The PowerMAX 5000 precise slip compensation works in the whole speed range, including the

over-synchronous area) and adapts in less than 3 milliseconds

Precision PowerMAX 5000 determines the correct stable speed that can react in milliseconds (speed adaptation in less

than 3ms) Achieved by providing constant torque at all speeds with a 160% overtorque in the whole speed range to 0 rpm

Automatic Motor

Adaption

Ensures optimal cooperation between inverter and motor by reading and checking values without motor spinning

Inverter Set-Ups User definable inverter/motor set-ups stored in non-volatile memory (4 maximum)

Energy Efficient An automatic energy optimizer makes sure the inverter provides the lowest possible energy consumption

compared to actual motor load This can cut energy consumption by up to 10% and cuts noise level drastically

Recyclable The PowerMAX 5000 inverter is 95% recyclable

Safety Inverter protection for: short circuit phase to phase or phase to earth, over current, over temperature, over

voltage, under voltage, over load, motor over temperature, motor phase missing, mains fault, mains phase missing

I/O Protection All digital and analogue inputs and outputs are galvanically isolated Galvanic isolation, in accordance with

Protective Extra Low Voltage (PELV), between the supply voltage and the low current circuits

Communication RS485 serial communication as standard Optional Fieldbus netork card for Profibus or Devicenet to link to a

factory wide network can slot into all units as standard

Compact Design Two styles available for different applications "Compact" and "Bookstyle" Bookstyle (IP20) has a small width

and allows side by side mounting - ideal for small installations Compact has a small depth and a choice of enclosure ratings IP20 or IP54

Motion Control Powerful motion control card to allow full speed and position control of up to 32 axes as individual units or

synchronised The control card just slots in to any unit as standard and can link direct to the optional Fieldbus network card

Two Voltages Two three phase voltage ranges: 200-240 VAC and 380-500 VAC

RFI Filter Built in as standard

DC Coils As standard built-in DC-link coils that reduce mains harmonics by 40%

Cable Runs 150 metre screened motor cables possible without additional motor coils

Encoder Ability to connect two encoders.

Switching Switching on outputs allowed

Trang 5

7.1.1.3 Inverter Control Panel

7.1.1.2 Standard Control

Motion Control

• Four independent set-ups with bumpless transfer and infinite output switching

• Analogue reference (2) scaleable: 0±10VDC, 0/4±20

mA, potentiometer

• Configurable digital inputs (8): 5 Stop & Start types, Resets, Quick Stop, Pulse Start, Direction(s), Jog, 4 Presets, 4 Set-ups, Raise/lower, feedback (Encoder/s), Freeze

• Configurable digital / analogue outputs (2):

Frequency, Reference, Current torque, 4-20mA, 0-24VDC

• Brake resistor terminals

• External 24 VDC supply option for control module

• Internal space and plug in connections for motion control and/or FieldBus cards

The control panel on the inverter is detachable and can be removed

whether the inverter is in operation or not It contains a copy function

so extra drives can quickly be set-up by downloading parameters The

inverter control panel can be installed up to 3 metres away with an

optional mounting kit and has a protection rating of IP65 The control

has a large LCD screen giving full operator, programming, and

diagnostics capability through a user friendly interface with plain

English commands and engineering units The display can show 4

measurements and three operating conditions and is illustrated

opposite

If the control panel is not suitable for normal operator use then the

inverter may be controlled by external electronic devices directly wired

to its terminals

7.1.1.4 Installation

a) Operating 0OC → +40OC

b) Storage -25OC → +70OC

2 Power supply 3 phase 380-400 VAC (3 phase 200-240 VAC available)

3 Enclosure IP20 (IP54 available)

a) Emission - EN50081-1/2, EN61800-3, EN55011, EN55014

a) Immunity - EN50082-2, EN61000-4-2, IEC1000-4-3, EN61000-4-4, EN6100-4-5, ENV50140, ENV50141, VDE0160/1990.12

6 Motor cable lengths: 150 m screened/armoured, 300 m unscreened

7 Brake cable length 20 m screened/armoured

Full dimensions consult Power Jacks

• Up to 37 kW constant torque units for 3 ph 380-500 VAC

• Up to 18.5 kW constant torque units for 3 ph 200-240 VAC

• Open and closed loop speed control

• Process control with PID

• Torque regulation - open loop or with speed feedback

• High overload capacity for constant and variable torque

applications

• Automatic motor adaptation

• Automatic energy optimisation

• Advanced load compensation

• Powerloss regulation

• Dynamic braking facility (brake resistors available)

• Regeneration control

• Flying start

For full inverter details consult Power Jacks

Cancel

Stop Alarm

Reset JOG REV Start

FWD.

