HLE 60 Series Linear Drives

Transcription

1 Modular Automation Systems HLE 60 Series Linear Drives Installation, Operation, Maintenance and Repair Manual Manual No Rev C HLE 60 SR - Square Rail Version HLE 60 RB - Roller Bearing Version Automation The right to make technical changes is reserved. Data is current as of print date. Parker Hannifin Corporation Daedal Division 1140 Sandy Hill Road Irwin, PA Phone: (724) (800) Fax: (724) ddlcat@parker.com Oct 00

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3 Table of Contents 1 Safety General Identification & definitions End User safety notice Safety-operating personnel Advice on particular dangers Unauthorized modification Handling & transporting Technical data Product construction and description Technical data Carriage loads & timing belt strength SR Carriage loads & timing belt strength RB Dimensions Dimensions HLE60SR Drive Unit Dimensions HLE60SR Idler Unit Dimensions HLE60RB Drive Unit Dimensions HLE60RB Idler Unit Installation General Substructure preparation Installing Installing a single axis Installing a double axis Limit switches/sensors General Setting up end of travel limits...11 & 12 4 Maintenance Maintenance schedule Replacement interval for steel strip cover wearing parts Abnormal timing belt wear Maintenance and repair Safety notice Replacing, tensioning and aligning timing belts General information Replacing timing belt Tensioning timing belt Checking & adjusting belt tension Measuring timing belt tension Timing belt tracking Carriage Checking carriage play SR Checking carriage play RB Carriage removal SR & RB Changing bearing blocks SR Changing steel square rail SR Lubrication of bearing blocks Replacing carriage RB Adjusting carriage wheels Adjusting reference point Removing motor/gearbox Replacing motor block coupling Replacing motor Motors with new style Neugart planetary Motors with old style Neugart planetary Further gearbox designs Replacing drive and tension stations Replacing drive station HLE SR Replacing drive station HLE RB Replacing drive housing on double axis Replacing tension station HLE SR Replacing tension station HLE RB Double axes General Aligning carriages of double axes Steel strip cover Steel strip cover removal Steel strip cover Installation Replacing the steel strip Replacing wipers Replacement parts Replacement parts HLE 60 Series Index Replacing motor block housing III

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6 1 Safety 1.1 General It is the responsibility of the end user to ensure that equipment is installed and operated in accordance with both local and federal safety codes and guidelines. The user must ensure that the attachment of workpieces/tools or other devices on the moving carriage of the linear unit does not endanger persons and/or property. 1.2 Symbols and Definitions used within this document Special attention with regard to the safety of personnel, equipment and property should be considered when one or more of the symbols listed below are shown in this document. During equipment installation and operation, any area/condition considered unsafe should be identified by posting appropriate signs or placards. Safety notices used: Danger Dangerous situation - can lead to death or serious physical injury if not otherwise prevented by corresponding safety measures. Warning Possible dangerous situation - can lead to possible serious injury if not otherwise prevented by corresponding safety measures. Caution Possible dangerous situation - can lead to minor physical injury or damage to property if not otherwise prevented by corresponding safety measures. Note Important product information - special handling instructions or indicates a certain section of the handbook to which you should refer Operating personnel The following work should only be carried out by trained and authorized personnel: Installation and calibration of the linear drive. Connection of safety limit switches. Installation and start-up of motors and drives. 1.3 End User Safety notices Supervisors, Technicians, and Installation personnel should familiarize themselves with chapters on "Safety" and Installation of this document prior to Installation/operation of equipment. 1.4 Safety notice for operating personnel Operating personnel must inspect linear drive unit(s)/machine once per shift for any signs of visible damage or loose hardware. Do not operate equipment suspected of erratic behavior or unusual noise levels. Parker has specially designed components and accessories. Use only genuine Parker replacement parts. Use of unauthorized parts can effect machine performance and safety. 1

7 We accept no liability for damages arising through the use of non-genuine parts and accessories. We accept no liability for safety features removed or disabled. Use Federal and local safety requirements/regulations during installing and operation. 1.5 Advice on particular dangers HLE linear drives must be supported at the prescribed minimum distances (see Chapter 3.2). Stand clear of moving parts, such as the HLE carriage. 1.6 Unauthorized conversions and modifications Linear drive units can not be altered in any manner that will affect safety. Any unauthorized alterations will exclude any liability on the part of Parker. 1.7 Handling and Transporting Danger When lifting, stand clear of suspended load(s)! Ensure parts subject to movement do not move off-center or shift out of position. Caution When transporting long axes, permanent deformation of the aluminum profile due to deflection can result if not supported properly. Changes in profile straightness can adversely affect the performance of the moving carriage. Always use transport equipment with adequate lifting capacity. Lifting straps or ropes must not be twisted, knotted, or frayed. If several ropes are used, all should be under equal tension. An estimate of weight on the HLE 60 Series can be made as follows: L B Weight HLE 60 SR HLE 60 RB Basic Unit (0 Travel) 20.3 kg 17 kg Each additional Meter 5.5 Kg 3.62 kg B= 57.2mm HLE 60 Figure 1: Reference value for HLE 60 Series transportation weight (with motor and gearbox) 2

