Rapport - Siste nytt

Hovedprosjekt
for: Ingeniørutdanningen
HØGSKOLEN I AGDER
Fakultet for teknologi, Grimstad
Tittel:
Banestyrt 2-akse hydraulisk robot
Prosjektnr.: HPR/MD-009/2007
Fagområde: Mekatronikk
Antall sider: 81
Tilgjenglighet: Åpen
Dato: 04.06.2007
Oppdragsgiver:
HiA v Morten Ottestad
Veileder(e):
Morten Ottestad
Forfatter(e): Gruppe 9:
Morten Skeie
Andreas N Malme
Dominic Fiane
Emneord:
HIL
Hia
Mekatronikk
Stikkord:
ComapctRio, hydraulikk, styresystem, regulering
Telefon: +47 37 25 30 00
Grooseveien 36, N-4876 Grimstad
Telefaks: +47 37 25 30 01
Forord:
Dette er rapporten til hovedprosjektet ”hydraulisk 2-akse banestyrt testjigg”. Dette er et
prosjekt som er blitt gitt fra HIA. Oppgaven er skrevet av Morten Skeie, Andreas N Malme og
Dominic Fiane. Den er skrevet ved Høyskolen i Agder, Teknologisk avdeling Grimstad i
perioden 8.mars- 28.mai.
Bakgrunn for oppgaven er at det i forbindelse med oppstart av masterstudie i mekatronikk
skal kunne tilbyes givende labboppgaver. Det skulle med grunnlag i dette utvikles en
hydraulisk testjigg som skulle da kunne brukes i denne labbsammenheng.
Takk til:
Veileder Morten Ottestad som har hjulpet oss når det har vært behov og kommet med mange
gode råd og gitt oss verdifull hjelp.
Eiken mek. verksted som har lånt oss maskiner og utstyr og hjulpet til med maskinering.
ASI Automatikk A/S i Drammen for gratis lager og oppfølging
Labbpersonell Eivind Johansen, Roy Folgerød og Thorstein Wroldsen som har hjulpet oss
med maskinering, bestilling av deler og kommet med mange gode innspill.
Til slutt vil vi takke alle som har hatt tro på at prosjektet kunne gjennomføres og som har
støttet oss.
___________________
Morten Skeie
____________________
Andreas N Malme
HPR-009
____________________
Dominic Fiane
Side 2 av 81
Sammendrag
Denne rapporten dokumenterer hovedprosjektsoppgaven ”hydraulisk 2-akse banestyrt
testjigg”. Selve oppgaven går ut på å redesigne, modifisere, programmere og fredigstille den
hydrauliske jiggen.
Rapporten inneholder dokumentasjon av alt det mekaniske arbeidet, samt en fullstendig
oversikt over det elektriske med tilhørende koblingsdiagrammer og tegninger. Den inneholder
også en enkel matematisk og dynamisk beskrivelse av enkelte deler som ble stilt av
oppdragsgiver.
Videre er programmering og alle programmer tilknyttet prosjektet beskrevet og dokumentert.
Det er også laget en liten innledning til hvordan komme i gang med programmering i
Labview med Crio som applikasjon.
Jiggen er ferdig montert og kalibrert. Den er testkjørt med alle forskjellige programmoduler
med meget tilfresstillende resultater.
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Innholdsfortegnelse
1
2
3
4
5
Innledning........................................................................................................................... 6
1.1
Prosjektrapportens Organisering........................................................................... 6
1.1.1
Språk................................................................................................................... 6
1.1.2
Layout................................................................................................................. 6
1.1.3
Vedlegg .............................................................................................................. 6
1.1.4
Referanser........................................................................................................... 7
1.1.5
Arbeidstegninger ................................................................................................ 7
1.1.6
Figurer og tabeller .............................................................................................. 7
1.2
Oppgaven .................................................................................................................. 8
1.2.1
Mål ..................................................................................................................... 8
1.2.2
Hvem rapporten henvender seg til ..................................................................... 8
1.2.3
Oppgavetekst...................................................................................................... 9
1.2.4
Omfang............................................................................................................... 9
1.2.5
Begrensninger................................................................................................... 10
1.2.6
Kravspesifikasjoner.......................................................................................... 10
1.2.7
Uklarheter......................................................................................................... 10
1.3
Organisasjon ........................................................................................................... 11
Bakgrunnsteori ................................................................................................................. 12
2.1
CompactRIO........................................................................................................... 12
2.2
Enkoder (inkrementell).......................................................................................... 14
2.3
Potensiometer ......................................................................................................... 17
2.4
Sylindere.................................................................................................................. 18
2.5
Slanger..................................................................................................................... 18
2.6
Koplinger................................................................................................................. 19
2.7
Rør ........................................................................................................................... 19
2.8
Servoventiler ........................................................................................................... 20
Beregninger og teori......................................................................................................... 23
3.1
Dynamikk................................................................................................................ 23
3.1.1
Ventildynamikk................................................................................................ 28
3.2
Invers kinematikk .................................................................................................. 30
3.3
Hastigheter.............................................................................................................. 32
Det Mekaniske.................................................................................................................. 34
4.1
Igus® Lager ............................................................................................................ 34
4.2
Festing av knekkbom ............................................................................................. 35
4.3
Enkoder og potensiometerfester ........................................................................... 36
4.4
Koblingsboks........................................................................................................... 37
4.5
Monteringsbenk og tavle ....................................................................................... 38
4.6
