alpha Rack & Pinion System

Transcription

1 alpha Rack & Pinion System Precise Dynamic Efficient

2 alpha Rack & Pinion System New systems specially designed for your machine concepts New unique pinion connection New classes of rack Design improved using cymex design software Contents The alpha Rack & Pinion System System range and applications Advantages of the system cymex the design software Details technical data Lubrication system Assembly accessories Ordering codes

3 alpha Rack & Pinion System a perfect collaboration of state-of-the-art technology and many years of experience. alpha is the next generation of rack and pinion systems. Our unique knowledge extends from the separate coupling of gearhead, motor, pinion and rack to complete system solutions. The alternative not only for long distances Rack and pinion combinations do not only excel in applications involving long, precise movement paths. The alpha technology achieves maximum precision when using a Master/Slave tensioning system. The high-precision manufacturing of individual components is an essential aspect here because manufacturers and users must be able to rely on the installed drives to achieve the level of accuracy required. We offer the highest levels of precision, dynamics, and rigidity as well as an extended service life that more than satisfy the demanding requirements of machine and system manufacturers. The result of our efforts is maximum performance across the board. alpha has managed to move the old established system of rack and pinion back into the fast lane. 4

4 Always there for you. If you are striving to achieve your objectives quickly and implement solutions efficiently and individually, then alpha is the perfect partner for you. Make a decision in favour of world-class technology that will give your customers a leading edge and help further consolidate your partnership together. 5

5 The systems and applications Machine precision * 1 μm 5 μm 20 μm The right gearhead, rack and pinion for every application from low-cost to high-end solutions. The position accuracy required in the application, the existing measuring system, and the machine design essentially determine the configuration of linear systems and system combinations. 50 μm 100 μm A real powerhouse with a compact design. Constant rigidity and outstanding dynamics. Easy to operate, quickly becomes indispensable. Customised to suit your specific application needs. 200 μm >300 μm * Depending on further components. HSC (High Speed Cutting) portal milling machines Source: F. Zimmermann GmbH Profile machining centres Source: Handtmann A-Punkt Automation GmbH Eroding machines Grinding machines HSC portal milling machines Turning machines Machining centres Boring machines 6

6 Master/Slave: TP System output with Premium Class + pinion and Premium Class rack TP System output with Premium Class + pinion and Premium Class rack TP output with Premium Class RTP pinion and Premium/Smart Class rack SP System output with Premium Class + pinion and Premium/Smart Class rack SP involute output with Standard Class RSP pinion and Value/Smart Class rack Key output with Value Class pinion and Value/Smart Class rack Competent consultation Staff at our alpha Technical Office will be glad to answer any questions you may have about alpha rack & pinion system and your specific configurations. Give us a call! Laser machines Source: TRUMPF Werkzeugmaschinen GmbH + Co. KG Wood, plastic/composite machining centres Source: MAKA - Max Mayer Maschinenbau GmbH MAKA Precision System Smart System Economy System Laser machines Punching machines Water jet cutting machines CNC Wood-/plastic processing machines 7

7 Measuring system Page DIRECT 1 μm P Precision + System/ Precision System for highest requirements with regard to dynamics and accuracy in high-end applications. 5 μm μm 50 μm S Smart System for positioning options with more design freedom in flexible applications. 100 μm INDIRECT 200 μm >300 μm E Economy + System/ Economy System for standard linear applications in mid-range/low-cost applications. Plasma cutting machines Source: LIND GmbH Industrial Equipment Floor mounted robot tracks Source: MOTOMAN Robotics Europe AB Plasma cutting machines Pipe bending machines Foam cutting machines Automation 8

8 Linear drives with the alpha Rack & Pinion System provide a suitable solution for every application and break new ground in drive engineering. The right combination of alpha gearhead, pinion and rack in various systems tailored specifically to meet your application requirements. Dynamic Precise Efficient 9

9 Master/Slave: TP System drive with Premium Class + pinion and Premium Class rack alpha Rack & Pinion System alpha Rack & Pinion System the benefits for you Dynamic Maximum speed and acceleration with low moments of inertia. Extremely precise control characteristics due to constant linear rigidity along the entire movement path. Precise New drive solutions with unique true running accuracy. Maximum positioning accuracy due to precision alignment of components. Efficient Effortless operation. Minimal mounting space and high power density. Enormous savings potential due to high energy efficiency. 10

