Ball Rail and Roller Rail Systems with Integrated Measuring System

Transcription

1 Ball Rail and Roller Rail Systems with Integrated Measuring System RE / The Drive & Control Company

2 Rexroth Linear Motion Technology Ball Rail Systems Roller Rail Systems Ball Rail Systems Super Ball Rail Systems Ball Rail Systems with aluminium Runner Block High-Speed Ball Rail Systems Corrosion-resistant Ball Rail Systems Wide Ball Rail Systems Ball Rail Systems with Integrated Measuring System Clamp and Brake Elements for Ball Rail Systems Racks for Ball Rail Systems Miniature Ball Rail Systems Cam Roller Guides Roller Rail Systems Wide Roller Rail Systems High-load Roller Rail Systems Roller Rail Systems with Integrated Measuring System Clamp and Brake Elements for Roller Rail Systems Racks for Roller Rail Systems Linear Bushings and Shafts Linear Bushings, Linear Sets, Shafts, Shaft Support Rails, Shaft Support Blocks Ball Transfer Units Traditional Technical arts Ball Screw Assemblies Linear Motion Systems Linear Motion Slides Ball Screw Toothed Belt Linear Modules Compact Modules recision Modules Ball Rail Tables Ball Screw Toothed Belt Gear Rack neumatic Drive Linear Motor Ball Screw Toothed Belt Linear Motor Ball Screw Ball Screw Linear Motor Controllers, Motors, Electrical Accessories Elektric Cylinders RE /

3 Ball Rail and Roller Rail Systems with Integrated Measuring System roduct Overview 4 roduct Overview and Technical Data 10 Ordering System 19 robe Connector Options and art Numbers, robe Dimensions, Connector art Numbers 20 Ball Runner Blocks with Measuring System Options and art Numbers 22 Roller Runner Blocks with Measuring System Options and art Numbers 23 Ball Guide Rails with Measuring System Options and art Numbers 24 Roller Guide Rails with Measuring System Options and art Numbers 26 Connectors Options and Dimensions 28 Cables Options and Dimensions 30 Assembly Instructions 31 Maintenance Instructions 33 Inquiry/Order Form 35 3 RE /

4 Ball Rail and Roller Rail Systems with Integrated Measuring System roduct Overview Rexroth Bosch Ball Rail and Roller Rail Systems can be supplied with an integrated, inductive linear measuring system. This development combines the guiding and measuring functions in one unit and opens up new opportunities in machine design. In one word: MECHATRONIC. Highlights: Integrated Measuring System Easy retrofitting and replacement Rail with integrated scale utilizes the same mounting area and installation as standard rail No additional space is required except in the longitudinal direction to accommodate the probe No costs for external mounting No measuring inaccuracies due to deviations in parallelism Inductive Measuring System Contact-free scanning Maintenance-free Resistant to water, oil, dust, shavings, etc. Insensitive to magnetic fields Virtually indestructible Up to 4 m measuring length in one piece Several scanners can be mounted on one rail Incremental Measuring rinciple recise position detection through a high-precision scale paired with distance coded reference marks High resolution, up to 0.25 µm Ball Rail Systems with Integrated Measuring Systems Mounting hole pattern remains unchanged due to standardized guide rails Mounting hole pattern remains unchanged due to standardized runner block Scanner (probe) with sensor system and signal conditioning electronics Signal types: 1 Vpp HTL RE /

5 Distance coded reference marks over the entire rail length, covered by a laser-welded stainless steel strip Reference mark recognition through hole in the reference edge of the rail 1 2 1) Steel scale integrated in the guide rail: insensitive to vibration thermal expansion matches that of the rail, guaranteeing consistently accurate measuring data non-magnetic, suitable for metalcutting machine environments 2) Scale protected by a laser-welded stainless steel strip Roller Rail Systems with Integrated Measuring Systems pos. number direction neg. number direction Note: Sensor and runner block form one unit and must be replaced together when being serviced. 5 RE /

6 Ball Rail and Roller Rail Systems with Integrated Measuring System roduct Overview Ball Rail Systems Gen 1+2 Size Gen 1 Runner Block Signal Type Accuracy Class reloading Options Others on request S S S S S S S Signal Type Accuracy Class reloading Options Others on request S S S S S S S Signal Type Accuracy Class reloading Options Available only in Gen 2 Signal Type Accuracy Class Others on request reloading Options Others on request Available only in Gen 2 runner block > can be used on the same rail with the integrated measuring system 1) Accuracy class H and preloading of 13% not possible RE /