OK Change

Data

Quick Menu Menu Disply

Status

Warning ON

Trang 6

7.1.1.5 Motion Control Card

For applications where electronic control of actuator or drive systems is preferred the integral motion control card option is ideal Power Jacks can supply the inverter with card installed, pre-programmed and tested to perform the control for motion applications

As the control card is integral in the inverter this reduces installation space and wiring and the need for extra external control devices such as PLC Up to 32 axes can be controlled in a master-slave arrangement for synchronisation or individual control A mix of rotary and linear motion devices can be controlled in one installation

Operator controls can be via pushbutton and the standard inverter control panel, which is customisable to allow operator key parameters such as target positions, speed, acceleration, etc or via an HMI (Human Machine Interface) keypad/display which can directly communicate with the inverter on the RS485 port The other option is to link via the FieldBus option into a machine or factory network central control

The option control card is programmed from a PC using a powerful language specially designed for positioning control with commands based on frequently used control terminology Power Jacks offer full motion programming so a complete motion package through actuator, gearbox, motor, feedback devices, inverter, and operator panel can be provided

Features

1 User definable motion programs (127 maximum) stored in non-volatile memory These programs can be selected or automatically activated Programs transferred to the card via RS485 port to a PC

2 Communications - via plug in connectors "Phoenix" type

a) Digital inputs - 8, PNP, 0-24 VDC, (further 8 on main inverter card)

b) Digital outputs - 8, PNP, 0-24 VDC

c) Both digital inputs and ouputs are galvanically isolated in accordance with PELV

d) Direct connection of encoders(2) incremental or absolute - 5 VDC, com, A, A, B, B, Z, Z

i)Incremental: 5V differential, linedriver or RS422, 220 kHz maximum frequency

i)Absolute: SSI signal, Gray code protocol, 8192 max ppr, 4096 max revolutions

3 Inverter 24 VDC power source can supply up to 420 mA including load on the control card The 5 V supply is generated from the 24 V supply and has a maximum power of 60 mA on the 24 V side

Stacking Machine

Two individually motorised actuators electronically sychronised move to set positions to load product to a platform At the end of the loading cycle the stack is off loaded and the actuators fast return to repeat the operation

Sensors indicate when product is loaded Key user parameters such as number of product per stack, product size, number of cycles per process run are entered via the inverters keypad display

Position and speed feedback from encoder on motor

Datum point set via proximity sensor with two further sensors as extreme limits

7.1.1.6 FieldBus Network Card

In many applications there is a need to transfer process data as the real-time position of a lift system or the real-time synchronisation deviance of an application To relay this kind of information a Fieldbus option can be used Using a Fieldbus option can also help to free up the digital inputs and outputs for other tasks

Two standard protocols are available for the networkcard: Profibus and Devicenet

The motion control and Fieldbus card can be installed in one unit with internal plug in connections

For full information on the network card option consult Power Jacks

Example Installation

Trang 7

7.1.2 Rotary Limit Switches

Motion Control

7.1.2.1 RLS-51 Rotary Cam Limit Switch

Power Jacks actuators are used in a wide spectrum of industries for lifting, positioning and materials handling applications All of which require a level of motion control Power Jacks RLS-51 series geared cam limit switches are ideal for use

as:-• End of travel limit switches to stop or reverse an actuator system

• Mid travel signal providers to allow integration of other process operations

And allow integration of other feedback devices such as potentiometers and encoders inside their compact housing

RLS-51 Features

include:-1. Useable revolutions from 4 to 16,000

2. 2 to 8 position limit switches

3. Enclosure IP66 as standard

4. Mounting options for B14 face, B5 flange and B3 foot mounted

5. Available in three voltages 250 VAC, 24 VDC and 80 VDC

6. Modular design to allow a wide variety of options

7.1.2.1.1 Illustrated Examples

RLS-51 with 8 Limit Switches and foot mounting

The switching points for all contacts can be changed commonly

by block

adjustment-An electric adjusting motor can be retrofitted

Analogue feedback systems, e.g potentiometers, can easily

be fitted The same applies to the pulse generator used as

motion indicator for actuator systems

With absolute encoder

For safety disengagements positive opening switching contacts are used: for position or incremental encoders to offer highest safety and finest resolution

With motorised adjustment Gear Part

With pulse generator and B5 flange mount With potentiometer

Trang 8

7.1.2.1.2 RLS-51 Features and Options

The RLS-51 geared cam limit switches are universal mechanical switching devices that have been designed for use in conjunction with cam discs on a specific angle of rotation for the indication of a large number of shaft revolutions These cam discs serve to operate mechanical contacts Design features

include:-Low Friction Planetary Gearing with irreversable, self-locking worm adjustment of the cam discs.

Fixed Cam Adjustment in the housing The adjusting worms of the cam discs are arranged so that they can be accessed from the

same direction as the contact connections for optimal accessibility in confined conditions Adjustment is possible during operation The simplicity and accuracy of the cam adjustment is unsurpassed

Block Adjustment of all switching contacts jointly is made possible by a single adjusting worm (black) without the switching points

of individual switching contacts being altered with respect to each other

Large Cam Disc Diameter for good adjustability and high switching point repeat accuracy.

Reinforced Polycarbonate Housing as standard with IP66 protection and a wide operating temperature range.

Modular Design allows adaptation to suit individual requirements via intermediate pieces.

Maintenance Free gearbox components.