10 Better Worse The right gearhead, rack and pinion for every application. A direct comparison Ball screw Linear motor alpha Rack & Pinion System Speed Feed force Acceleration Workpiece surface finish Noise level Power consumption Safety after power failure Life cycle Crash behaviour Easy to service Investment costs Maintenance costs Operating efficiency (low utilisation) Operating efficiency (high utilisation) The comparison is based on typical processes involved in machining large workpieces and machines with long movement paths. In detail Feel the dynamics. Experience the precision. Maximise efficiency. Solution-oriented concepts, sophisticated development stages and perfect results. Helping you become a top performer. alpha rack & pinion systems will optimise your applications. Find out for yourself. Help your company take giant strides towards achieving its goals. 11

11 Gearhead Pinion - Rack 10,000 different combinations for greater precision, dynamics and efficiency cymex, the innovative design software from alpha, reduces routine work to a minimum while allowing maximum freedom for innovation. Extensive information, operating instructions and CAD graphics make assembly procedures easier. Complete machine configurations are tested, and detailed documentation is produced. Visualisation of the results allows extensive experimentation and permanent documentation. cymex accesses a database containing a collection of more than 7,000 motors from different manufacturers, which makes it the largest library of its kind worldwide. Combined with products from alpha, this information memory contains about 10,000 different gearhead, rack and pinion configurations (without motor). Immerse yourself in the virtually unlimited world of cymex. 12

12 cymex So simple, so quick, so comprehensive. cymex will help you find the right combination of motor, gearhead, rack and pinion quickly and easily. Accessing cymex is just as easy: The cymex 3.0 Design Edition is available for free download at This program version enables you to install one of over 7,000 servo motors from global manufacturers in an alpha gearhead at the click of a mouse and generate the necessary documents: simple, quick and secure. The comprehensive design software cymex Motion Edition can generate more than 10,000 gearhead, rack and pinion combinations as well as complete system configurations including detailed documentation. A complete version of this program is available directly from our sales force. Visit our homepage for more information. cymex cymex is the only software in the world designed specifically for calculating the best drivetrain configuration. Design engineers can be sure that all drivetrain variants will be taken into consideration when calculating the best solution. 13

13 alpha Rack & Pinion System Discover the overwhelming variety of alpha Rack & Pinion System combinations. 14

14 Details 15

15 Three classes of rack unlimited possibilities The correct rack is an essential component in realising your machine concepts. alpha offers three classes of rack Premium Class, Value Class and Smart Class to find the right solution for your application requirements. Have the freedom to implement your ideas! Precision System Premium Class Solution for high dynamic, precision high-end applications. For ultra precision use linear or gantry sorted racks. Feel free to contact us. Standard installation concept: fixed connection with a reference edge Economy System Value Class Solution for mid-range and economy applications. New feature: free connection option Smart System Smart Class The flexible rack for applications with no available mounting edge in the economy to mid-range sector. New: free connection without a reference edge The flexible modular assembly concept makes the Smart Class rack a versatile all-rounder. 16

16 Extremely flexible concept Free connection concept: The absence of a reference edge allows simple and uncomplicated mounting of the rack parallel to the machine guide. Modular machine concept: The 60 mm hole pattern and length of 480 mm are compatible with the hole patterns on linear guides produced by well-known manufacturers and enable the implementation of modular machine concepts. Clearing the way for unlimited movement paths. 17