7 Ball Rail Systems Gen 1+2 Size Gen 1 Runner Block Signal Type Accuracy Class reloading Options Others on request Signal Type Accuracy Class reloading Options Others on request Signal Type (only in G2) Accuracy Class reloading H H H H Options Others on request Signal Type (only in G2) Accuracy Class reloading H 0.13C H 0.13C H 0.13C H 0.13C Options Others on request 1) Accuracy class H and preloading of 13% not possible 7 RE /

8 Ball Rail and Roller Rail Systems with Integrated Measuring System roduct Overview Roller Rail Systems Runner Block Signal Type Size Accuracy Class reloading S S S Options Others on request Signal Type Accuracy Class reloading S S S S Options Others on request 1) Accuracy class H and preloading 13% not possible RE /

9 Roller Rail Systems Size Runner Block Signal Type Accuracy Class reloading S S S Options Others on request Signal Type Accuracy Class reloading S S S S Options Others on request 1) Accuracy class H and preloading 13% not possible 9 RE /

10 Ball Rail and Roller Rail Systems with Integrated Measuring System roduct Overview and Technical Data Scale The scale (1), a high precision graduated steel strip, is welded into a groove on the guide rail and protected by a rust-proof laser-welded stainless-steel band (2). The scale used by Rexroth Bosch is produced on a specially designed machine and has the following features: pitch of 1000 µm, same thermal expansion coefficient as the guide rail α Therm K Reference Marks When scanned, the scale itself delivers only ascending or descending numerical values (incremental signals) : Incremental Measuring rinciple. Distance Coded Reference Marks In order to be able to approach a specific position, an absolute reference point is necessary. This reference point is achieved by distance coded reference points that are machined into the guide rail, parallel to the scale, to deliver a reference signal. The reference marks are also protected by a tightly welded stainless-steel strip. The side with reference marks is designated with a hole drilled into the reference edge of the guide rail (3). The advantage of distance coded reference marks is that a precise positioning signal is available as soon as the probe on the runner block has passed two reference marks. Single, absolute reference point The location of the reference point may be designated by the customer, but must remain within the measuring range. Scanning Signals Output Signals R 5 T R + 1 mm Distance coding of reference marks L max (mm) T R (mm) Distance coded reference marks T R T R T R T R R 4 T R + 1 mm R 3 T R + 1 mm R 1 to R n = Single, absolute reference point L L Reference marks The relative, contact-free movement between the two elements generates: sinusoidal voltage signals (1 Vpp), supplied directly by the probe during scanning, or square-wave output signals (RS 422 A), available after the interpolation unit. Both signal outputs are equipped with evaluation electronics in real-time mode so that highly dynamic drives can be served. R 2 3 T R + 1 mm R 1 10 mm RE /

11 Signal Types Analog Sinusoidal scanning signals 1Vpp Incremental signals Sinusoidal signals U sin + and U cos + and their inverse signals U sin - and U cos -. Signal magnitude: U sin /U cos = 1 Vpp ( V) with terminating resistance Z 0 = 120 Ω Reference mark signals One or multiple signal peaks U RI + and their inverse signals U RI -. Signal magnitude: U RI 0.5 V (usable component) with terminating resistance Z 0 = 120 Ω U 0 = 2.5 V ± 0.5 V U sin U cos U 0 U RI Signal period (1000 µm) 360 electr. 90 ± 0.05 electr. Graphical representation of sensor in positive counting direction Recommended interface switching for sinusoidal signals Imax ca. 20 ma C2 Signal-In R 0 /2 - Sin-, Cos-, RI- IN- R1 R2 +Vb C0 R 0 /2 U ZD Z 0 C1 + IN+ R1 U 0 U 0 Sin+, Cos+, RI+ C1 -Vb R2 U1 R 0 < 100R C 0 < 50pF U 0 < 2.5V +/- 0.5V Z 0 = 120R U1 ~ U 0 C2 11 RE /