8 2 Technical data 2.1 HLE 60 Series construction and description Aluminum profile (1) Main body of drive unit, with 4 External integrated T slots, running the entire length. Provides the support structure for drive unit. All profiles are anilite coated. Running surfaces SR & RB Steel square rail bolted within profile (1) for Square Rail version and extruded guidance system for wheels of Roller Bearing version. Plastic T Slot cover (3) Protects T slot from dirt. Contains wiring when T slots are used as conduit. Flanged Drive Pulley (4) Transfers drive torque to timing belt (11) and simultaneously guides the belt. Carriage (5) Positioned by the timing belt, the carriage rigidly pilots the load along the travel length. Bearing Blocks SR (6) Linear bearings specifically designed to transport heavy loads at high speeds make up the SR version. Rides on a precision square rail running the length of profile. Lubrication system (7) Lubrication fittings located on both ends of the carriage provide easy access for lubrication. Carriage Wheels RB (8) Totally enclosed, permanently lubricated ball bearings with polymer treads provide smooth and quiet high speed positioning on the RB version. Rides on extruded internal channels within the profile. Timing belt holding bracket (9) Secures timing belt within carriage. Makes changing timing belt possible without having to dismantle the load attachment plate (10). Provides method of adjusting timing belt tension. Load attachment plate (10) Aluminum profile with integrated T slots and cavity for passage of steel cover strip. Timing belt (11) Slip-free polyurethane timing belt reinforced with inlaid steel-cord. Used to provide power transmission between drive pulley and carriage. Drive station (12) Provides flange mounting on both sides of housing and flexibility in the options available: Motor block (standard) Motor or gearbox coupled directly to input shaft. Left shaft (WLO) / Right shaft (WRO) / Double shaft (WBO) Fixed mounting of drive pulley through a keyed shaft positioned between ball-bearing sets. 3

9 2.2 Technical data HLE60 Linear Drive Unit HLE 60 Dimensions, mass moments of inertia Dimension of base unit, 1m stroke RB SR Carriage + load attachment plate NL kg Carriage + load attachment plate VL kg Mass of drive profile kg/m Mass moment of inertia related to the drive shaft Normal carriage NL kgcm Extended carriage VL kgcm Travel and speeds Maximum travel speed 1 m/s Maximum acceleration 1 m/s Maximum travel distance, normal carriage NL Maximum travel distance, extended carriage VL Geometrical data mm 3,048 3,048 mm 2,896 2,896 Cross-section mm x mm 57.2 x 57.2 Moment of inertia I x cm Moment of inertia I y cm Modulus of elasticity N/mm Pulley data, torque s and forces Travel distance per revolution mm/rev 125 Pulley diameter mm 39.8 Belt weight g/mm Peak drive torque 2 Nm 8.87 Max. belt traction 2 (effective load) N 668 Repeatability mm ±0.1 1 Higher speeds and accelerations are possible. Please consult factory. 2 increased tension of timing belt necessary. Technical data as at 01/99, Safety taken into consideration S=1. Data valid for a temperature-range from -10 C to +40 C. 4

10 2.3 HLE 60 SR Carriage loads and timing belt strength Forces transferred by the carriage and timing belt are speed dependent. Curves shown in graphs are valid for the normal carriage (NL). Curves show the maximum load-bearing capacity of a carriage in one direction of force or torque. If several loads are applied from different directions, values stated in the curves may not be fully exploited, i.e. the load or speed should be reduced if necessary Life vs. Load HLE60SR Fz & Fy Normal & Side Loads 20 Life vs. Moment Load HLE60SR Mx m/sec Force (N) m/sec 1.0 m/sec 2.0 m/sec 3.0 m/sec Moment (Nm) m/sec 0.5 m/sec 1.0 m/sec 2.0 m/sec 3.0 m/sec 0 10,000 20,000 30,000 40,000 50,000 60,000 Carriage Life (Km) 0 10,000 20,000 30,000 40,000 50,000 60,000 Carriage Life (Km) 90 Life vs. Moment Load HLE60SR My & Mz Moment (Nm) m/sec 0.5 m/sec 1.0 m/sec 2.0 m/sec 3.0 m/sec 0 10,000 20,000 30,000 40,000 50,000 60,000 Carriage Life (Km) 5

11 2.4 HLE 60 RB Carriage loads and timing belt strength Forces transferred by the carriage and timing belt are speed dependent. Curves shown in graphs are valid for the normal carriage (NL). For extended carriages (VL), all values except for Fx (load-bearing capacity of timing belt) can be doubled if the load is applied in pairs or distributed uniformly along length of carriage. Curves show the maximum load-bearing capacity of a carriage in one direction of force or torque. If several loads are applied from different directions, values stated in the curves may not be fully exploited, i.e. the load or speed should be reduced if necessary Fx 400 F (N) Fz Fy v (m/s) My 15 M (Nm) 10 5 Mz Mx v (m/s) 6

12 2.5 Dimensions Dimensions HLE 60 SR Drive unit Dimensions HLE 60 SR Idler 7

13 2.5.3 Dimensions HLE 60 RB Drive Unit Dimensions HLE 60 RB Idler 8

14 3 Installation 3.1 General Single HLE linear drive units ordered with limit switches will be supplied completely assembled and mechanically ready for operation. HLE double axes will be supplied dismantled for delivery and safety reasons. (Assembly instructions can be found in chapters 4.10). Unless otherwise noted, motors should always be mounted in accordance to the motor manufacturers specifications. Unless otherwise specified, the standard installation of the linear drive is horizontal, with open slot in profile facing up. Note In vertically mounted applications, the drive station should be at the top of the unit, placing belt tension between drive pulley and load. 3.2 Substructure preparation Each point of support must be level and plane parallel to 0.2 mm. All points of support must be aligned to one another with parallelism not to exceed 0.5 mm. For double drive units, a one axis parallelism of 0.2 mm must be guaranteed. Ideal distance between supports provides drive deflection of 1 mm per meter, see catalog for reference dimensions. To simplify leveling, points of HLE drive support can include a series of adapter plates that can be leveled using adjustment screws. 9