17 Rack Dimensions Premium Class rack Module p t L z a a) a 1 B d d 1 b) D f +0.5 h h B h D H I I 1 L All dimensions in [mm] Cumulative pitch error Fp: 12 μm at m2 and m3 (250 mm in length); Fp: 15 μm at m > 2 Single pitch error fp: 3 μm b) Recommended tolerance dimension: 6 H7 /8 H7 /10 H7 /12 H7 /16 H7 p t = Reference circle pitch z = Number of teeth m = Module Value Class rack Module p t L z a a) a 1 B d d 1 b) D f +0.5 h h B h D H I I 1 L All dimensions in [mm] Cumulative pitch error Fp: 35 μm/1000 mm Single pitch error fp: 8 μm; 10 μm at m5 and m6 b) Recommended tolerance dimension: 6 H7 /8 H7 /10 H7 /12 H7 /16 H7 p t = Reference circle pitch z = Number of teeth m = Module New feature: free connection option Smart Class rack Module p t L z a a) a 1 B d d 1 b) D f +0.5 h h B h D H I I 1 L All dimensions in [mm] Cumulative pitch error Fp: 30 μm/500 mm Single pitch error fp: 6 μm b) Recommended tolerance dimension: 8 H7, 10 H7 p t = Reference circle pitch z = Number of teeth m = Module 18

18 a) Precision System a) Installing several racks leads to small gaps between the individual parts. Teeth hardened and ground All faces ground Pressure angle α= 20 Economy System a) Installing several racks leads to small gaps between the individual parts. a) Smart System Teeth hardened and ground All faces ground Pressure angle α= 20 a) a) Installing several racks leads to small gaps between the individual parts. Teeth hardened and ground All faces ground Pressure angle α= 20 19

19 Precision + System Dimensions Premium Class + pinion on TP system output with Premium Class rack TP System output Module z A-PC ± 0.3 a) b B d a d w D1 h7 D6 D7 D14 L7 L12 L13 L14 L15 L16 TP (MA, MF) TP (MA, MF) TP (MA, MF) TP (MA, MF) TP 300 (MA, MF) TP 500 (MA, MF) All dimensions in [mm] a) please contact alpha for precise dimensions; align mechanism recommended (alignment dimension ± 0.3 mm) z = Number of teeth d a = Tip diameter d w = Pitch circle diameter MA = HIGH TORQUE MF = Standard concentricity < 10 μm (m2) 20

20 Technical data TP + gearhead with Premium Class + pinion on TP system output with Premium Class rack TP (MA, MF) TP (MA, MF) Module z [N] i = 4 [N] i = 22 [Nm] i = 4 [Nm] i = 22 V max [m/min] i = 4 V max [m/min] i = m pinion [kg] Precision + System TP (MA, MF) TP (MA, MF) Module z i = 31 i = 22 i = 31 i = 22 V max [m/min] i = 31 V max [m/min] i = 22 m pinion [kg] TP 300 (MA, MF) TP 500 (MA, MF) Technical data based on 1000 load cycles per hour. For additional combination use cymex. = Max. moving force = Max. acceleration torque MA = HIGH TORQUE MF = Standard Load factor for rack moving force Load factor Number of load cycles per hour 21

21 Precision/Smart System Dimensions Premium Class RTP pinion on TP output with Premium and Smart Class rack TP output Module z A-PC ± 0.3 b) A-SC ± 0.3 b) b B d a d w D5 h7 D6 D7 D14 L4 L5 L7 L12 L16 TP + /TK a) TP + /TK + / TPK a) TP + /TK + / TPK c) a) TP + /TK + / TPK c) c) TP + /TK + / TPK d) TP a) c) TP a) All dimensions in [mm] a) with adapter flange b) please contact alpha for precise dimensions; align mechanism recommended (alignment dimension ± 0.3 mm) c) also in combination with TP + HIGH TORQUE z = Number of teeth d a = Tip diameter d w = Pitch diameter d) only in combination with TP + HIGH TORQUE concentricity < 10 μm (m2) 22

22 Technical data TP + gearhead with Premium Class RTP pinion on TP output with Premium and Smart Class rack Module z [N] i = 4 (PC) [N] i = 4 (SC) [N] i = 22 (PC) [N] i = 22 (SC) [Nm] i = 4 (PC) [Nm] i = 4 (SC) [Nm] i = 22 (PC) [Nm] i = 22 (SC) V max [m/min] i = 4 V max [m/min] i = 22 TP TP m pinion [kg] Precision System TP a) TP a) a) TP b) TP 300 (MA, MF) TP 500 (MA, MF) Module z i = 31 i = 22 i = 31 i = 22 V max [m/min] i = 31 V max [m/min] i = a) _ m pinion [kg] Smart System Technical data based on 1000 load cycles per hour. For additional combination use cymex. a) also in combination with TP + HIGH TORQUE d) only in combination with TP + HIGH TORQUE = Max. moving force = Max. acceleration torque SC = Smart Class PC = Premium Class MA = HIGH TORQUE MF = Standard Load factor for rack moving force Load factor Number of load cycles per hour 23