12 Ball Rail and Roller Rail Systems with Integrated Measuring System Digital Square-wave output signal through an integrated interpolation unit Incremental signal -square-wave signal A+, B+ and their inverse signals A-, B- per the RS-422 standard (DIN part 3). Reference mark signal One or multiple square-wave pulses RI+ and their inverse pulses RI-. ulse width: 90 electr. Delay time: t d < 0.1 µs Signal Level U H > 2.5 V at -I H = 20 ma U L < 0.5 V at I L = 20 ma Capacity -I H < 20 ma I L < 20 ma C Last < 1000 pf Switching time: Ramp time: t+ < 100 ns Decay time: t- < 100 ns Terminal resistance Z 0 = 120 Ω A B RI Edge spacing = 90 t d ± 5 electrical t d Graphical representation of sensor in positive counting direction Resolution and Interpolation Example: An interpolation factor of 256 yields a signal period of 4 µm. Rexroth Bosch offers different resolution Through a 4-edge evaluation by the rates: control, a resolution of 1 µm results µm, 1 µm, 5 µm, 10 µm Integrated interpolation factors after 4 The sinusoidal scanning signal must be edges: interpolated to achieve these resolutions. 1Vpp > No external unit is needed for 10 µm 25x interpolation. 5 µm 50x For resolution rates of 0.25 µm, 1 µm, 1 µm* 256x 5 µm and 10 µm, the interpolation unit 0.25 µm** 1024x is integrated in the scanner. * x256 = µm ** 1000 = µm 4x1024 Recommended interface switching for signals RS-422 DIN Z 0 = 120R + 5V A+ / B+ / RI+ A- / B- / RI- Z 0 + 5V R1 A- / B- / RI- R2 R1 R1 = 4k7 R2 = 1k8 RE /

13 Digital Square-wave output signal HTL through an external /HTL adapter If a higher voltage level of the output signal is required, the converter can be set to provide HTL signals. Incremental signals HTL square-wave signals A+, B+ and their inverse signals A-, B- per the RS-422 standard (DIN part 3). Reference mark signal One or multiple square-wave pulses RI+ and their inverse pulses RI-. ulse width: 90 electr. A B RI Edge spacing = 90 ± 5 electric Input signal level from measuring system 5 V- as per RS422 Output signal level HTL 8 to 30 V, depending on power supply, max. 20 ma per channel ower supply voltage 8 to 30 V; < 30 ma Enclosure type I 66 /HTL Adapter art number This part number is valid for Ball Rail and Roller Rail Systems. Input connection (scanner side) Input (scanner side) Output (control side) 12-pin CONNEI flange with female socket contacts (connector type ) Output connection (control side) pin CONNEI flange with male pin contacts (connector type ) RE /

14 Ball Rail and Roller Rail Systems with Integrated Measuring System roduct Overview and Technical Data External interpolation unit for analog signals Division factor 256x Resolution 1 µm* art number The part number is valid for Ball Rail and Roller Rail Systems. Input signal level from measuring system 1 Vpp Output signal level 5V- as per RS422 Input connection (sensor side) 12-pin CONNEI flange with female socket contacts (connector type ) Output connection (control side) 12-pin CONNEI flange with male pin contacts (connector type ) 64 Input (sensor side) Output (control side) 4, Division factor 1024x Resolution 0.25 µm** art number The part number is valid for Ball Rail and Roller Rail Systems. Entry signal level from measuring system 1 Vpp Output signal level 5V- as per RS422 Input connection (sensor side) 12-pin CONNEI flange with female socket contacts (connector type ) Output connection (control side) 12-pin CONNEI flange with male pin contacts (connector type ) Notes on resolution rates * 1000 = µ 4x256 ** 1000 = µ 4x1024 Technical Data Input frequency max. 2.3 khz max khz rocess speed max. scale division 1 mm 2 m/s 0.5 m/s Enclosure I 66 ower supply ins and assignment Shielding on plug housing 5V ±5%, 100 ma IN Signals B 5 V- RI+ RI A+ A B+ 0 V 0 V- +5 V Sensor Sensor RE /