15 3.3 Installing Caution Note Permanent deformation of long drive units can occur if handled improperly. Twisted and bent profile can affect the performance of the carriage. During installation, plastic film tape may be used to cover the slot opening to prevent contamination by dirt and debris (does not apply to units equipped with cover system). Note Always make provisions for easy access to the belt tension adjustment screws and carriage assembly for maintenance purposes! Installing a single axis 1. Remove drive unit from crate, strip off protective film and inspect for transportation damage. 2. Place protective tape over drive slot (does not apply to units equipped with cover system). 3. Place HLE on pre-leveled connection points (use leveling instrument). 4. Secure drive using clamping profiles within the T -slot grooves of profile. Do not drill into profile! 5. Attach equipment to load plate. 6. Remove dust cover (adhesive film) Installing a double axis 1. Remove drive unit from crate, strip off protective film and inspect for transportation damage. 2. Place protective tape over drive slot (does not apply to units equipped with cover system). 3. Place HLE s on pre-leveled connection points (use leveling instrument). 4. Secure motor driven HLE using clamping profiles within the T -slot grooves of profile. Do not drill into profile! 5. Install second drive (non-driven axis) same as in step #4, but do not tighten fasteners. 6. Measure for parallelism using tape measurer [Figure 2 left]. 7. Check squareness with diagonal measurement (tape measurer) [Figure 2 right]. If adjustment is needed, correct by moving non-driven axis. 8. Check horizontal orientation of both axes to one another (use leveling instrument), and correct by moving non-driven axis. 9. Install connecting axle shaft (does not apply if second axis is an idler unit). 10. Remove the dust cover (adhesive film). 11. Tighten all hardware. = = = = Figure 2: Aligning double axis unit 10

16 3.4 Limit Switches/Sensors General HLE s supplied with limit switches are pre-mounted to the unit but must be properly adjusted to customer requirements. Note Requirements for switches/sensors when connecting motors and drives vary depending on manufacturer. Consult driver/controller manual for switch configuration. Note Recommendation: A minimum end of travel safety distance of 125mm should be maintained Setting up end of travel limits Note Unless otherwise specified, the tripping magnet and initiator switches are mounted on the motor/gearbox side of the unit. Figure 3: Limit Switches (initiators): setting up end of travel limits and safety zones. Dimen- HLE 60 SR/RB with cover seal sions Unit Std. Carriage Ext. Carriage A mm B mm Table 1: Distances for setting up the limit switches (initiators), based on 125 mm safety zone 11

17 3.4.3 Setting up the end limits E- and E+ 1. Standard limit switch assemblies consist of NPN Hall effect type sensors. A magnet embedded within the load attachment plate activates the switch. 2. Arrange limit switches according to sequence given in Figure E-: Position carriage with the load attachment plate as indicated in Figure 3 and Table 1 (dimension B). Slide limit switch E- from drive station toward the direction of the tension station end until it triggers. 4. E+: Re-position carriage with load attachment plate as shown in Figure 3 and Table 1 (dimension A). Slide limit switch E+ away from tension station in the direction of the drive station until it triggers. 5. Make certain the carriage runs smoothly. Check distance between surface of magnet and limit switch bodies (approx. 1.0 mm). 6. Four (4) T slot grooves running the length of the profile can be used as conduit for limit switch wire leads. Plastic T slot cover secures wires within the groove. 12

18 4 Maintenance 4.1 Maintenance schedule When What Action Reference After Start-up Timing belt Check belt tension, tracking and adjustment. Chapter & One week, Timing belt Measure timing belt tension. If tension is less than 0.9 x the operating tension, increase timing belt tension to 1.1 x the operating tension. Daily Entire drive Depending on the application, clean all affected parts (internal, tensioning station, drive station). Chapter Every six months Bearings For HLE 60 SR, lubricate carriage bearing blocks (see Note below). For HLE 60 RB, check carriage side play. Timing belt Check tension. Visually inspect timing belt for wear. Excessively worn belts should be replaced. For abnormal timing belt wear, see chapter 4.3, for possible cause(s) and cure(s). Table 2: HLE 60 maintenance schedule Chapter Chapter Chapter & Note: For HLE 60 SR Only. Use only LITHIUM 12 HYDROXYSTEARATE SOAP BASE containing additives to enhance oxidation resistance and rust protection. Daedal grease type #1, Model # G1 (70/ degrees C) is recommended for grease lubrication and ISO grade for oil lubrication. CAUTION: Never mix petroleum base, with synthetic base lubricants. For special or severe service conditions, consult factory. 4.2 Replacement interval for steel strip cover wearing parts Travel What Action Reference 3750 km Felt wiper bar Replace Chapter km Steel cover strip Table 3: HLE 60 wearing parts with steel strip cover Replace Chapter

19 4.3 Abnormal timing belt wear Several factors can cause abnormal timing belt wear. Determination of the type of belt wear may allow for the specification of a particular cause. The following table shows possible causes for typical cases: Observation Probable Cause Cure Abnormal wear on belt tooth flank. Abnormal wear on belt sides. Shearing of belt teeth. Tears in belt teeth or abnormal wear on loaded tooth profiles. Tension too high. Drive torque too high. Incorrect timing belt tracking. Edge of roller/pulley deformed. Tension too low. Overload or system crash. Incorrect belt tension. Change timing belt, adjust tension (see 4.5.3). Check drive characteristics. Change timing belt, adjust tension (see 4.5.3). Change belt pulleys. Change timing belt, adjust tension (see 4.5.3). Change timing belt, adjust tension (see 4.5.3). Overload. Aging of belt material. Change timing belt, adjust tension (see 4.5.3). Check if load is greater than drive units capability. Change timing belt, adjust tension (see 4.5.3). Broken timing belt. Incorrect belt tension. Change timing belt, adjust tension (see 4.5.3). Overload. Change timing belt, adjust tension (see 4.5.3). Softening of belt material. Belt skipping over pulley, loss of machine zero point. Table 2 : Abnormal belt wear Operating temperature too high. Contact with solvents. Tension too low Incorrect motor position (bottom) in vertical application. Check if load is greater than drive units capability. Change timing belt, adjust tension (see 4.5.3). Lower operating temperature. Change timing belt, adjust tension (see 4.5.3). Do not clean belt with solvents. Adjust tension to correct value. If possible, have drive on top. Alternative: increase tension or reduce loads in longitudinal direction. 14