Nødstoppen ............................................................................................................. 39
4.7
Flushing av oljesystem ........................................................................................... 39
4.8
Teststang ................................................................................................................. 40
4.9
Endestoppbrytere ................................................................................................... 41
4.10 Kalibrering/referansekjøring................................................................................ 41
Det elektriske.................................................................................................................... 42
5.1
Din skinne oversikt................................................................................................. 42
5.2
Elektriske komponenter ........................................................................................ 43
5.2.1
Servoventiler .................................................................................................... 43
5.2.2
Enkodere........................................................................................................... 44
5.2.3
Endestoppbrytere.............................................................................................. 46
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6
Ytelser og spesifikasjoner ................................................................................................ 47
6.1
Arbeidsområde ....................................................................................................... 47
6.2
Regulering ............................................................................................................... 48
6.3
Posisjonsmålinger................................................................................................... 53
7
Programmering av CompactRIO...................................................................................... 57
7.1
Sette opp et Real-time Project............................................................................... 57
7.2
Bruk av Shared variable........................................................................................ 61
7.2.1
Lage nye variabler............................................................................................ 62
7.2.2
Variabler brukt i vårt prosjekt: ......................................................................... 63
7.3
FPGA program....................................................................................................... 65
7.4
Real-Time – Program............................................................................................. 68
7.5
Program maler........................................................................................................ 69
7.5.1
Program mal for posisjonering med 1 DOF ..................................................... 69
7.5.2
Program mal for posisjonering med 2 DOF ..................................................... 71
7.5.3
Program mal for banestyring med 2 DOF........................................................ 72
7.6
Sub vi’er .................................................................................................................. 75
7.6.1
Invers kinematikk.vi......................................................................................... 75
7.6.2
hpg to xy cord 2.vi............................................................................................ 75
7.6.3
Interpolering.vi................................................................................................. 75
7.7
Programmer brukt av gruppa .............................................................................. 77
8
Oppsumering .................................................................................................................... 79
8.1
Status ....................................................................................................................... 79
8.2
Konklusjon.............................................................................................................. 79
8.3
Erfaringer ............................................................................................................... 79
9
Litteraturliste .................................................................................................................... 80
10
Vedlegg ........................................................................................................................ 81
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1 Innledning
Denne rapporten vil inneholde arbeidet med hovedprosjektet ”2-akse banestyrt hydraulisk
testjigg”.
1.1
Prosjektrapportens Organisering
Denne rapporten vil være organisert som en vanlig teknisk rapport. Den vil følge de
retningslinjer gitt fra høyskolen. Videre vil det være innslag og ideer hentet fra rapporten [1].
Den vil videre følge vanlige normer for rapporter.
1.1.1
Språk
Rapporten inneholder en del tekniske ord og forklaringer. Det er derfor forventet at leser av
rapporten innehar en viss teknisk forståelse. Rapporten er skrevet med så enkelt språk som
mulig og det er brukt så få engelske ord som mulig. Videre er det en fordel at leseren har
kjennskap til Solid Works samt kjennskap til grunnleggende fysiske fenomen, mekanikk og
elektronikk.
1.1.2
Layout
Vi bruker skrifttype Times New Roman størrelse 12 og halvannen linjeavstand. Så har det
videre blitt brukt titler i logisk rekkefølge. Innholdsfortegnelsen er lagt opp på slik at man skal
kunne følge hver enkelt del aktivitet for seg selv. Det er brukt sidetall for praktiske hensyn, og
nummerering av hvert underkapittel slik at leser kan lett finne igjen ønsket området. Forsiden
er laget etter malen for prosjektrapporter ved Hia.
1.1.3
Vedlegg
Alle vedlegg er nummeret i en liste og plassert bakerst i rapporten. Ved referering til vedlegg
i rapporten vil dette bli gjort ved bruk av nr.
Vedleggene er som regel ofte enten datablad eller andre tekniske dokumenter. Det er derfor
ikke noen standard form på disse. Vi gjør også oppmerksom på at en del av disse vil være på
engelsk.
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1.1.4
Referanser
Alle referanser er merket med individuelle nr. Ved å finne frem til tilsvarende tall i
referanselisten bakerst i rapporten kan man så finne frem til det dokumentet det refereres til.
1.1.5
Arbeidstegninger
I og med at Solid Works er brukt for å modellere opp alle deler foreligger også alle
tegningene på denne form. Tegninger er fullstendige og merket med nr og navn. Disse vil
ligge som vedlegg bak i rapporten.
1.1.6
Figurer og tabeller
Alle figurer, tabeller, illustrasjoner og bilder vil være nummeret. Henvisninger til disse vil da
bli gjort ved bruk av disse numrene i rapporten. Om disse er hentet fra eksterne kilder vil de i
tillegg ha et referansenummer. Det vil også bli gitt forklaringer der det er nødvendig.
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1.2
1.2.1
Oppgaven
Mål
Målet med oppgaven er å få vist og brukt en del av kunnskapen vi har tilegnet oss gjennom
studietiden. Den skal videre gi en dypere innsikt og kunnskap om valgt emne og teori. Vi skal
også få erfare hvordan det er å jobbe med prosjektbaserte oppgaver som er så
virkelighetsnære som mulig.