15 Additional technical data Notes on resolution rates * ** 1000 = µm 4x = µm 4x1024 The sinusoidal scanning signal must be interpolated to achieve these resolutions. No external unit is needed for interpolation. For resolution rates of 0.25 µm, 1 µm, 5 µm and 10 µm, the interpolation unit is integrated in the scanner. If higher process speeds are needed for the resolutions 0.25 µm or 1 µm, select a sensor with signal type 1Vpp and the appropriate external interpolation unit ( or -07). Resolution with signal 0.25µm**; 1µm*, 5µm; 10 µm Repeatability 0.5µm**; 2µm*; 10µm; 20 µm rocess speed max. Vibration ( Hz) 100 m/s 2 Shock (11 ms) 500 m/s 2 Max. rail length 5 m/s at resolution 5 µm, 10 µm, 1Vpp 0.25 m/s at resolution 0.25 µm 1 m/s at resolution 1 µm 4000 mm (standard rail) Enclosure (DIN 40050) I 67 Operating temperature 0 to 50 C Storage temperature 10 to 70 C ower supply 5 V ± 5 % 1 Vpp: 250 ma Signal input 5; 10: 400 ma 0.25; 1: 350 ma Extension Voltage drop 1 Vpp: 60 mv 20 mv (for standard cable/extension 5; 10; 100 mv 30 mv cable of 1 m lengths) 0.25; 1: 80 mv 25 mv 15 RE /

16 Ball Rail and Roller Rail Systems with Integrated Measuring System roduct Overview and Technical Data Accuracy of the measuring system The accuracy of the measuring system is made up of 3 components: Scale pitch accuracy Guideway accuracy Deviation of the interpolation The sums of the deviations are summarized in the term system accuracy. Definition of system accuracy: The system accuracy is the maximum deviation from the mean of any position over a measuring distance of 1m, expressed in ± a (µm). Four different system accuracies are available: ± 3 µm ± 5 µm ± 10 µm ± 30 µm at 20 C A detailed system accuracy report can be provided on request. For examples, see the following pages. When ordering: The system accuracy is selected by stating the appropriate code in the guide rail part number. RE /

17 Test Report part 1 (System Accuracy Report) 17 RE /

18 Ball Rail and Roller Rail Systems with Integrated Measuring System Test Report part 2 (System Accuracy Report) RE /

19 Ordering System Composition of ordering data Measuring system components The measuring system is made up of 3 main components: robe (scanner)/connector (to connect the probe to the computer/ control loop/master control system) Runner block (determined by Ball Rail or Roller Rail System) Guide rail with integrated scale and reference marks (determined by Ball Rail or Roller Rail System) art numbering system Due to the many options available, the complete ordering data is divided into 3 sections, each with its own part numbers. The probe/connector and runner block form one unit and must therefore be ordered together. The connectors are shipped preassembled to the probe. As a result, the connector options are coded into the last 3 digits of the probe/connector part number. Ordering for existing rail systems If Ball Rail or Roller Rail Systems without measuring systems are already in use, these can be easily replaced. To ensure the correct replacement, Rexroth Bosch needs the information in the box at right: [ [ Complete ordering data consists of: art Number robe/connector (6-digit) art Number Runner Block - _ - (9-digit) art Number Guide Rail - _ - (9-digit) + rail length in mm To find the specific part numbers, refer to the appropriate following sections. Accessories: Extension cable Cable length in m + art number connector 1 and 2 (see page 20) /HTL Adapter IE IE The part numbers are applicable for Ball Rail and Roller Rail Systems. Information for replacement/retrofitting: art number robe/connector (6-digit) art number Runner Block - _ - (9-digit) All information should be identical to that of the existing system. Rexroth Bosch will select the correct size and version (KSF/RSF*) of the probe based on this information. Guide Rail part number - _ - (9-digit) All information should be identical to that of the existing system. In addition, it is essential to state the existing mounting hole pattern: Note the location of the scale. T 1A Scale T 1E To find the specific part numbers, refer to the appropriate following sections. * KSF = Ball Rail System; RSF = Roller Rail System 19 RE /

20 Ball Rail and Roller Rail Systems with Integrated Measuring System robe/connector Options and part numbers A probe must be selected for each runner block. Differentiation by Ball Rail or Roller Rail Systems is made when selecting runner blocks and guide rails. The part number for the probe consists of: art number, part 1 from the table xxx xxx art number, part 2 from the table Ordering example: Resolution: 1 µm Signal type: Length of standard cable L 1 : 3 m Connector type: 12-pin Connei Male coupling Ordering data: art number, part art number, part 2 KSF Resolution Length art Number, art 1 Signal Type Cable L 1 (m) 1 Vpp none ) µm ) µm ) µm ) µm ) RSF In addition, the part numbers for the runner block and guide rail are required. KSF = Ball Rail Systems RSF = Roller Rail Systems 1) For cable length 3 m: voltage drop of 0.3 V. 2) For detailed information on connectors, see the section "Connectors and Cables". 3) connector. Included automatically unless another type is specified. Connector Type Version art Number, art 2, Connector Selection 2) Contact Type male female 12-pin DIN 12-pin Connei 9-pin Connei Connector Coupling Flanged socket Connector Coupling Flanged socket Connector Coupling Flanged socket pin Sub-D Connector ) Type 1 Connector pin Sub-D Type 2 Connector Connector Special Connectors Coupling Flanged socket RE /