20 4.4 Maintenance and repair Safety notices Before performing maintenance and/or repair, ensure the main electrical disconnect switch for the equipment being worked on is in the OFF position and secured with padlock(s). If additional automation equipment is in operation within the work area, barriers, fences or other means must be taken to ensure safety. Where it is necessary to disconnect or remove safety devices during maintenance, such devices must be refitted and tested prior to placing equipment back in operation. 4.5 Replacing, tensioning and aligning timing belts General information Unpack new timing belts immediately. Store flat on their side, in a coiled circular shape at room temperature in a dry place. Timing belts must not be kinked. The pitch of timing belt and mating pulley teeth must be the same. Long-term temperatures at a maximum of 178 F (80 C) are permitted. Store linear drives in a clean dry environment Replacing timing belt 1. Move carriage to a reference point along the HLE profile (e.g. machine zero, real zero...). Mark the carriage position (felt pen) on profile. 2. Remove steel strip cover bracket bolts at the tension station end of unit (see ) 3. Timing belt removal for HLE 60 Series: Carefully roll back steel cover strip (39) from tension station. Locate timing belt adjustment screw (25) on the very end of the carriage. Loosen and remove this screw (turn clockwise) and pull timing belt bracket (15) out of carriage, and slide timing belt bracket from end of belt. Repeat this step for the drive station side of carriage. 4. Remove tension station assembly (see & 4.9.5). Remove drive station assembly (see & 4.9.2). Thread timing belt out through lower cavity of extrusion (2). 5. Cutting new timing belt to proper length: Measure profile length and calculate belt length by adding a correction value from table 3 below, or simply measure the old timing belt. 15

21 HLE without Strip Cover HLE with Standard Strip Cover L Carriage L Carriage L Profile L Profile HLE 60 Correction value mm Table 3: Correction values. Belt length = 2 x L profile - L carriage + correction value Formula 1: Calculation for timing belt length. 6. Timing Belt installation. Reminder: HLE60 Series: timing belt passes through cavity in lower portion of HLE 60 profile. Hint After belt has been removed from carriage, but prior to pulling out of linear drive, tape old timing belt end to new belt end, and thread through drive unit using old belt. 7. Remove steel strip cover (see ). 8. Slide belt retaining bracket (15) onto end of timing belt (14). 9. Locate the cavity on the end of carriage just below load attachment plate. Insert timing belt bracket into cavity (timing belt teeth down). Insert timing belt adjustment screw (25) through hole in bracket and thread into carriage body (3). 10. Repeat steps 7 & 8 on opposite end of carriage. 11. Tension timing belt: chapter Check tracking and align belt: chapter Re-install steel strip cover: (see ). 14. Re-set reference point: (see 4.6.9) Tensioning timing belt General Note Timing belt tension depends on mass of load to be transferred and forces required to move that load. Do not exceed values for setting tension stated in Table 5. Factors when tensioning timing belt: Drive used (gearbox, drive orientation). Total force transferred by the timing belt Fx (Fx = F static + F dynamic ). To keep teeth of belt from skipping over drive pulley teeth, timing belt tension (operating tension) must be approximately 10% above actual force required to perform its function (Fx). During the break-in period of a linear drive unit, timing belts will take an initial stretch. As a result, belts will lose approximately 20% of their tension. Therefore, tension must be compensated for, by adjusting to 1.25 times greater than the operating tension. 16

22 Figure 4: Tension to be set. Travel (mm) Applied Wt. (kg.) Belt Deflection (mm) Table 4: Standard tension values 17

23 Table 5 provides a service life you might expect based on standard values as outlined in Table 4. Standard value Maximum value HLE 60 SR HLE 60 RB HLE 60 SR HLE 60 RB Service life 25,000 km N/A 100 km 25,000 km Direct & side load (Fz, Fy) 1611 N N/A N 710 N Pitch & yaw moment (My, Mz) 70 Nm N/A 441 Nm 45 Nm Roll Moment ((Mx) 11 Nm N/A 90 Nm 9 Nm Table 5: Drive unit service life For maximum service life, the standard value should be set first. Timing belts within long drive units may sag to the point that belt teeth rub along square drive rail during operation. Tension must be increased in stages until the belt teeth no longer touch. Never exceed the maximum value shown in Table 4. For double axis units with an equally shared load, total belt tension for each drive can be cut in half. If timing belt tension of drive unit drops below 0.9 x operating tension after one week of operation, belt tension should be increased to 1.1 x operating tension. Note HLE drives supplied with gearboxes or drive stations with bearing sets will have timing belts tensioned timing from the factory (adjusted to standard value). a max v m 1 α Determining force Fx m L α α=90 α=0 Stationary load: Fx = F static F static = (m L +m 1 ) * 9.81* sin α If load is in acceleration /deceleration: Fx = F static + F dynamic F static = (m L +m 1 ) * 9.81 * sin α F dynamic = (m L +m 1 ) * a max Fx F static F dynamic m L m 1 α a max Total force [N] static force [N] dynamic force [N] Mass of carriage [kg] Mass of load [kg] Angle between surface plane and HLE 60 maximum acceleration [m/s 2 ] 18