Den konkrete oppgaven er å ferdigstille og fullføre den hydrauliske jiggen slik at den er klar
for labbruk. Vi håper det ferdige produktet vil være et grunnlag for lærerike og spennende
labboppgaver.
1.2.2
Hvem rapporten henvender seg til
Denne rapporten henvender seg til prosjektgruppen, veiledere, oppdragsgiver og
medstudenter.
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1.2.3
Oppgavetekst
Utvikling av multifunksjons hydraulisk servojigg
Studenter: D. Fiane, A. Malme, M. Skeie
Oppgavens bakgrunn:
Høgskolen i Agder har med utgangspunkt i den regional industriprofil valgt å satse på heavy
duty motion control som tema i sitt mastergrads studium. Det er derfor viktig at HiA kan tilby
interessante og givende lab oppgaver innen dette feltet. Vi ønsker oss derfor en hydraulisk
testjigg der det kan kjøres lab oppgaver med varierende vanskelighetsgrad.
Oppgavens mål:
Den eksisterende 2 DOF testjigg skal videreutvikles. Det skal utvikles en dynamisk modell
for jiggen. Det skal utvikles matematiske modeller som gir sammenhengen mellom aktuator
koordinater og endepunktets koordinater i et kartesisk koordinatsystem og omvent. Det skal
utvikles en metode for kalibrering av roboten. Testjiggens posisjonsnøyaktighet skal
identifiseres. Styring av testjigg skal skje ved bruk av CompactRIO Real-Time Kontroller
med sanntids operativsystem for å sikre deterministisk kontroll.
Det skal utvikles programmaler for fire forskjellige modus.
• Det skal utvikles og implementeres programmal for posisjoneringssystem med 1 DOF med
varierende massetreghetsmoment
• Det skal utvikles og implementeres programmal for posisjonsfølgesystem med 1 DOF med
varierende massetreghetsmoment og oversenter bevegelse
• Det skal utvikles og implementeres programmal for posisjoneringssystem med 2 DOF
• Det skal utvikles og implementeres programmal for banestyring
1.2.4
Omfang
Da vi valgte oppgaven ble vi fort klar over at dette var en utfordrende oppgave som krevde
innsats og arbeid, men at arbeidsmengden var overkommelig.
Rapporten skal inneholde videreutvikling av jiggen mekanisk med arbeidstegninger og
dokumentasjon for alle modifikasjoner som er gjort. Dette gjelder også elektriske
komponenter og kretser.
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Side 9 av 81
Videre omfatter den mye programmering som er gjort i labview. Dette er begrenset til de
programmene vi skulle lage.
Den omfatter også endel bakgrunnsteori om de forskjellige komponentene og diverse
utregninger.
1.2.5
Begrensninger
For det første begynte vi med noe som allerede var laget etter visse spesifikasjoner og krav.
Det kreves en del tid og arbeid for å sette seg inn i tidligere arbeid og få en forståelse for
hvordan oppgaven er tenkt løst og hva som manglet. Vi er også bundet opp i grunndesignen
slik at all modifikasjon må bygges rundt denne.
Videre er prosjektet begrenset ved at vi har et konkret mål å nå.
1.2.6
Kravspesifikasjoner
I og med at vi hadde som oppgave å videreutvikle eksisterende jigg ble det ikke stilt noen nye
kravspesifikasjoner. Vi har derfor tatt utgangspunkt i de foregående spesifikasjonene.
1.2.7
Uklarheter
I oppgaveteksten står det følgende ”Det skal utvikles matematiske modeller som gir
sammenhengen mellom aktuator koordinater og endepunktets koordinater i et kartesisk
koordinatsystem og omvent”.
Vi har tolket det som at vi skal beskrive den kinematikken som ligger til grunn for systemet.
Det står også ” Det skal utvikles en metode for kalibrering av roboten”. Med dette tolker vi at
roboten skal ha mulighet for å nullstilles slik at man har en utgangsposisjon den kan kjøres til
som er kjent.
Punktet, ” Det skal utvikles en dynamisk modell for jiggen” har vi tolket som at det skal vises
hvordan dynamikken for sylinder og servoventil fungerer
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1.3
Organisasjon
Oppgaven er gitt av Høyskolen i Agder og tildelt prosjektgruppen Dominic Fiane, Morten
Skeie og Andreas Nødtvedt Malme. Videre omfatter prosjektet veileder Morten Ottestad samt
lab personell.
Oppdragsgiver:
Høyskolen i Agder
Fakultetet for teknologi
Studieretning Mekatronikk
V/ Kjell G Robbersmyr/Morten Ottestad
Serviceboks 509
4898 Grimstad
Veileder:
Morten Ottestad
Tlf: 37 25 31 22
Mail: morten.ottestad@hia.no
Prosjektgruppen:
Dominic Fiane
Tybakken 43
4818 Færvik
Tlf: 90842558
Mail: dominic.fiane@gmail.com
Morten Skeie
Solhøga 25
4876 Grimstad
Tlf: 90529447
Mail: moskeie@gmail.com
Andreas Nødtvedt Malme
Løvås 1, Televeien 2
4879 Grimstad
Tlf: 97774340
Mail: a_malme@hotmail.com
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2 Bakgrunnsteori
I de følgende underkapitelene følger teori og beskrivelser av alle de forksjellige
komponentene som er brukt i dette prosjektet.