21 Dimensions robe for Ball Rail Systems The probe for Ball Rail Systems attaches to the ball recirculation cap. X X 1 Y Cable Length* (m) L ) Z * Recommendation for cable lengths: For cable lengths > 3m, use extension cable robe dimensions for Ball Rail Systems (mm) Size X X 2) 1 Y Z KSF robe for Roller Rail Systems The probe for Roller Rail Systems is integrated in the roller recirculation cap. X X 1 Cable Length* (m) Y L ) Z 1) For cable length 3 m: voltage drop of 0.3 V. 2) X 1 : osition of the reference sensor in the probe robe Dimensions for Roller Rail Systems (mm) Size X X 2) 1 Y Z RSF RE /

22 Ball Rail and Roller Rail Systems with Integrated Measuring System Ball Runner Blocks with Measuring System Options and part numbers The runner block part number consists of the following: art number from the table 1682-xx (G2 without chain) 1683-xx (G2 with chain) 1684-xx. -.. (G1) + Variant code + Runner block code G1 = Generation 1 Ball Runner Blocks G2 = Generation 2 Ball Runner Blocks Codes for steel Ball Rail runner blocks width runner blocks length Long G2 standard short Slimline runner blocks length ) 3) Long ) 3) length, high )2)3) Long, high )2)3) G2 slimline, short ) Not in size 20 2) Not in size 65 3) Not in accuracy class S Runner block code Ordering example Runner block, standard width, long Complete, with low-friction (L) seal Size 35 Accuracy class H reloading 0.02 C Reference edge of the runner block and scale on the same side Size Accuracy art Numbers Class for preload class reload reload reload 0.02 C 0.13 C 20 S H S H S H S H S H S H S H Runner Block Version Scale Variant Codes Reference edge Scale Ordering data: art number from the table Variant code + Runner block code The part numbers for the selected probe and guide rail are also required. Complete, 1 4 Only up to size 35 Complete, 2* Only accuracy class H with L-seal Only preloading 0.02 C 5* Complete, ZnFeC 3** 6** plated * ) Available with G1 only ** ) On request Reference Edge RE /

23 Roller Runner Blocks with Measuring System Options and part numbers The runner block part number consists of the following: art number from the table 1884-xx Variant code + Runner block code Code for steel Roller Rail runner blocks: width runner blocks length ) Long Slimline runner blocks length high ) Long high ) Not in size 65 Runner block code Size Accuracy art Numbers Class for preload class reload reload 0.13 C 35 S H S H S H S H Ordering example width runner block, long With aluminum end cap Size 35 Accuracy class reload Reference edge of the runner block and scale on the same side Ordering example: art number from the table Variant code + Runner block code The part numbers for the selected probe and guide rail are also required. Runner Block Version Variant Codes Reference edge Scale Complete, 1 5 Complete, with aluminum 2* 6* end cap Complete, ZnFeC 3* 7* plated Complete, with aluminum end cap 4* 8* ZnFeC plated * ) On request Scale Reference edge 23 RE /

24 Ball Rail and Roller Rail Systems with Integrated Measuring System Ball Guide Rail with Measuring System Guide Rails with Rail Seal Cover Strip The part number of the guide rail with Rail Seal cover strip consists of the following: art number from the table 1685-xxx -..,... + Accuracy code + Sections code + Rail length in mm Guide rails, mounted from above, with Rail Seal and screw-on protective caps Additional ordering data for single reference mark Scale Reference mark position (mm) Remaining length (mm) Ordering example Guide rail size 35 with Rail Seal Accuracy class Rail length 1756 mm With single reference mark Accuracy ± 10 µm One-piece Ordering data: art number from the table , Accuracy code + Sections code + Rail length in mm Measuring length (mm) Rail length (mm) Reference mark position: Measuring length: Remaining length: 1200 mm 1000 mm 556 mm Size Accuracy art Numbers Class Guide Rails with Rail Seal without with single with distance coded reference mark reference mark reference marks 20 S H S H S H S H S H S H S H Measuring System Accuracy Code Accuracy ± 3 µm 1* ± 5 µm 3 ± 10 µm 6 ± 30 µm 7 Number of Sections Section Code One-piece 1 (max mm) 2 to 8 sections 2-8* * In preparation RE /