24 4.5.4 Checking and adjusting timing belt tension 1. Measure timing belt tension (see 4.5.5). 2. Compare actual tension with required value shown in Table 4. If timing belt tension is less than 0.9 x operating tension, shown in Table 4, re-adjust belt to correct value. 3. Belt tension of the HLE 60 Series is performed through an adjustment screw (25) located below the steel cover strip and threaded into both ends of carriage (3). 4. Adjusting belt tension: With carriage positioned at far end of travel at drive station end (see figure 4), place a weight (see Table 4) at mid travel and measure maximum belt sage from top of profile to belt surface. 5. Adjust for proper sag. Clockwise rotation of adjustment screws (25) will increase belt tension. Screws at each end of carriage should be adjusted equally until values outlined in Table 4 are achieved. Measure distance between carriage body and inside edge of belt retainer bracket (15) after adjustment is made (not to exceed 6 mm). 6. Should belt retainer bracket (15) bottom out against carriage body (due to belt stretch), remove belt from bracket (see step #3) and cut one tooth from end of belt. Re-install belt/bracket assembly and re-adjust tension. 7. Check timing belt tracking: (see 4.5.6) Measuring timing belt tension The most accurate method of measuring belt tension is the RSM (+/- 5% accuracy). Belt tension measuring device RSM The RSM belt tension measuring device uses the oscillation frequency of the free running belt length, and converts this information into force (performs calculations specific to belt mass and free running belt length). This is a very fast and easy method of tensioning any type of timing belt. The belt tension measuring device can be obtained through Daedal (Part. No ). Diagram 2: Torque readings and resultant timing belt tension. 19

25 4.5.6 Timing belt tracking Note Adjustments to timing belt tension must be done prior to checking/adjusting belt tracking. Tracking can only be checked with the carriage in motion. Proper tracking is when timing belt oscillates between tension station pulley flanges, but does not attempt to ride up on the sides of the flanges. 1. Remove hardware (10,34) and cover strip bracket (33). Carefully roll back steel cover strip (39) from drive station area. 2. Remove hardware (9,10) from upper drive housing access cover. 3. Lift upper access cover off of drive housing. 4. Looking into drive station, check operation of belt by moving the carriage (manually, if possible - or electrically at reduced speed). If belt operation is correct according to the above definition (Note), replace cover strip seal (39). 5. If not: Timing belt has been stretched unevenly. There is no adjustment on the HLE 60 series drive units to correct for tracking. Replace timing belt (see 4.5.2), and adjust belt tension (see 4.5.4). 4.6 Carriage Checking carriage play on HLE 60 SR Note Carriage play is when one can grab the load attachment plate and find movement (side to side or up and down) when applying moderate forces. Check for a worn out linear bearing block or wear on the steel rail. 1. Remove the load from the load attachment plate. 2. If equipped with a steel strip cover - remove it: (see ). 3. Remove timing belt from carriage: (see 4.5.2). Danger On vertical axis units, secure the carriage to prevent movement. When timing belt is disconnected from carriage, it will fall due to gravity if not supported. This can result in damage to people or property. 4. Visually check for rust or corrosion of the steel rail system. If corrosion exists, completely change out both steel rail and bearing block assembly (see & 4.6.5) 5. Push the carriage over the complete travel while observing the area were the linear bearing block meets the steel rail. The carriage should feel smooth but tight throughout the travel. 6. Lubricate the bearing block (see 4.6.6) and check for excessive leakage at end seals. 7. Excessive side to side movement indicates wear between linear bearing block and steel rail.. Completely change out both steel rail and bearing block assembly (see & 4.6.5). There are no adjustments to linear bearing blocks to compensate for wear. 20

26 4.6.2 Checking carriage play on HLE 60 RB Note Carriage play is when one can grab the load attachment plate and find movement (side to side or up and down) when applying moderate forces. Check for improper adjustment or worn carriage wheels. 1. Remove the load from the load attachment plate. 2. If equipped with a steel strip cover - remove it: (see ). 3. Remove timing belt from carriage: (see 4.5.2). Danger On vertical axis units, secure the carriage to prevent movement. When timing belt is disconnected from carriage, it will fall due to gravity if not supported. This can result in damage to people or property. 4. Visually check to ensure all wheels are in contact with rail guides over the complete travel. 5. To check wheel pressure against profile guides; prevent wheels from turning using your index finger; wheels should stop rotating when applying minimal force against them. The carriage should feel smooth but tight throughout its travel Carriage removal HLE 60 SR and HLE 60 RB 1. Move carriage to a reference point (e.g. machine zero, real zero...). Mark carriage position on HLE profile (felt pen). 2. If equipped with a steel strip cover - remove it: (see ). Slacken and remove timing belt: 1. Remove bolt (25) that secures timing belt clamp (15) to carriage (both ends of carriage). 2. Pull belt (14) and clamp out of carriage and up out of profile (2) slot. 3. Remove timing belt from clamp by sliding clamp off side of belt. 4. Remove tension station from profile (see & 4.9.5). 5. Remove drive station from profile (see & 4.9.2). 6. Slide carriage out through end of profile (2). 21

