ZF Friedrichshafen AG Special Driveline Technology. Hysteresis brakes Hysteresis clutches Electronic control unit

Transcription

1 ZF Friedrichshafen G Special Driveline Technology Hysteresis brakes Hysteresis clutches Electronic control unit

2 2 ZF-Servoplan CG Compact Gearbox ZF-Duoplan 2K Two-speed Gearboxes ZF-Ecolift Elevator Gearboxes ZF-Servoplan PG Servogearboxes Customer specific Gearboxes

3 3 Precision in movement The ZF Friedrichshafen division Special Driveline Technology is able to offer you a wide range of machine drives, brakes and clutches for applications in engineering as well as customer specific drive solutions. ZF-Tiratron Hysteresis Brakes Our development and production activities are focused on servo-assisted drives for automation engineering, two-speed drive gearboxes for machine tools as well as customer-specific drives, such as for printing machines, robot applications and elevator gearboxes. Our innovative standard products range from low backlash servogearboxes (ZF-Servoplan), and robust two-speed gearboxes (ZF- Duoplan) to hysteresis clutches and brakes for non-contact web control (ZF-Tiratron).

4 ZF Hysteresis products 4 ZF Hysteresis components are brakes, clutches and ERM electronic control unit. ZF Tiratron, i.e. the combination of the brake with the electronic control unit or the clutch with the electronic control unit, enables the exact control of tensile forces as well as a defined setting of a torque. Exemplary operation The ZF hysteresis technology can be used and applied wherever products, such as paper, wire etc., are processed by winding. Loads can be simulated with Tiratron on test benches or in ergometers. Continuously adjustabel torque The brake torque or the transferable torque depends only on the current. It is largely speed-independent and form zero to maximum speed constantly available. High slip power in continuous mode, overload capability The brakes of the power optimized series can bear high slip power continuously. Overloads can be applied for a short-term period. The system, consisting of the break or clutch and the universal usable control unit, is standardized and can be used for most of the applications. Operating principles The operating principles of hysteresis brakes and clutches are based on the magnetic force effect of attracting poles in synchronous mode and on continuous magnetic reversal in slip mode. Non-contact torque transmission The non-contact torque transmission via the airgap of the mechanical componentes brake or clutches, is continuously variable, then constant and free of any wear.

5 Installation examples bb.1: Hysteresis brakes to produce a defined thread tension. bb.2: Hysteresis brakes with flyer for unwinding flexible leads with constant tensile force. bb.3: Hysteresis clutches to wind up a foil with constant tensile force. bb.4: Hysteresis brake to unwind a tape with constant tensile force. toothed belt is used to produce a higher braking torque. 5

6 Hysteresis brakes Types: - Torque-optimized series - Power-optimized series - Power-optimized series with gearbox The armature and the brake magnet are the individual components making up the ZF hysteresis brake. ZF Hysteresis brakes are offered with a nominal torque ranging from 0.05 Nm to 520 Nm, depending on the size, available as bearing version with shaft end or non-bearing version as individual components. The brakes have a power capacity of up to 2000 W during continuous operations and of 4000 W during shortterm operations (interval operations). Typical torque-current-diagram Only the current preset in the magnet solenoid defines the slip and holding torque, which can be infinitely adjusted from zero to the maximum value. The torque is almost independent from speed. Major temperature increases cause a slight reduction of torque. They can be used both in the slip mode range and as a holding brake. 6 F ig.: Reversal of magnetization Slip power During continuous slip mode, heat generation caused by slip power must also be taken into account. Permissible continuous slip power limits are included in the selection tables. Required continuous slip power is calculated as follows: P s = T. n s s or Ps = F. v 9.55 P S : Slip power in W T S : Slip torque in Nm n S : Slip speed in rpm F: Tensile force in N v: Band pull speed in m/s Residual magnetism Torque ripple occurs as a result of residual magnetism when the current is changed to below 50% of the initial value either abruptly or without turning the armature/rotor. reliable way to avoid torque ripple is to reduce the current while simultaneously turning the armature and rotor resp. brake solenoid during approx. 1 turn (relative). Every following operation cycle is removing possible residual magnetism. Manufacturing and torque tolerances: When ordering the standard version according to the catalog, an individual unit s torque-current curve as well as its torque relative to nominal current may deviate slightly from the published data due to production tolerances. typical deviation for individual units would be +/- 10 %. Upon request, we can offer specially matched pairs for those applications requiring lower tolerances. The actual torque-current curve for a specific unit is exactly reproducible under the same conditions.