Options

• Position indicating plate for block adjustment

• Potentiometer feedback drives (2 available) to suit single and multi-turn potentiometers

• Pulse transmitter with 50 pulses per revolution

• Anti-condensation heater to prevent condensation and excessively low temperatures in switches

• Motor driven contact block adjuster

• Mounting for encoders (incremental and absolute)

• Extended drive shaft for feedback devices

• Aluminium housing for harsh environments and fitment of large and heavy encoders, IP 65 enclosure

• Cam discs with a 40O cam angle can be provided at no extra cost Standard is 15O cam angle Other angles can be manufactured at extra cost on request Note different cam angles alter the number of useable revolutions from the standard The 40O cam has less useable revolutions than a 15O cam, consult Power Jacks

• Stage Technology Tested Unit can be provided to VBG 70 with test certificates A 40O angle cam disc is used for this application

Note

The ideal drive for the limit switch is transmitted by a torsionally stiff, flexible coupling with low axial and radial restoring forces Thereby misalignment and axial displacement are balanced For radial load ratings and coupling advice consult Power Jacks

Trang 9

7.1.2.1.4 Switching Contacts

The contacts can either be connected through screw terminals for a cable cross section of 0.75 mm2 to 1.5 mm2 or through flat plugs 6.3 x 0.8 mm or through a printed card with cage tension spring terminals for a cross section of 0.14 to 2.5 mm2 For contacts with flat-plug connection, insulated flat - flat-plug receptables must be used at voltages above 25V AC and 60 VDC

7.1.2.1.3 RLS-51 Performance

Motion Control

Gear

Size

Usable

revs.

selected

Usable revs.

theoretical with 15° cam discs

4.16 6.88 11.23 17.84 29.5 48.13 76.45 126.39 206.26 327.6 541.5 883.8 1403.7 2320.2 3787.1 6014.77 9942.2 16227.6

4.1

6.5

11

17.5

29.0

48

75

125

205

323

540

880

1384

2288

3735

5900

9800

16000

1

2

3

4

5

6

Input/

output stage

1 rev of the drive shaft -corresp to an ang motion of cam disc = °

No of in-term stages

Change - over contact reset rev at driving shaft

Max drive speed (RPM) Gear Ratio

4.285 7.083 11.56 18.361 30.35 49.538 78.678 130.054 212.272 337.135 557.284 909.59 1444.62 2387.96 3897.58 6190.204 10232.407 16701.17

1x4.285 1x4.285 1x4.285 2x4.285 2x4.285 2x4.285 3x4.285 3x4.285 3x4.285 4x4.285 4x4.285 4x4.285 5x4.285 5x4.285 5x4.285 6x4.285 6x4.285 6x4.285

-1.653 2.698 -1.653 2.698 -1.653 2.698 -1.653 2.698 -1.653 2.698 -1.653 2.698

1000 1200 1500 1800 1800 1800 1800 1800 1800 1800 1800 1800 1800 1800 1800 1800 1800 1800

0.00714 0.0118 0.0193 0.0306 0.0505 0.0825 0.131 0.2166 0.3536 0.5616 0.9284 1.515 2.406 3.978 6.493 10.313 17.047 27.824

84 50.8 31.14 19.6 11.86 7.27 4.57 2.77 1.69 1.06 0.65 0.4 0.25 0.15 0.09 0.06 0.04 0.02

Min drive shaft speed (only for change - over contact)

0.67 1.1 1.8 2.9 4.7 7.7 12.2 20.2 33 52 87 141 224 371 606

*

*

*

* Caution! Due to the slow actuation speed of the switching contacts caused by the high gear reductions, the change-over

behaviour of the contacts is affected negatively

From gear size 6 it is therefore recommended to use only the only normally - closed contacts of the switches Before using analogue feedback systems (e.g potentiometer) please consult our technical department

Contact

Designation Contact type material Contact

92

97 2)

99L

99P

96

Silver Gold Silver Silver Silver

Yes Yes Yes Yes Yes

6 6 6 3 6

250 250 250 250 250

6 6 3 3 6

2 2 2 2 2

10 10 10 10 10

Snap action Snap action Snap action Snap action Snap action

Screw terminal Screw terminal Printed card Flat plug 6.3 Screw terminal

Change-over switch Change-over switch Change-over switch Change-over switch Normally closed contact

DC switching capacity with T=0 ms (pure resistive load) DC switching capacity with inductive load on request

Contact 97 for SPC applications (gold contacts)

1)

2)

Type of contact connection

Switch Rating

Amps Volts

Positive opening to VDE0660 part 200 from 7.92 EN60947T5-1

Switch

switching operations

Change over switch Normally closed contact

92 97 99L 99P

96 (12,22, )

(11,21, )

1

(11,21, )

1 2

Trang 10

7.1.2.1.5 RLS51 Dimensions

B14, Face Mounted

B3, Foot Mounted

L1

18

27

15

ø40 -0.1 ø8

pg x 1.8

6

128

PG 16

Blanking Plug

PG 16

M6 x 10 tief

30 O 30 O

104

±0.1

18

7

75

27 15

h9 pg3

PG16

130 145

Blanking Plug

PG 16

30 O 30 O

104

±0.1

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