27 4.6.4 Changing bearing blocks HLE 60 SR General Linear bearing blocks consist of re-circulating (one string on each side) ball bearings captured within the block. Bearing blocks are sealed against the square steel rail and lubricated through a fitting located at the end of each block. Lubrication is required (see 4.6.6). Although linear bearing blocks are capable of operating at a maximum temperature of 248 F (120 C) and continuously at 212 F (100 C), the timing belt can only withstand environmental temperatures between 40 F (-40 C) to 178 F (+80 C). Warning If checking for bearing block damage while carriage is in motion within profile, care should be taken to prevent injury. If possible, move the carriage manually (best done if motor and gearbox are removed and drive unit is horizontal). If using motor, operate drive unit with jog button at low speed (< 1m/min). Note When removing bearing block from guide rail observe reference markings on both block and rail. Bearing blocks are ground on one side (its ref. mark) and rails have arrows embossed on the top of the rail indicating its ref. mark. During re-assembly it is important to match these reference marks (see below). 1. Remove carriage from steel rail guide (see 4.6.3). 2. Place on a clean surface. 3. Remove socket head cap screws (28) from top of carriage. 4. Lift old bearing block from carriage frame. Position replacement block on carriage (note reference mark on side of block). 5. Thread in socket head screws (28) with screw retention (Locktite 243) but do not tighten. 6. Repeat steps 3 through 5 for second bearing block. 7. Clean inside of linear drive profile and apply grease to steel rail (see 4.6.6). 8. Guide carriage assembly onto steel rail and insert into profile (match ref. mark on side of block to ref. marks on rail). 9. Align and center load attachment plate (3) with profile (2). 10. Tighten socket head cap screws (28). 12. Manually move the carriage along the full length of travel. Movement should be smooth with no apparent binding. 13. Check for side to side carriage free-play. If excessive play is present, replace steel square rail (see 4.6.1). 22

28 4.6.5 Changing steel square rail 1. Remove carriage (see 4.6.3). 2. Using a 4mm allen wrench remove all bolts/washers (20,21) located on top of square rail (59). 3. Lift rail up and out through access slot in profile (2). 4. Clean inside of profile. 5. Position new rail within profile (ref. arrow mark side of rail against ledge running the length of profile) and re-install hardware from step #2 into new square rail (do not tighten). 6. Push rail against ledge while tightening all bolts Lubrication of bearing block 1. Remove steel strip seal (39 - see ). 2. Center carriage in relation to travel. 3. Remove timing belt (see 4.5.2) from carriage (3). 4. Using a grease gun, pump 3 shots of grease (type specified in chapter 4.6.6) into fitting. 5. Repeat steps 3 & 4 on opposite side of carriage for second bearing block. 6. Re-install timing belt (see 4.5.2). 7. Replace steel strip seal (see ). NOTE: Use only LITHIUM 12 HYDROXYSTEARATE SOAP BASE containing additives to enhance oxidation resistance and rust protection. Daedal grease type #1, Model #G1 (70/ degrees C) is recommended for grease lubrication and ISO grade for oil lubrication. CAUTION: Never mix petroleum base, with synthetic base lubricants. For special or sever service conditions, consult factory Replacing carriage HLE 60 RB Wheels on the HLE 60 RB drive unit are not replacable. Replace entire carriage assembly when wheels wear or bearings are damaged. 23

29 4.6.8 Adjusting carriage wheels HLE 60 RB Carriages are designed with both concentric and eccentric wheels located on three sides of carriage body. Fixed or concentric wheels require no adjustment. Eccentric wheels are equipped with an off-set bushing, and when adjusted properly, remove excess play between carriage and profile. 1. Remove steel strip seal (39 - see ). 2. Remove timing belt (see 4.5.2) from carriage. 3. Remove carriage (see 4.6.3). 4. Clean inside surfaces of profile. 5. Adjust eccentric bushing with a 10 mm socket wrench in small stages until the carriage can be pushed freely and without play through the HLE profile. Proper adjustment has been achieved when, with minimal pressure from your finger, the wheel can be stopped from rotating. 6. Repeat step 5 as necessary, until carriage adjustment is correct Adjust reference point Correct machine zero (home) point on the basis of previously marked carriage/profile position. There are several ways of doing this depending on motor/controller used. For further details, see controller handbook. 4.7 Replacing motor Block Housing Danger Danger due to electrical shock, disconnect all electrical power to the system prior to removing old motor Removing motor/gearbox 1. Remove motor/gearbox hardware (174,175). 2. Pull motor/gearbox straight out of motor block housing (105). 24

30 4.7.2 Replacing motor block coupling 1. Remove motor/gearbox from motor block housing (see 4.7.1). 2. Measure distance R from motor/gearbox face to end of coupling half (109)and record. 3. Manually move carriage until clamping screw of coupling half (107) aligns with access hole of motor block housing (105). 4. Insert allen key into access hole, loosen clamp screw and pull coupling half (107) out of motor block. 5. Loosen clamp screw of coupling half (109), on motor shaft, and pull coupling half off of shaft. 6. Discard both coupling halves (107,109) along with disc insert (108). 7. Position new coupling half (109) to motor/gearbox shaft at R distance (recorded from step 2)and tighten clamp screw. 8. Place new disc insert (108) onto motor/gearbox coupling half (109). 9. Fully engage coupling half (107) with it s clamping screw loose, onto disc insert (108). 10. Align clamping screw of coupling half (107) to access hole of motor block (105), while inserting motor/gearbox assembly into motor block and onto drive input shaft. 11. Install and tighten motor/gearbox mounting hardware (174,175). 12. Insert allen key into access hole of motor block and tighten clamping screw of coupling half (107). 25