2.1
CompactRIO
(Compact reconfigurable I/O)
Compact rio er en programmerbar I/O modul fra National instruments. Denne modulen
brukes til industrielle prosessstyringer. Fordelen med denne modulen er at den har en kjerne
som er enkel å programmere ved hjelp av labview. Den har en såkalt FPGA (fieldprogrammable gate array) chip, men man slipper unna tunge programmeringsspråk VHDL.
Man kan da enkelt programmere dette i labview, og labview kompilerer det til VHDL kode.
Denne chipen funker slik at man skriver programmet i labveiw, kompilerer det på PC-en og
laster det ned på compactRIOen. Dette programmet kompileres til logiske kretser som blir
”tegnet” inn på chipen. Man slipper dermed unna med utvikling av avansert hardware og man
kan enkelt endre på ting som ikke fungerer. Dette kan kutte store utviklingskostnader og kutte
ned utviklingstiden betraktelig. En annen ting med systemet er at det er utrolig raskt, med
opptil 25ns oppdateringsfrekvens. Dermed kan en få veldig kjappe systemer noe som ikke er
oppnåelig med direkte styring gjennom en PC, da denne har for mange delte ressurser.
FPGA
Enheten fungerer slik at den konfigurerbare FPGA chipen ligger i chassiet og utgjør hjertet av
enheten. Her er det veldig kjapp oppdatering og her er den mest tids kritiske koden ligger.
Man konfigurerer denne ut i fra hvilke I/O enheter og hvilke porter man skal lese/skrive til.
Man kan også legge inn enkle matematiske funksjoner, PID regulering og en håndfull andre
funksjoner inn i FPGA.
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Figur 1
Realtime controller
Real time controlleren kommuniserer med fpga og får inn signalene fra I/O enhetene. For å
sikre deterministisk kontroll brukes det noe som heter shared variable og gjennom disse
kommuniserer vi med en host. (dette er forklart nærmere i kapittel 7.4)
I/O enhetene
Kobles til chassiset i slottene. I/O enhetene velges etter behov med analoge eller digitale inn
eller ut moduler. Her er det mye å velge mellom og NI har en tabell der en kan velge enheter
med de spesifikasjonene du trenger.
Her er skolens compactRIO system:
Chasiss og FPGA:
NI-9101
Real time controller:
NI cRIO-9002
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I/O modulene:
NI-9411 Digita Input modul
NI-9474 Digital output modul
NI-9215 Analog input modul
NI-9263 Analog output modul
2.2
Enkoder (inkrementell)
En inkrementell enkoder består av en sirkulær skive med lysåpninger. Vi kan sammenligne
det med en kam som er bøyd. Den slipper igjennom lys med mellomrom. Denne skiven ligger
i en lesegaffel. Lesegaffelen består av en optisk sender på den ene siden og en mottaker på
den andre siden. Når kodeskiven kommer i en posisjon der det oppstår en lysåpning vil det bli
opprettet optisk kontakt og transistoren vil lede og utgang gå høy. Når kodeskiven flytter seg
vil lysåpningen bli brutt og utgangen gå lav. Vi vil da få en puls for hver lysåpning.
Her ser man ett godt eksempel
på hvordan en enkoder kan
være bygget opp. Denne har
riktignok langt mindre
oppløsning og er mye enklere
enn de vi bruker, men
prinsippet er det samme. Som
man ser her er det fysiske hull
i skiven. Ofte er disse byttet ut
med svarte streker på en
transparent skive.
Bilde 1 , [1]
Ved å telle antall pulser samtidig med at vi vet oppløsningen kan vi finne frem til hastighet.
Problemet med den inkrementelle posisjonsmåleren er at vi ikke kan registrere hvilken vei
den roterer. Det problemet kan vi løse ved å innføre en lesegaffel til, eller to integrert
lesegafler satt sammen. Vi får da ut to sett med pulser fra enkoderne, ett fra kanal A og ett fra
kanal B. Sensor A og B må plasseres med en halv spalteavstand for at det skal bli riktig. Vi
bruker A og B på den måten at vi ser på hvem av kanalene som leder den andre. Det vil si at
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vi ser hvilken tilstand B har når A har stigende flanke. Vi har to tilstander, medurs og moturs.
Under ser man bittmønsteret for de to.
Figur 2,[4]
Figur 3,[4]
En måte å få til det vi har beskrevet kan gjennomføres ved bruke av en krets som består av en
D-vippe, XOR krets og en binær opp/ned teller. D-vippa vil sette det som står på D inngangen
over til Q utgangen når CL inngangen har en stigende flanke. Vi ser at Q er koplet til U/D
inngangen på telleren. Det som skjer da er at når Q er 1 eller 0 vil telleren telle enten oppover
eller nedover.
Figur 4,[4]
Xor kretsen virker slik at den gir endring på ut signal når det er forandring på en av
inngangene. Denne kretsen vil vi enkelt kunne simulere i labview og slipper dermed en fysisk
krets.
En posisjon vil bli representert av det binære tallet n, som er n*ΔL/2 fra en utgangsposisjon.
Binærtallet på den digitale utgangen vil angi vinkel posisjon til skiva.