25 Guide Rails without Rail Seal Cover Strip The part number of the guide rail without Rail Seal cover strip consists of the following: art number from the table + Version + Accuracy code + Section code + Rail length in mm 168x-xxx -..,... Top-mount or bottom-mount guide rails Top-mount guide rail with plastic mounting hole plugs art number 1685-xxx -.. Otherwise as per table Bottom-mount guide rails with steel mounting hole plugs art number 1686-xxx -.. Otherwise as per table Bottom-mount guide rails art number 1687-xxx -.. Otherwise as per table Size Accuracy art Numbers Class Guide Rails without Rail Seal without with single with distance coded reference mark reference mark reference marks 20 S H S H S H S H S H S H S H Additional ordering data for single reference mark Scale Measuring System Accuracy Code Accuracy ± 3 µm 1* ± 5 µm 3 ± 10 µm 6 ± 30 µm 7 Reference mark position (mm) Remaining length (mm) Measuring length (mm) Rail length (mm) Number of Sections Section Code One-piece 1 (max mm) 2 to 8 sections 2-8* * In preparation 25 RE /

26 Ball Rail and Roller Rail Systems with Integrated Measuring System Roller Guide Rails with Measuring System Guide Rails with Rail Seal Cover Strip The part number of the guide rail with Rail Seal cover strip consists of the following: art number from the table 1885-xxx -..,... + Accuracy code + Sections code + Rail length in mm Guide rails, mounted from above, with Rail Seal and screw-on protective caps Additional ordering data for single reference mark Scale Reference mark position (mm) Remaining length (mm) Measuring length (mm) Rail length (mm) Ordering example Guide rail size 45 with Rail Seal Accuracy class Rail length 1886 mm With single reference mark Accuracy ± 10 µm One-piece Ordering data: art number from the table , 1886 Size Accuracy art Numbers Class Guide Rails with Rail Seal without with single with distance coded reference mark reference mark reference marks 35 S H S H S H S H Measuring System Accuracy Code Accuracy ± 3 µm 1* ± 5 µm 3 ± 10 µm 6 ± 30 µm 7 Number of Sections Section Code One-piece 1 (max mm) 2 to 8 section 2-8* * In preparation + Accuracy code + Section code + Rail length in mm Reference mark position: Measuring length: Remaining length: 1300 mm 1000 mm 886 mm RE /

27 Guide Rails without Rail Seal Cover Strip The part number of the guide rail without Rail Seal cover strip consists of the following: art number from the table + Version + Accuracy code + Section code + Rail length in mm 188x-xxx -..,... Top-mount or bottom-mount guide rails Top-mount guide rail with plastic mounting hole plugs art number 1885-xxx -.. Otherwise as per table Bottom-mount guide rails with steel mounting hole plugs art number 1886-xxx -.. Otherwise as per table Bottom-mount guide rails art number 1887-xxx -.. Otherwise as per table Additional ordering data for single reference mark Scale Size Accuracy art Numbers Class Guide Rails without Rail Seal without with single with distance coded reference mark reference mark reference marks 35 S H S H S H S H Measuring System Accuracy Code Accuracy ± 3 µm 1* ± 5 µm 3 ± 10 µm 6 ± 30 µm 7 Number of Sections Section Code One-part 1 (max mm) 2 to 8 sections 2-8* * In preparation Reference mark position (mm) Remaining length (mm) Measuring length (mm) Rail length (mm) 27 RE /