31 4.8 Replacing motor Motors in combination with planetary gearbox Gearboxes supplied on purchase orders after 7-98 will be equipped with input clamping devices of the split collar design (See Figure 4). This design captures the sungear within the back flange portion of gearbox. 1. Move carriage to reference point (e.g. machine zero, real zero, home...). Mark carriage position on HLE profile (felt pen). 2. Place main electrical disconnect switch in OFF position. Allow motor and gearbox to cool. 3. Remove motor and resolver cable. 4. Remove motor mounting bolts. 5. Remove cover screw from side of back flange plate (Figure 5). 6. While back driving the linear drive unit (slowly push load attachment plate by hand) the motor shaft will rotate to a position where the clamp screw on the clamping collar aligns with the hole in the side of the back flange. 7. Insert an allen key through the access hole, into clamp screw and loosen (rotate counter clockwise). 8. Pull motor straight off from gearbox housing. 9. Inspect internal bore and shaft of new motor to insure sizing of both are correct. 10. Clean motor shaft and clamping bore of any grease. Figure 4 Figure Adjust position of clamping screw located on clamping collar to provide easy access of allen key through hole on side of back flange (Figure 5). 12. If motor was supplied with key embedded in output shaft, remove it and discard. 13. Install motor onto gearbox with keyway in motor shaft aligned with slots in clamping collar as shown in Figure Position motor flange to gearbox flange, verify that no air gap is present between flange faces and bolt the two together (Figure 7). 26

32 Figure 6 Figure Insert allen key through hole in back flange and into bolt on clamping collar. Tighten to values shown in table 7. Gearbox PL 70 PLE 60 Torque 3.5 Nm 3.5 Nm Table 7. Clamping collar torque values. Gearbox PL 70 PLE 60 Max. motor wt. 7 kg 2 kg Table 8: Maximum motor weight on planetary gearbox (horizontal position) Motors in combination with old style planetary gearbox Gearboxes supplied on purchase orders prior to 7-98 will be equipped with input clamping devices of the ring feeder type. In this design, the sungear is not captured within the gearbox. Once removed from the gearbox back flange, loss of grease can occur. Care should also be taken as to not damage lips of seal or mating shaft of sun gear when removing from gear box. P Gearbox model # Dimension P [mm] Tightening torque [Nm] 97 PLE PL Face of the shaft seal Tensioning element Table 9: Details of tensioning elements Figure 8: Distance P 1. Move carriage to reference point (e.g. machine zero, real zero, home...). Mark carriage position on HLE profile (felt pen). 2. Place main electrical disconnect switch in OFF position. Allow motor and gearbox to cool. 3. Remove motor and resolver cable. 27

33 4. Remove motor bolts (97). 5. Pull the motor straight off from gearbox housing. Note Motor gearbox combinations mounted vertically, with motor down, may loose lubricant once the motor is removed. Lubricant that is lost must be replaced! 6. Measure distance P (Figure); dimension from upper edge of pinion to motor flange (accuracy +/- 0.1mm). 7. Loosen clamp screws of tensioning element connection. 8. Pull pinion straight off motor shaft. 9. Clean motor shaft and pinion hole of all lubricant. 10. With standard HAUSER motors (HDX, HBMR), the pinion can be pushed until it meets the motor shaft. All other motors; place pinion on new motor at distance P. If fit is too tight, use emery paper on shaft of motor (grade 360). 11. Tighten clamp screws of tensioning element connection in stages, and in turn to torque value shown in Table Lightly grease running surfaces of pinion gear and shaft seal within gear box. 13. Install motor and tighten motor bolts (97). 14. Reconnect motor and resolver cable. 15. Re-set reference point (see 4.6.9) Further gearbox designs Shaft-hub connection with keyway 1. Move carriage to a reference point (e.g. machine zero, real zero...). Mark carriage position on HLE profile (felt pen). 2. Place main electrical disconnect switch in OFF position. Allow motor gearbox to cool. 3. Remove motor and resolver cables. 4. Remove motor/gearbox bolts (97). 5. Pull the motor off gearbox. 6. Clean motor shaft and inside pinion sleeve of all lubricant. 7. If key shows signs of damage, replace it. 8. Insert key in keyway of motor shaft. 9. Insert motor into input of gearbox and tighten motor bolts (97). 10. Reinstall motor and resolver cables. 11. Re-set reference point (see 4.6.9) 28

34 4.9.1 Replacing drive station HLE 60 SR 1. Remove motor/gearbox (see 4.7.1). 2. Remove steel cover strip (see ). 3. Remove timing belt (see 4.5.2). 4. Remove upper cover plate (16). 5. Remove lower cover plate (51). 6. With an allen key remove drive housing hardware (96, 97, 100). 7. Lift drive housing from bumper plate (91). 8. Unthread socket head cap screws (83) and lift bumper plate from profile (2). 9. Thread timing belt (14) through lower cavity in profile (2). 10. Install new bumper plate to profile using hardware (83, 100) while threading belt through lower slot in bumper plate. 11. Feed belt through lower slot in drive housing, under and around drive pulley. 12. Position new drive station to bumper plate and secure with hardware (96, 97,100). 13. Re-install timing belt (see 4.5.2). 14. Re-install steel cover strip (see ) Replacing drive station HLE 60 RB 1. Remove motor/gearbox (see 4.7.1). 2. Remove steel cover strip (see ). 3. Remove timing belt (see 4.5.2). 4. Remove upper cover plate (16). 5. Remove lower cover plate (51). 6. With an allen key remove drive housing hardware (96, 97, 100). 7. Lift drive housing from profile (2). 8. Thread timing belt (14) through lower cavity in profile (2). 9. Feed belt through lower slot in new drive housing, under and around drive pulley. 10. Re-install timing belt (see 4.5.2). 11. Re-install steel cover strip (see ). 29