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På en del enkodere har man også noe som kalles indeksering. Dette er en ekstra bittlinje som
gir ut en puls pr. omdreining. Vi kan ved hjelp av denne registrerer antall omdreininger. Det
finnes indeks funksjon på de enkoderne vi skal bruke, men pga av at vi kun har ca 60 graders
vinkelutslag vil det ikke være nødvendig å bruke denne funksjonen.
Enkodere blir brukt på jiggen vår for å oppnå pålitelige målesignaler som har stor grad av
nøyaktighet. De blir brukt på både underliggende og overliggende arm. De er festet ved hjelp
av braketter som vist på tegning. Det er sørget for at enkoderne står støtt og stabilt slik at
eventuell slark ikke skal kunne forstyrre signalet.
Enkoderen vi bruker i toppen er en Eltra EH 53A enkoder. Denne har 1024 impulser pr
omdreining. Ved bruk av xor-krets og telling på både stigende og synkende flanke vil antall
impulser komme opp til 4096 impulser pr omdreining. Vi kan dermed måle vinkel endringer
på 0,087 grader. Maksimal rpm er oppgitt til å være 6000 rpm og power supply på 5V.
Enkoderen som blir brukt i bunnen er en Hengsler RI58-O. Denne har 1000 pulser pr
omdreining og supply spenningen er på 10 volt. Oppløsningen på denne enkoderen er 0,09
grader.
Får å få ut riktig tall må vi bruke pull-up motstander når vi kobler til enkoderne. Grunnen til
dette er at spenningene som kommer ut fra enkoderne er for lave. Ved da å bruke pull-up
motstander vil vi greie og registrerer de.
For full produktspesifikasjon og detaljtegninger henviser vi til vedlegg 5 og 6.
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2.3
Potensiometer
Potensiometer er en del av den resistive typen sensorer. Det vil altså si at det er en sensor som
forandrer resistivitet med hensyn på hvilken posisjon den er i. Ofte er de laget slik at jo lenger
man går, altså jo større x, jo større motsand vil man få. De potensiometrene vi bruker i dette
prosjektet er vinkelmålere. Potensiometer som endrer resistans etter vinkel. Da vil vinkelen
være sammenhengen mellom antall viklinger og posisjon til slepekontakten.
Potensiometeret består av en slepekontakt og en rundt bane den glir på. Banen kan enten være
trådviklet eller en massiv ring. Slepekontakten glir så over dette materialet og det blir ført
spenning igjennom. Spenningen går inn, så gjennom hele ”banen” og så ut igjen til jord. Eo
vil være midtuttaket der lesespenningen kommer ut, altså der slepekontakten er. Vi kan da
lese hvor langt slepekontakten har kommet ved å se hvor høy spenning vi får ut i forhold til
spenning sendt inn og total spenning.
Vi bruker bourns og visha potensiometer i dette prosjektet.
Bourns
Dette potensiometeret har resistans fra 1KΩ til 100KΩ med toleranse på ± 10% , en effektiv
elektrisk vinkel på 340° med toleranse på ± 3%.
Det har en oppløsning på 1000 fordelt på 340 grader. Vi kan dermed måle en vinkelendring
på 0,34°.
Vishay
Disse har motsandsspenn på 1K-100K ± 10%. Den effektive graden er på 340 grader ± 3
grader.
Potensiometrene i vår applikasjon vil primært bli brukt som posisjonsmålere ved manuell
kjøring ved bruk av servoforsterkerene.
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2.4
Sylindere
Servi:
Den nederste sylinderen er en dobbeltvirkende sylinder levert av Servi. At den er
dobbeltvirkende vil si at den både kan skyve og trekke. Den har bestillingsnummer: NH30SD-40/20 X 300-S-(TV) . Sylinderen har et stempel på Ø40mm, en stempelstang på Ø20mm
og har en slaglengde på 300mm. Den tåler et maks trykk på 250 bar. For å regne ut hvor mye
kraft sylinder kan gi har vi trykk ganger areal.
Vi har følgende:
P = 250 *10 5 = 25MPa
A1 = π * 0,02 2 = 0,0012566 m 2
A2 = π * (0,02 2 − 0,012 ) = 0,00094247 m 2
F1 = P * A1 = 31415 N
F2 = P * A2 = 23561,75 N
Det vil si at denne sylinderen har en maks skyvekraft på 31415 N og en maks trekk-kraft på
23561,75 N.
Faroil:
Sylinder oppe er også en dobbeltvirkende sylinder. Denne sylinderen har samme diameter på
stempel og stempelstang som Servi sylinderen og tåler også 250 bar. Det eneste som er
forskjellig er slaglengden som her er 100mm. Det vil si at denne har samme skyv og dra kraft
som Servi sylinder.
2.5
Slanger
Slangene som er brukt er kjøpt hos Tess på stoa i Arendal og er av typen DIN 20022 2SN.
Slangene har innvendig diameter på 3/8” og tåler et arbeidstrykk på 330 bar. De har et
sprengningstrykk på 1320 bar og krever en bøynings radius på minimum 130mm.
Slangene måtte byttes ut med litt lengre slanger. Dette fordi bøyingsradiusen på slagene som
sto ikke tilfredsstilte overnevnte kravene.
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2.6
Koplinger
Koplingene som er brukt er fra GSHydro og er kjøpt av tess. Disse er av typen 12L(light duty)
og tåler et nominelt trykk på 250 bar. Det er også brukt 12S (heavy duty) ved noen
koplingspunkter der disse tåler et trykk på 630 bar som er helt unødvendig i vårt system. Det
er også brukt en del 90 graders fittings som tåler trykk på 250 bar.