28 Ball Rail and Roller Rail Systems with Integrated Measuring System Connectors in Assignment 12-pin Connei (I67) in No. Color Signal 1 white B- 2 red-white 5V Sensor 3 pink RI+ 4 gray RI- 5 green A+ 6 yellow A- 7 8 brown B blue 0V 11 blue-white 0V Sensor 12 red +5V shield Enclosure black purple 12-pin DIN (I 40) in No. Color Signal A B blue+blue-white 0V C green A+ D yellow A- E brown B+ F G pink RI+ H gray RI- J K red+red-white +5V L white B- M shield Enclosure black purple Type 1: 15-pin Sub-D (I40) in No. Color Signal 1 red-white 5V Sensor 2 blue-white 0V Sensor 3 gray RI- 4 pink RI+ 5 white B- 6 brown B+ 7 green A+ 8 yellow A blue 0V red +5V shield Enclosure black purple Typ 2: 15-pin Sub-D (I40) in No. Color Signal 1 red +5V 2 blue 0V 3 green A+ 4 yellow A- 5 6 brown B+ 7 white B- 8 9 red-white 5V Sensor 10 pink RI+ 11 blue-white 0V Sensor 12 gray RI shield Enclosure black purple 9-pin Sub-D (I40) in No. Color Signal 1 yellow A- 2 blue+blue-white 0V 3 white B- 4 5 gray RI- 6 green A+ 7 red+red-white +5V 8 brown B+ 9 pink RI+ shield Enclosure black purple RE /

29 Connector in Assignment (view from contact side) Contact Type pin CONNEI ø 28 ø pin DIN ø A K J L H M F G B C D E 15-pin 9-pin Sub-D X x = 42.7 mm x = 34.3 mm Coupling pin ø 25.5 M 23 x 1 ø Flanged Socket on Mounting Block* M 4 x ø ø Contact Type Connectors, couplings, and flanged sockets can have either male or female contacts. male female * on request 29 RE /

30 Ball Rail and Roller Rail Systems with Integrated Measuring System Cables Wire Assignment Color assignment for standard cable L 1 (on probe) UR cable, black Signal A+ A- B+ B- RI+ RI- +5V 0V + 5V Sensor 0V Sensor Shield Color green yellow brown white pink gray red blue red/white blue/white Enclosure Cable Structure Cores: 5 x (2 x 0.05 mm 2 ) + 1 x (2 x 0.14 mm 2 ) Shield: braided, galvanized, high-conductivity Cu wire coverage approximately 85% Sheath: UR Color: flat black Outer Diameter: 5.0 ± 0.15 mm outer diameter L 1 Color assignment for extension cable L 3 (accessory) UR cable, black Signal A+ A- B+ B- RI+ RI- +5V 0V + 5V Sensor 0V Sensor Shield Color green yellow brown white pink gray red blue red/white blue/white Enclosure Cable Structure Cores: 4 x (2 x 0.14 mm 2 ) + 2 x (2 x 0.5 mm 2 ) Shield: braided, high-conductivity Cu wire coverage approximately 85% Sheath: UR Color: flat black Outer Diameter: 8.3 ± 0.2 mm outer diameter L 1 L 3 Mechanical properties (standard and extension cables) Bending radius for one-time bending (stationary): 5 x d (outer diameter of cable) Bending radius for repeated bending (flexing installation): 10 x d Operating temperatures: 30 C to max C Shipping and storage temperatures: 40 C to max C Chemical properties (standard and extension cables) Oil resistant per VDE 0472 part 803 test type B Halogen-free per VDE 0472 part 815 Flammable Generally resistant to acids, alkalis, and cleaning solutions Generally resistant to dust Generally resistant to microbe and fungus infestation RE /

31 Assembly Instructions Assembly and disassembly of runner blocks Always handle the measuring system with great care! Assembly If the runner block must be pushed onto the guide rail probe-end first, use extreme care! For roller runner blocks: The mounting arbor must remain in the runner block until the block is pushed onto the guide rail. Otherwise, rollers may be lost! ush the runner block carefully onto the guide rail. For roller runner blocks: osition the runner block on its mounting arbor against the end of the guide rail and carefully push the runner block off the mounting arbor and onto the guide rail. Disassembly If the runner block cannot be removed probe-end first, use extreme care! Carefully slide the runner block off the guide rail. For roller runner blocks: Always slide the runner block directly off the guide rail and onto the mounting arbor! For roller runner blocks: The removed roller runner block must remain on the mounting arbor! Otherwise, rollers may be lost! 31 RE /