7 Torque Current 1. Brake magnet with solenoid 2. rmature with hysteresis ring F ig.: Bearing version with shaft 7 2 1

8 Power-optimized hysteresis brakes Sizes: T echnical data: 250/1 500/3 1000/ /30 Nominal torque* T N (Nm) Nominal torque* at speed n Permitted speed in continuous mode at nominal torque Permitted slip power in continuous mode Max. slip power in short time mode Nominal current T P (Nm) n (rpm) P (W) P max (W) I N () Nominal voltage U N (V) Max. speed n max (rpm) Shaft side inertia torque J W (kgcm 2 ) Power consumption at coil temperature 70 C Mass P 70 (W) m (kg) *Tolerances: See Scattering/Torque tolerances ll bearing types balanced, balance quality 6.3 Non-bearing types when supported in d5: balance quality: 23.6 mbient temperature up to 40 o C Dimensions (mm): 250/1 500/3 1000/ / B B , B D 1 h D D E d 1 k d 2 M 4 M 5 M 6 M 8 d 3 M 5 M 6 M 8 M 12 d d 5 S d 6 H a b c e l l l l l v P w L DIN

9 vailable versions: ** * Centering DIN 332 (D) ** connecting leads 0,5 mm 2, length 500 mm B1 45 : Bearing type, shaft right side l1 v l4 l3 l2 a * D3 d1 D1 d4 D2 d2 c b d3 (4x90 ) ** B2 d2 a l1 l2 d4 d1 D1 D2 D3 w L B: Bearing type, shaft left side l5 l4 v 500/3-2000/30 w L * d4 (4x90 ) b c C: Non-bearing type for integrated solutions 9 D3 d5 E d6 D1 B3 d4 0,1 d3 (4x90 ) b c

10 Torque-optimized hysteresis brakes Sizes: T echnical data: Nominal torque* 0,05 L 0,1 L 0,1 LW T N (Nm) Max. slip power in short time mode Nominal current P max (W) I N () Nominal voltage U N (V) Max. speed n max (min -1 ) rmature side inertia torque Power consumption at coil temperature 70 C Mass J arm (kgcm 2 ) P 70 (W) m (kg) *Tolerances: See Scattering/Torque tolerances mbient temperature up to 40 o C Dimensions (mm): 0,05 L 0,1 L 0,1 LW C D D D D 8 h E c d j d 2 24/2 x180 32/3 x120 - d 3 M 4 M 3 - d d M 4 M 4 d e f / f f f f l

11 vailable versions: f 1 E 1 MX. D 1 d 5 e c f 2 f 4 f 3 d 3 2kt SW 14 d 2 d 11 D 8 D 2 d 4 10 D ±1 f 5 MP plug Steckverbinder connection 200 x10 0,05L D 1 D 8 d 2 d d ,1L d e C f 2 D 1 d 300 0,1LW 60 d d 5 e 11 l 34 34

12 Torque-optimized hysteresis brakes Sizes: T echnical data: 0,3 L 1 L 3 L 10 L 30 L Nominal torque * Max. slip power Nominal current Nominal voltage Max. speed rmature side inertia torque Power consumption at coil temperature 70 o C Mass T N (Nm) P max (W) I N () U N (V) n max (min -1 ) J arm (kgcm 2 ) P 70 (W) m (kg) *Tolerances: See Scattering/Torque tolerances mbient temperature up to 40 o C Dimensions (mm): 0,3 L 1L 3 L 10 L 30 L D D D 3 22 K7 35 H7 42 K6 80 H7 140 H7 D f7 160 h8 240 h8 D L DIN L B DIN b d 7 h7 9 h7 14 h7 24 h7 38 h7 d d 5 M 5 M 5 M 6 M 8 M 8 d M 5 x12.5 M 8 x19 M10 x24.5 e f f l l l l vxw x 3 8 x 4 10 x 5 w