2.7
Rør
Rørene er også fra GSHydro (Part Nr: 12X2AISI316L) og er i størrelsen 12X2.0mm. De er
laget i rustfritt stål og kan kaldbøyes. Disse tåler arbeidstrykk på 426 bar og har et
sprengningstrykk på 1590bar.
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2.8
Servoventiler
En servoventil er en ventil som kan ta imot et lite signal på inngangen, og omgjør dette
signalet til ett større utgangssignal som en forsterker. Dette systemet har de fleste brukt i
forbindelse med bil og styringen. (servostyring)
Jiggen har to servoventiler av typen Moog D631 serien, disse er både magnet og manuell
styrte. Servoventilene er noen av de mest primære komponentene på hele jiggen, der de
omgjør elektroniske signaler fra styreenhet til hydrauliske signaler.
Moog ventilene som vi bruker, er i hydraulik verden regnet for å være noe av det beste som er
på markedet. Dette kommer av at ventilene er robuste, presise og veldig raske, de kan for
eksempel forandre flowretning opptil 100 ganger i sekundet.
Magnet aktuatoren blir brukt når ventilen skal styres av CompactRio. Virkemåten er at strøm
signal driver magnet motoren, som skrur eller flytter en plate i retningen til en av to dyser.
Den dysen platen går mot blir noe strupet og dette øker motstanden, samtidig som den
motsatte siden får større avstand til dysen og får mindre motstand, som gir en trykkforskjell.
Denne trykkforskjellen beveger sleiden i ønsket retning. Når denne sleiden blir flyttet så vil
den åpne for den ene utgangen, lukke for den andre og åpningen er alt ettersom hvor mye olje
en vil åpne for. Men når den åpner ut for en retning, så må den åpne tilsvarende i inn
retningen så oljen tilført og returnert er lik.
Den manuelle funksjonen på ventilen er en bryter som er koblet direkte inn på
momentmotoren. Denne typen servo ventil kan brukes som en 3/2 ventil til for eksempel åpne
systemer, men er primært konstruert som en 4/2 ventil til lukkede systemer som vi jobber
med.
Ventilene er beregnet for å arbeide mellom 15 til 210 bar trykk, men kan også arbeide med
trykk oppimot 315 bar hvor åpningen er avtagende.
Flowen avhenger av faktorer som elektriske kommando signaler og trykktap over ventilen, så
væskemengden for et bestemt ventil trykk kan regnes ut på følgende måte.
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Side 20 av 81
Q=Qn√∆P/∆Pn
Der Q=kalkulert væskestrømm i Liter pr min
Qn= målt væskestrøm i liter pr min
∆P=aktuelt trykkfall over ventil i bar
∆Pn=målt trykkfall over ventilen i bar (moog general technical data)
Figur 5,[5]
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Side 21 av 81
Figur 6,[5]
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Side 22 av 81
3 Beregninger og teori
3.1
Dynamikk
Om vi ser på hver sylinder, har vi to 1.ordens system med tilbakekopling.
H (s) =
K
T (s) + 1
er standard funksjonen for et første ordens system der K er forsterkning og T er tidskonstant.
Vi kan se på systemet som et massedemper system der sylinder virker som en demper. Under
er det vist et helt enkelt blokk diagram som illustrerer hvordan slike systemer blir seende ut.
Figur 7, [2]
I og med at ventilene er så raske vil de ha minimal innvirkning på systemet, derfor kan vi se
bort ifra de her og beskrive de under et eget punkt. Vi har også sett bort ifra
aktuatordynamikken. Under følger en utledning og forklaring av den situasjon vi har. I og
med at vi har to forskjellige sylindere, og kan ha mange forksjellige sitasjoner er det
utarbeidet et generelt likningssett. Her kan vi alt etter sette inn hva slags variabler vi har til en
hver tid og finne ønsket verdi med tanke på den spesielle situasjonen. Skal vi for eksempel
regne på ”topp sylinder” setter vi inn volumer for den osv. Under kan man se en illustrasjon
på hvordan systemet ser ut, og hvilke verdier som betyr hva.
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Side 23 av 81
Figur 8, [6]
Figur 9,[6]
Over kan vi se en sylinder som styrer en masse eller last frem og tilbake. I vårt tilfelle vil da
massen være arm, bom og last. Lasten vil forandre seg avhengig av hvilken posisjon vi er i.
Det første vi gjør er å sette opp en massebalanse for kammer 1. Vi tar hensyn til at væsken er
kompressibel. Massebalansen blir da:
(1)
d
ρV
dt
1
=
ρ& V + ρ V& = ρ q − ρ q
1
1
1
1
1
1
1
l
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Side 24 av 81
Så bruker vi videre sammenhengen mellom tetthet og trykk i kompressible væsker.
(2)
ρ&
=
ρ
p&
β
Vi setter så dette inn i vår første likning (1) og deler på
(3)
V ρ& + & = q − q
V
β
ρ . Da får vi følgende:
1
1
1
1
l
Her kan vi si at :
(4) V 1 = V k1 + V 1 =
AL +
Ax + V
2
l1
Som gir:
(5) V& 1 =
Ax&
Vi setter inn i likning (3) og får da:
(6)
Al
2
+
Ax
+
V
l1
β
*ρ
&+
1
Ax& = q − q
1
l
Dette er resultatet av massebalansen for kammer 1 med tilførselsledning. Vi kan kalle det
volumbalansen.