23 Precision/Smart System Dimensions Premium Class + pinion on SP + System output with Premium and Smart Class rack SP system output Module z A-PC ± 0.3 a) A-SC ± 0.3 a) b B d a d w D1 g6 D4 D5 L3 L4 L11 ± 1 L12 L13 L14 L15 L16 SP SP SP SP SP SP _ All dimensions in [mm] a) please contact alpha for precise dimensions; align mechanism recommended (alignment dimension ± 0.3 mm) z = Number of teeth d a = Tip diameter d w = Pitch diameter concentricity < 10 μm (m2) 24

24 Technical data SP+ gearhead with Premium + pinion on SP + System output with Premium and Smart Class rack Module z [N] i = 4 (PC) [N] i = 4 (SC) [N] i = 16 (PC) [N] i = 16 (SC) [Nm] i = 4 (PC) [Nm] i = 4 (SC) [Nm] i = 16 (PC) [Nm] i = 16 (SC) V max [m/min] i = 4 V max [m/min] i = 16 SP ,4 SP , , ,0 m Ritzel [kg] Precision System ,3 SP , , , ,4 SP , , ,1 SP , , , ,4 Smart System ,4 SP , ,5 Technical data based on 1000 load cycles per hour. For additional combination use cymex. = Max. moving force = Max. acceleration torque Load factor for rack moving force Load factor Number of load cycles per hour 25

25 Economy + /Smart System Dimensions Standard Class RSP pinion with SP involute output with Value and Smart Class rack Output with SP involute Module z A-VC ± 0.3 a) A-SC ± 0.3 a) b B d a d w D1 g6 D4 D5 L3 L4 L11 ± 1 L12 L16 L23 toothing SP + /SK SP + /SK + / SPK SP + /SK + / SPK SP + /SK + / SPK SP + /SK + / SPK SP SP All dimensions in [mm] a) please contact alpha for precise dimensions; align mechanism recommended (alignment dimension ± 0.3 mm) z = Number of teeth d a = Tip diameter d w = Pitch diameter concentricity < 40 μm 26

26 Technical data SP + gearhead with Standard Class RSP pinion on SP involute output with Value and Smart Class rack Module z [N] i = 3 (VC) [N] i = 3 (SC) [N] i = 16 (VC) [N] i = 16 (SC) [Nm] i = 3 (VC) [Nm] i = 3 (SC) [Nm] i = 16 (VC) [Nm] i = 16 (SC) V max [m/min] i = 3 V max [m/min] i = 16 m pinion [kg] SP SP SP Economy + System SP SP SP SP Technical data based on 1000 load cycles per hour. For additional combination use cymex. = Max. moving force = Max. acceleration torque SC = Smart Class VC = Value Class Smart System Load factor for rack moving force Load factor Number of load cycles per hour 27

27 Economy/Smart System Dimensions Value Class pinion (shrunk/bonded) on shaft key with Value and Smart Class rack Key output Module z A-VC ± 0.3 a) A-SC ± 0.3 a) b B d a d w D1 g6 D4 D5 D7 L3 L4 L11 L12 L13 L14 L15 L16 SP + /SK + / 060 SP + /SK + / SPK SP + /SK + / SPK SP + /SK + / SPK All dimensions in [mm] a) please contact alpha for precise dimensions; align mechanism recommended (alignment dimension ± 0.3 mm) z = Number of teeth d a = Tip diameter d w = Pitch diameter concentricity < 40 μm Value Class pinion (shrunk/bonded) on shaft key with Value and Smart Class rack Key output Module z A-VC ± 0.3 a) A-SC ± 0.3 a) b B d a d w D1 h6 D4 D5 D7 L3 L12 L13 L14 L15 L16 LP + /LK + / LPK LP + /LK + / LPK LP + /LK + / LPK LP + /LK + / LPK M M M M All dimensions in [mm] a) please contact alpha for precise dimensions; align mechanism recommended (alignment dimension ± 0.3 mm) z = Number of teeth d a = Tip diameter d w = Pitch diameter concentricity < 40 μm 28