13 D1 D7 D3 d D8 D2 d5 300* 120 e d2 b 0,3L- 30L f1 f2 l l3 l2 w l3 l1 v w L LB L L B d10 l1 13

14 Torque-optimized hysteresis brakes Sizes: T echnical data: Nominal torque * Max. slip power Nominal current Nominal voltage Max. speed rmature side inertia torque Power consumption at coil temperature 70 o C Mass 0, T N (Nm) P max (W) I N () U N (V) n max (min -1 ) J arm (kgcm 2 ) P 70 (W) m (kg) *Tolerances: See Scattering/Torque tolerances mbient temperature up to 40 o C Dimensions (mm): 0, D D D 3 22 K7 35 H7 42 K6 80 H7 140 H7 D K6 42 K D 5 32 K7 42 K7 52 K7 90 H7 110 H7 D 6 26 K D h8 240 h8 a b c d / /-0.1 d 3 M 4 M 5 M 5 M 8 M 8 d / /-0.2 d 5 M 5 M 5 M 6 M 8 M 8 d / /-0.2 d M 8 M 10 e f g h

15 D3 d d 3 (4x90 ) D4 b 300 d 3 (4x90 ) D3 D4 e f b h a D6 D5 d2 D2 D1 d DIN 472 d 4 0,1 c 0,3 e g h f D5 d2 0,1 D2 D1 d c a d D6 D7 D3 e b d3 (4x90 ) D4 D5 d2 D2 D1 d 6 d 4 90 d7 0,1 f c 15 g a

16 Power-optimized brakes with gearbox Sizes: T echnical data: 500/30 G 1000/100 G 2000/300 G 2000/600 G Ratio Nominal torque* Nominal torque* for speed n Idling torque Permitted speed in continuous mode Max. slip power in continuous mode Max. slip power in short time mode Nominal current Nominal voltage Max. speed Shaft side inertia torque Power consumption at coil temperature 70 C Mass i** T N (Nm) T P (Nm) T L (Nm) n (rpm) P (W) P max (W) I N () U N (V) n max. (rpm) J W (kgcm 2 ) P 70 (W) m (kg) *Tolerances: See Scattering/Torque tolerances mbient temperature up to 40 o C **Other ratios on request Dimensions (mm): 500/30 G 1000/100 G 2000/300 G 2000/600 G B D D d 1 k e f s a b c l l l l v P w Z 2 h

17 w Sizes: ZF-Type: 500/30 G 1000/100 G 2000/300 G 2000/600 G Brake Gear PG 500/3 1000/ / / /1200 vailable versions: * Centering DIN 332 ** connecting leads 0,5 mm 2, length 500 mm b l3 G ** c 2 l2 l1 l6 a 45 xs 1 z 2 d1 f 1 xe 1 D 3 D11 * v 45 4x90 B 17

18 Permanent magnet hysteresis brake Remarkable features of the permanent magnet (PM) hysteresis brake are its high nominal torque with a compact design. The brakes permanent magnet excitation makes it independent of any power supply. The torque values can be set and reproduced easily and in a user-friendly fashion with the 37-times detented setting ring. The tolerance of the nominal torque amounts to +/- 5 %. Torque curve Torque (Ncm) Setting detents () Size: *Tolerances: See Scattering/Torque tolerances mbient temperature up to 40 o C T echnical data: Max. nominal torque * Min. nominal torque * Number of detens Permitted slip power in continuous mode Max. speed Inertia torque Mass Bearing type DBU 0,2 L T Nmax (Nm) 0.35 T Nmin (Nm) P (W) 20 n max (min -1 ) J w (kgcm 2 ) 0.63 m (kg) 0.36 L DIN

19 vailable version: Torque-adjustment 37 Detents ( ) 10 marked numbers ( ) 10 intermediate numbers ( ) x M4 L M h8 60 DBU 0,2 L ll dimensions in mm 19