Helt likt vil vi få for kammer 2, altså:
(7)
Al
2
−
Ax
β
+
V
l2
*ρ
& −
2
Ax& = − q + q
2
l
Nå har vi kommet frem til to massebalanser, en for hvert kammer med respektive
tilførselsledninger. Vi vil imidlertid ha 1, dette fordi det er mer hensiktsmessig. Utledingen av
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Side 25 av 81
1-kammer modellen er basert på en beregning av den gjennomsnittlige ventilstrømmen
q
v
gjennom servoventilene.
(8)
q
v
=
+
q
1
q
2
2
Vi setter så inn for
q
1
og
q
2
som kommer fra de to massebalanselikningene for kammer 1
og kammer 2, (6) og (8). Vi får da dette:
(9)
q
v
=
Al
4β
*
( p& − p& )+ Ax * ( p& + p& )+ V
1
β
2
1
p& − V * p& + Ax& + q
2β
2β
2
l1
*
l2
1
2
l
Dette kan vi forkorte og forenkle ved å innføre noen nye variabler.
Når sylinderen blir styrt av en servoventil vil følgende gjelde:
(10)
p+p
1
2
=
p
s
p& + p& = 0
= konst Æ
1
2
Lasttrykket er gitt ved:
(11)
p=p−p
1
l
2
Æ
p& = p& − p&
l
1
2
Vi antar at volumet i tilførselsledninger er det samme, hvilket gir et totalvolum:
( 12) V l1 = V l 2 = V lt der V lt er det totale volumet i tilførselsledingene.
2
Videre antar vi det er en liten klaring mellom stempel og sylinder slik at vi får en liten
lekkasje mellom kamrene. Vi antar at det er en lineær sammenhengen mellom lekkasjen og
trykkeforskjellen og får da uttrykket:
q
lekk
=
K
lekk
*
( p − p ) der K
1
2
lekk
er lekkasjekoeffisienten.
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Side 26 av 81
Ved å sette inn vil vi få den endelige likning med hensyn på volumstrøm:
(13)
q
v
=
V * p& + & + p
Ax K
4β
;her er V t =
q
v
l
l
For å finne sammenhengen mellom
(14)
l
t
F =m a
eller da
A L +V
lt
og lastens posisjon setter vi opp en kraftbalanse:
A p = m &x&
l
Vi kan da til slutt sette opp et blokk diagram.
q =q , K =K
v
1
L
lekk
Figur 10, [7]
Vi har nå utledet likningene vi trenger for å se på noen dynamiske egenskaper. Som sagt har
vi sett bort ifra ventilkraeristikk og aktuatordynamikk. Vi vil nå sette inn noen verdier og sette
opp likningen for en gitt situasjon. Situasjonen vi da ser for oss er nedre sylinder med full last,
øvre feste for bom.
Vi bruker likning (13):
q
v
=
V * p& + & + p
Ax K
4β
t
l
l
0,53m 0,5m π
V =
2
l
2
t
+
(π
2
)
3
* 0,2m * 0,4m = 0,06868m
A = π * 0,2m = 0,12566m
2
p=F
A
2
l
l
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Side 27 av 81
p
=
l
1363N = 10846 N
m2
0,12566m
2
Satt inn får vi da følgende likning:
3
0,06868m * +
q=
p& 0,12566m * x +10846 N 2 * K
4β
m
2
v
l
der bulkmodul
β
l
er oppgitt i databladet. Denne verdien varierer avhengig av oljetype man
bruker.
K
l
er ikke oppgitt for våre ventiler, så dette er noe man må finne ut ved testing.
3.1.1
Ventildynamikk
I figur 11 kan vi se en prinsipiell skisse av servoventilen. Bokstavene representerer utganger
og innganger. A og B er mot sylinder mens P og T er supply og tank.
Figur 11,[8]
Vi ser på ventilen som at det går en volumstrøm igjennom, altså den gjennomsnittlige
strømmen
q
l
som vi definerte over. Sammenhengen mellom volumstrøm og sleideposisjon er
gitt likningen:
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Side 28 av 81
q = K q *x * p
v
x
v
v
I figur 12 kan det sees et enkelt og illustrativt blokk diagram for ventilen.
Figur 12,[7]
Videre kan vi lese de dynamiske egenskapene direkte ut ifra databladet. I figur 13 kan man se
hvordan ventilen vil oppføre seg under forskjellige situasjoner. Vi har da en ”high response
valve”.
Figur 13,[8]
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Side 29 av 81
3.2
Invers kinematikk
Problemet med en toarmet jigg er at den ikke er lett å styre i rette linjer i x-y koordinater. Da
begge armene roterer om hvert sitt senter, må det være samspill mellom armene for at det skal
være mulig å bevege seg horisontalt eller vertikalt. For å beregne ønsket posisjon må vi se på
samspillet mellom lengdene på armene og den polare vinkelen til armene.
Figur 14
Her har vi to armer med lengde L1 og L2.