28 Technical data SP + gearhead with Value Class pinion on shaft key with Value and Smart Class rack Ratio Module z [N] (VC) [N] (SC) [Nm] (VC) [Nm] (SC) emer T 2 emer V max [m/min] i = 5 V max [m/min] i = 25 m pinion [kg] SP , / SP All SP All SP All Technical data based on 1000 load cycles per hour. For additional combination use cymex. = Max. moving force = Max. acceleration torque SC = Smart Class VC = Value Class Load factor Load factor for rack moving force Economy System LP Ratio Module z 3, 10, 15, 30, 100 [N] (VC) [N] (SC) [Nm] (VC) [Nm] (SC) Number of load cycles per hour LP + gearhead with Value Class pinion on shaft key with Value and Smart Class rack emer T 2 emer V max [m/min] i = 5 V max [m/min] i = , 7, 25, m pinion [kg] Smart System LP , 10, 15, 30, , 7, 25, LP All LP All Technical data based on 1000 load cycles per hour. For additional combination use cymex. Load factor for rack moving force = Max. moving force = Max. acceleration torque SC = Smart Class VC = Value Class Load factor Number of load cycles per hour 29

29 Perfect lubrication for a perfect system Efficient lubrication systems are available for our rack & pinion system to guarantee a long service life. We offer you the right felt pinions, mounting shaft and lubricator sets, adapted perfectly to our components. The lubricator supplies a preset quantity of grease to the felt pinion and guarantees a constant film of lubrication on the rack and pinion. Complete lubricator Kit order number Size Complete lubrication system SP + gearhead with adapter plate for motor installation Pinion, left-handed Felt pinion for rack, left-handed (LH) Pipe clamp Filled with Microlube GB 0 Sensor kit for fill level monitoring Aluminium hose connection Plastic hose, filled, 2 metres Felt pinion for gears, right-handed (RH) Centre distance = (d + d w pinion)/2 Rack, right-handed (RH) Mounting shaft with threaded pin 30

30 Replacement sensor for fill level monitoring Lubricator type Order number The sensor kit for fill level monitoring included in the lubricator set enables your machine to permanently monitor the fill level in the lubricator and therefore utilise the lubricator more efficiently. Felt pinion, helical-toothed Felt pinion Mounting shaft C Module Number of teeth Order no. d d 1 d k b Order no. D S b l L A 2 18 LH B 2 18 RH A 3 18 LH B 3 18 RH A 4 18 LH B 4 18 RH A 5 17 LH B 5 17 RH A 6 17 LH B 6 17 RH M M M M M All dimensions in [mm] A Felt pinion for racks, left-handed, LH B Felt pinion for pinions, right-handed RH C Mounting shaft for felt pinions D S d 1 d d k l R¼ b b L 31

31 Dimensions of the lubricator Kit order number Size D D 1 D 2 a) D 3 a) L L 1 A 1 A 2 Replacement lubricator b) R ¼ R ½ Nitrogen gas is generated in the electronically controlled lubricator. When the micro switches initiate the required dose, the nitrogen gas generated moves the piston continually. An emptying time of 1, 2, 3, 6, 12 or 18 months and individual lubricant quantities can be selected. Each product is supplied with detailed operating instructions. All dimensions in [mm] a) Lubricator connector b) No pipe clip, hose, screw connection, synchronous cable or sensor kit A 1 D Synchronous cable for machine operating time (l 150 mm) Transparent housing D 3 L L 1 Pipe clamp D 2 D 1 A 2 32

32 Technical data of lubricator Lubricator type Approx. capacity cm Connection thread R ¼ R ½ Setting time 1, 2, 3, 6, 12 or 18 months Weight 370 g 1000 g Pressure 0.2 to 3 bar Drive 2 x 1.5 V 4 x 1.5 V Temperature range 10 C to 50 C Battery capacity about 2000 ma/hr. about 4000 ma/hr. Battery consumption after 1 year about 285 ma/hr. about 800 ma/hr. Grease filling Klüber Microlube GB 0 Accessories Sensor, replacement lubricator Recommended lubrication Depending on the conditions of use, it is possible to set the lubricator to various emptying times with a micro switch (1, 2, 3, 6,12 or 18 months). Our recommendation for a constant speed of 90 m/min: for example, module 2: to 0.35 cm³/day or module 3: 0.35 to 0.7 cm³/day 360 Grease quantity for felt pinion lubrication 300 m = 2 m = 3 m = m = 5 V [m/min] 180 m = , ,5 1.5 cm 3 /24 h 33