32 STAR Ball Rail and Roller Rail Systems with Integrated Measuring System Assembly Instructions Assembly of guide rails Screw installation sequence (example) Always handle the measuring system with great care! To ensure that the repeatable accuracy of the measuring system is achieved upon assembly, the guide rails must be screwed down in sequence from the ends toward the center. artial sections should be centered Hint: For guide rails with distance coded reference marks, the side with the reference marks is indicated by a hole in the reference edge of the guide rail (see page 10). The scale is located on the opposite side. For more detailed information on assembling Ball Rail and Roller Rail Systems, as well as Rail Seal cover strips, see the following assembly instructions: Montage Mounting Montage Montaggio Montage Mounting Montage Montaggio Montageanleitung für Kugelschienenführungen Mounting Instructions for Ball Rail Systems Instructions de montage pour Guidages à billes sur rails Istruzioni di montaggio per Guide a sfere su rotaia Montageanleitung für Rollenschienenführungen Mounting Instructions for Roller Rail Systems Instructions de montage pour Guidages à rouleaux sur rails Istruzioni di montaggio per Guide a rulli su rotaia RDEFI /01.99 RDEFI / RDEFI / RDEFI / Montageanleitung für das Abdeckband für Kugel- und Rollenschienenführungen Mounting Instructions for the Rail Seal Cover Strip for Ball and Roller Rail Systems Instructions de montage pour la bande de protection pour guidages à billes sur rails et guidages à rouleaux sur rails Istruzioni di montaggio per il nastro di protezione per guide a sfere e guide a rulli su rotaia Montageanleitung für Montageanleitung für das Kugel- und Rollenschienenführungen Integrierte mit integriertem Messsystem in Kugel- und Rollenschienenführungen RDEFI /05.98 RD / Linear Motion and Assembly Technologies RE /

33 Maintenance Instructions Lubrication Ball Rail and Roller Rail Systems with Measuring Systems cannot be lubricated through the probe. Lubricate the runner blocks easily through the lubrication ports. Lubrication of Ball Rail Systems For more information on maintenance and lubrication, see the respective chapters in the Ball Rail Systems catalog (82 201) or Roller Rail Systems catalog (82 300). Lubrication of Roller Rail Systems 33 RE /

34 Ball Rail and Roller Rail Systems with Integrated Measuring System Sample Inquiry/Order Form [ Ordering Example art number: robe/connector Cable length L 1 : 3 (m) art number: Runner Block art number: Guide Rail , 1756 (mm) art number: Extension Cable L (m), 1 1 2, Additional ordering data for single reference mark T 1A Reference mark position *: 1200 (mm) Remaining length: 556 (mm) Measuring length: 1000 (mm) Rail length robe Resolution1 µm signal Cable length L 1 = 3 m Connector type 12-pin Connei Coupling with male contacts Runner Block Ball Rail runner block standard width, long With low-friction (L)-seal Size 35 Accuracy class H reloading 0.02 C Reference edge and scale on same side Guide Rail Ball Rail guide rail size 35 with Rail Seal cover strip, Accuracy class Rail length 1756 mm With single reference mark Accuracy ± 10 µm One-piece RE /

35 Ball Rail and Roller Rail Systems with Integrated Measuring System Inquiry/Order Form Rexroth Star GmbH D Schweinfurt Telephone Fax To be completed by customer: Inquiry / Order Cable length L 1 : (m) art number: robe/connector art number: Runner Block - _ - art number: Guide Rail - _ -, (mm) [ art number: Extension Cable L 3 T 1A , (m), _, _ Connector1/Connector2 Additional ordering information for single reference mark Reference mark position*: (mm) Remaining length: (mm) Rail length Measuring length: (mm) * Must be within the measuring length Axis= (x, y, z; please use a separate form for each axis) CNC control system used: KSF = Ball Rail System already on-hand: RSF = Roller Rail System already on-hand: Quantity Comments: Order of: pcs., per month, per year, per order, or From: Company: Name: Address: Department: Telephone: Fax: 35 RE /

36 Rexroth Star GmbH D Schweinfurt Member of Bosch Rexroth Gruppe Telephone Telefax (general) Telefax (direct) Internet Great care been taken during the compilation of this publication to ensure all the information contained is accurate. We accept no responsibility however for any damage resulting from incorrect or incomplete information contained. For deliveries and other services in the course of commercial business, the general terms and conditions in the valid price lists and the confirmations of order apply. As our products are constantly in the process of further development, they are subject to alteration without notice. Ball Rail and Roller Rail Systems with Integrated Measuring System RE / rinted in Germany - p 2003/01/-/-