35 4.9.3 Replacing drive housing on double axis unit 1. Remove motor/gearbox (see 4.7.1). 2. Loosen and disconnect timing belt from carriage on both axis (see 4.5.2). 3. Unthread bolts (95) and slide shaft cover support block (110) away from drive housing on the driven rail. 4. Rotate shaft cover (107) until universal joint clamping screw (93) aligns with access slot in cover. 5. Loosen clamp screw and separate universal joint/connecting shaft assembly from shaft of driven rail. 6. Repeat steps 3-5 on drive rail unit. 7. Replace drive housings from drives (see 4.10). Comment: Bild: HL1116.eps 8. Re-install timing belt (see 4.5.2). 9. Re-install steel cover strip (4.11.2) 30

36 10. Re-assemble connecting shaft to drive rail and ensure all universal clamp screws are tight, with the exception of the one closest to the driven rail. 11. Align carriages by positioning both against the bumpers at the drive station end of linear drive and tighten the last universal clamp screw. 12. Slide shaft cover support block(110) into position and secure with hardware (95,96) Replacing tension station SR 1. Remove motor/gearbox (see 4.7.1). 2. Remove steel cover strip (see ). 3. Remove timing belt (see 4.5.2). 4. Remove upper cover plate (16). 5. Remove lower cover plate (51). 6. With an allen key remove tension housing (62) and hardware (96, 97, 100). 7. Lift tension housing from bumper plate (91). 8. Unthread socket head cap screws (83) and lift bumper plate from profile (2). 9. Thread timing belt (14) through lower cavity in profile (2). 10. Install new bumper plate to profile using hardware (83, 100) while threading belt through lower slot in bumper plate. 11. Feed belt through lower slot in tension housing, under and around tension pulley. 12. Position new tension station to bumper plate and secure with hardware (96, 97,100). 13. Re-install timing belt (see 4.5.2). 14. Re-install steel cover strip (see ) Replacing tension station RB 1. Remove motor/gearbox (see 4.7). 2. Remove steel cover strip (see ). 3. Remove timing belt (see 4.5.2). 4. Remove upper cover plate (16). 5. Remove lower cover plate (51). 6. With an allen key remove tension housing hardware (96, 97, 100). 7. Lift tension housing (62) from profile (2). 8. Thread timing belt (14) through lower cavity in profile (2). 9. Feed belt through lower slot in new tension housing, under and around drive pulley. 10. Re-install timing belt (see 4.5.2). 31

37 4.10 Double axes General Double axes are generally shipped as two single axis assemblies. Link shafts with universal joints are dismantled for ease of shipping. These universal joints allow for misalignment and offset angles between the two axis. Clamping rings located at the ends of the universal joints provide a method of adjusting carriage position that would otherwise not be possible with a fixed keyway design Aligning carriages of double axes 1. Remove bolts (95) and slide shaft cover support block (110) away from drive housing on the driven rail. 2. Rotate shaft cover (107) until universal joint clamping screw aligns with access slot in cover. 3. Loosen clamp screw and reposition carriages by placing both of them at the extreme end of travel. 4. Tighten universal joint clamping screw. 5. Slide shaft cover support block (110) back into position and secure with hardware (95, 96). Comment: Bild: HL1116.eps 4.11 Steel strip cover Note While performing maintenance on drive units equipped with steel strip cover seals, ensure steel strip is never kinked, distorted, or damaged. Damaged strip seals must be replaced. 32

38 Steel strip cover removal 1. Position carriage (3) approx. 0.5m in front of tension station end of unit. 2. Switch off the axis at the main electrical switch. 3. Remove screws (34) and lift off strip clamp (33). 4. Dismantle the wiper covers (30) on both sides of load attachment plate. Ensure that wiper (felt) does not fall out of the covers. 5. Pull steel strip (39) out and through cavity in carriage. 6. Carefully roll up and tape steel strip to top of drive station (see illustration below). 33

39 Steel strip cover installation 1. Unroll steel strip and feed one end through cavity in carriage. Carefully pull and position steel strip along the entire length of profile. Strip should rest on magnets embedded in profile. 2. Inspect felt seal wiper located within wiper cover (30). Replace if worn or damaged. Bolt wiper cover assembly on both sides of load attachment plate (3). 3. Place gasket on top and at the end of steel cover, connect seal clamp (33) to end housings (39) using hardware (34). Note Do not strain or attempt to stretch steel cover strip! 4. Apply electrical power. 5. Operate drive unit approximately 10 cycles at low speed (v < 2 m/s), allowing carriage to travel entire length of unit. Check steel strip at leading edge of wiper cover for a possible "wave" to form in direction of movement. 6. If wave is present, position carriage 0.5m from tension station (2). 7. Loosen screws (34) of seal clamp (33) at tension station end. 8. Smooth out "wave", but do not strain the strip seal. 9. Tighten seal clamp hardware Replacing the steel strip. Steel cover strip material must be obtained from Daedal. Length of profile L must be provided when Note ordering this part, along with cross-section B of L profile in order to ensure proper size. B 1. Remove steel cover strip (see ) 2. Disassemble second strip clamp (33) from end housing cover plate. 3. Fasten strip clamp to end housing cover plate. 4. Install steel strip (see ) Replacing wipers. 1. Ensure main disconnect switch is in OFF position. 2. Remove wiper cover (30) on both sides of load attachment plate by unthreading screws (32). 3. Replace felt wiper (27). 4. Re-install wiper covers (30) on both sides of load attachment plate with existing hardware. 34