33 Assembly accessories You will need an assembly jig to align the transfers between the individual racks. You will also need a needle roller, when making a final check with the dial gauge (flatness and joint). Assembly jig Module L z B H h Needle roller Ordering codes, page 36 Module Order number Bolts and cylindrical pins (not included in the alpha scope of delivery) To fasten each rack, you will need bolts and cylindrical pins specified in the table below. The length of the bolts and pins depends on the design of the machine bed. Module Length Class Premium Smart Value Bolt DIN EN ISO (quantity x thread) Tightening torque (Nm) Quantity x cylindrical pin DIN EN ISO 2338 / DIN EN ISO 2338 / Cylindrical pin with inner thread DIN7979 / DIN EN ISO 8735, form A x 8 x M x 6 m x 4 x M x 6 m x 8 x M x 8 m x 4 x M x 6 m x 2 x M x 6 m x 8 x M x 8 m x 4 x M x 8 m x 8 x M x 10 m x 2 x M x 8 m x 8 x M x 8 m x 4 x M x 10 m x 8 x M x 10 m x 8 x M x 12 m x 4 x M x 12 m x 8 x M x 16 m x 4 x M x 16 m6 34

34 Ordering codes Rack The ordering code is composed of the following specifications: Z S T P A Rack type ZST = Rack Version PA5 = Premium Class SB6 = Smart Class VB6 = Value Class Ordering example for other racks: Value Class rack: ZST 200 VB Smart Class rack: ZST 200 SB6 480 Module 200 = = = = = 6.00 Length [mm] 480 = Smart Class 500 = Premium Class 1000 = Value Class Premium Class + and Value Class pinion R M T V C Ordering example for Premium Class + pinion: RMT 200 PC5 20 Pinion designation RMT = ready mounted pinion RMX = ready mounted pinion turned 180º (only for VC pinions) Version PC5 = Premium Class + VC6 = Value Class Number of teeth Module 200 = = = = =

35 Standard Class RSP and Premium Class RTP pinions R T P A A e Gearhead size For SP + : 060, 075, 100, 140, 180, 210, 240 For TP + : 004, 010, 025, 050, 300, 500 A High Torque output Number of teeth 015 = = 18 etc. Tolerance class 5e24 = For Premium Class RTP pinions 6e25 = For Standard Class RSP pinions Pinion designation RSP = Standard Class RSP pinions For SP involute output According to DIN 5480 RTP = Premium Class RTP pinions For TP output Module A02 = 2.00 A03 = 3.00 A04 = 4.00 A05 = 5.00 A06 = 6.00 Ordering example for RSP pinion: RSP 060 A02 6e Ordering code for assembling jig For ZST Module 2: ZMT 200 PD5 100 Module 3: ZMT 300 PD5 100 Module 4: ZMT 400 PD5 156 Module 5: ZMT 500 PD5 156 Module 6: ZMT 600 PD

36 Ordering example for an Economy + System Ordering an SP + gearhead, ratio i = 16 with a Standard Class RSP pinion, number of teeth 18; Value Class rack Assembly accessories Lubrication system Gearhead: SP S MF2 20 Catalogue SP + The new generation Required pinion installed: RSP 060 A02 6e A30 (page 26) Rack: ZST 200 VC (page 18) Assembling jig: ZMT 200 PD5 100 (page 36) Needle roller for checking purposes: (page 34) Complete lubricator set, size 125: (page 30) Felt pinion, for lubricating output pinion with module 2, right-handed: Alternative felt pinion for lubricating the rack, module 2, left-handed: (page 31) (page 31) Mounting shaft for felt pinion, module 2: (page 31) Please remember when ordering a TP + or SP + with system output: Order the correct form of output flange or shaft using index 3. 37