20 Hysteresis clutches Rotor, armature and clutch magnet are the components that make up the ZF hysteresis clutch. The nominal torque as offered ranges from 0.4 Nm to 12 Nm. The maximum continuous slip power of the hysteresis clutch amounts to 500 W. The magnitude of scattering and torque tolerances correspond to the values of the ZF hysteresis brakes. s is the case with the brakes, special series are available on demand. The ZF hysteresis clutch distinguishes itself by a stepless transition from synchronous to slip operations. 20 Slip power During continuous slip mode, heat generation caused by slip power must also be taken into account. Permissible continuous slip power limits are included in the selection tables. Required continuous slip power is calculated as follows: P s = T. n s s or Ps = F. v 9.55 Residual magnetism Torque ripple occurs as a result of residual magnetism when the current is changed to below 50% of the initial value either abruptly or without turning the armature/rotor. reliable way to avoid torque ripple is to reduce the current while simultaneously turning the armature and rotor resp. brake solenoid during approx. 1 turn (relative). P S : Slip power in W T S : Slip torque in Nm n S : Slip speed in rpm F: Tensile force in N v: Band pull speed in m/s

21 1. Clutch magnet with solenoid 2. rmature wih hysteresis ring, usually output 3. Rotor, usually input

22 Hysteresis clutches Sizes: T echnical data: Nominal torque* Max. slip power Nominal current Nominal voltage Max. speed Side inertia torque Rotor rmature side inertia torque Power consumption at coil temperature 70 C Mass EKU 0,3 EKU 1 EKU 3 EKU 10 T N (Nm) P max (W) I N () U N (V) n max (min -1 ) J Rotor (kgcm 2 ) J arm (kgcm 2 ) P 70 (W) m (kg) *Tolerances: See Scattering/Torque tolerances mbient temperature up to 40 o C Dimensions (mm): EKU 0,3 EKU 1 EKU 3 EKU D D D 3 H D 4 h D 5 32 K7 42 K7 52 K7 90 H7 d 2 +/ d 3 M 4 M 5 M 5 M 8 d 4 +/ d 5 M 4 M 5 M 6 M 8 a b +1/ c e f g z d 1 H vxw 5x1.3 8x1.7 12x2.1 14x2.6 d 1 H vxw 4x1.1 8x1.7 8x1.7 12x2.1 d 1 H vxw - 6x1.7 6x1.7 8x1.7

23 D4 D3 d1 b g f DIN 472 d3 (4x90 )* D 5 d2 D2 D1 v w d5 0,1 d4 0,1 z e c a EKU *EKU 0,3: d3 (3 x 120 ) 23

24 Electronic control unit ERM 24 The ZF hysteresis electronic control unit makes it possible to set individual operating modes for the most diverse applications. The programming variations allow the electronic control unit to be used for all brake and clutch types.

25 1. DIL switch for coding sizes and functions 2. LED function and error indicators 3. Diagnosis interface (Mobi Dig 200) 4. Jumper

26 Electronic control unit ERM ZF hysteresis clutches and brakes can be controlled in open or closed loop with the ZF electronic control unit, depending on their application in different operating modes. The electronic components are micro-processor controlled and have programming, operating and diagnosis interfaces. The ERM electronic control unit has been set so as to feed the ZF hysteresis clutches and the ZF hysteresis brakes in an optimal way. Open-loop control (current) Open-loop control (torque) Open-loop control with Ø-sensing 26

27 ERM operating modes: Open loop control: - current - torque - Ø-sensing - Ø-calculation Cloesd loop control: - PD position control - PI force control - PID mixed control - freely programmable (with diagnosis device Mobi Dig) The ERM also offers the following special functions, depending on the operating mode: - Maximum current: Output of the nominal current, depending on the size - Zero current: the power output is set to zero - Web-break detector in the operating mode Ø-calculation - Compensation of the friction existing in the system Open-loop controlled operating modes with a size codification are less suitable for the power-optimized brake series. Please refer to the ERM operating manual for further information on the functions, connections etc. Open-loop controlled with Ø-calculation Closed-loop controlled - with dancer force control Closed-loop controlled - with storage/position control 27

28 ZF Friedrichshafen G Special Driveline Technology Ehlersstrasse Friedrichshafen/Germany Telefon: +49(0) Telefax: +49(0) industrial-drives@zf.com Internet: Sheet-No.: c The data contained in this borchure have no binding force. For the purpose of mounting tests, please ask for the relevant assembly drawings as only the details stated there are binding.