Og de samsvarende vinklene er Φ1 og Φ2
Kinematikken til systemet her er som følgende: For å finne koordinatene til tippen på L2 går
vi frem med cosinus og sinus verdiene til L1 og L2 ved gitte vinkler Φ1 og Φ2. Vi finner x og y
verdiene ved følgende ligninger:
X = L1 * cos Φ1 + L2 * cos Φ2
Y= L1 * sin Φ1 + L2 * sin Φ2
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Side 30 av 81
Ved invers kinematikk gjør en motsatt ved at en ved gitte x og y verdier finner de tilhørende
vinklene Φ1 og Φ2 for å nå det gitte punkt. Dette gjøres ved å bruke trigonometriske formler og
regler. Følgende grunnformler er brukt:
Pytagoras formel:
a2 = b2 + c2
Cosinus formel:
a 2 = b 2 + c 2 − 2b cos A
sin 2 φ + cos 2 φ = 1
B = x2 + y2
φ = a tan 2( y, x )
ψ = a tan 2(L2 ∗ sin φ 2 , L1 + L2 ∗ cos φ 2 )
x 2 + y 2 − L12 − L22
cos φ 2 =
2 L1 L2
Figur 15
Sinφ 2 = ± 1 − cos 2 φ 2
φ1 = φ − ψ
φ 2 = Arc cos
L22 + L12 − B 2
2 L2 B
I vår oppgave er det begrensning på bevegelighet, men ved alle verdier for x-y er det to
løsninger på å nå samme punkt. Dette kan forklares med ligning Sinφ2 = ± 1 − cos 2 φ2 . Der ±
foran rot-tegnet beskriver de to løsningene. De to løsningene er albue ut eller albue inn, dette
er ikke noe å tenke på for vår del da vi kun kan bruke en løsning, albue ut. Ved hjelp av disse
ligningene får vi ved innsetting av lengder på armene og ønsket x og y verdi ut to vinkler, Φ1
og Φ2.
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Side 31 av 81
Ved hjelp av dette geometriske likningssettet er det ingen sak for et program som Labview å
finne kontinuerlige vinkelsett ved gitte x og y verdier.
Invers kinematikk er helt nødvendig for å få systemer som dette med flere ledd til å nå
forhåndsgitte posisjoner. Denne metoden blir brukt til avanserte robotarmer med mange flere
frihetsgrader enn det vi har her.
3.3
Hastigheter
Får å finne jiggens hastighet begynte vi med å ta noen målinger. Det gjorde vi ved å kjøre
jiggen i maks fart i begge retninger for samtidig å lese av volumstrømmen på aggregatet.
(med jiggens hastighet mener vi bommen sin hastighet bestemt av flow i sylinder). Det var
ingen laster påsatt under disse målingene.
Det vi så, ifølge aggregatets målinger, var at volumstrømmen var 21 l/min ved
”nedoverkjøring” og 15 l/min ved ”oppoverkjøring”. Dette ved full ventil åpning og med et
trykk på 150 bar. Beregningene er også gjort når sylinder er festet i toppfeste på bom. Om
man skal regne på nedre feste bruker man akkurat samme fremgangsmåte, men bytter om
verdier der de trengs.
Ved å regne dette om til kubikkmeter per sekund får vi:
q
ned
= 0,00035m
3
s
og
q
opp
= 0,00025m
3
s
Når vi har volumstrømmen og vet arealet av stempelet kan vi finne farten V. Arealet vi bruker
ved ”nedoverkjøring” er stempelareal, mens ved ”oppoverkjøring” bruker vi stempelareal men
tar bort det areal stempelstang utgjør. Vi får da:
q = A *V
Æ
A = π * 0,02 m
2
1
A = π * 0,01 m
2
2
Hastighetene V ned og V opp blir da:
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Side 32 av 81
3
m
0,00035
V
ned
=
s
0,0012566m
2
= 0,28 m
s
3
m
0
,
00025
s
V =
−
A
A
opp
1
2
= 0,265 m
s
Siden radius er den samme på begge sylindere vil vi få samme hastighet ut. Det vil da si at vi
vil ha tilsvarende hastighet opp om alle ting som for eksempel ventil gjennomstrømning er
den samme.
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4 Det Mekaniske
I dette kapittelet vil vi dokumentere, beskrive og legge frem alt av det mekaniske arbeid som
er blitt utført på jiggen.
4.1
Igus® Lager
Siden dette systemet har lav toleranse i forhold til slark, bestemte vi oss tidlig for å bruke en
eller annen type lager for knekkbom. Det vi kom fem til som var det beste alternativ var en
type lager fra IGUS®.
De lager en type plastikkforinger som har veldig lange molekyler og dermed er veldig
slitesterke. Disse lagrene trenger heller ikke smøring som gjør dem veldig
vedlikeholdsvennlige.
Den typen som passet best for oss er Iglidur® G. Disse er såkalt allround performer som
typisk brukes i systemer med lav til middels hastighet, middels belastning og middels
temperatur.
Lagrene er vibrasjonsdempende og demper vibrasjoner 150 ganger mer enn stål. Lagrene tåler
et maks statisk overflatetrykk på 80 Mpa og en overflate fart på 1 m/s. De tåler en konstant
temperatur mellom -40 og 130 grader men kan ved korte perioder utsettes for høyere
temperatur. Friksjonskoeffisient ved tørr kjøring er typisk 0,08.
Lagrene presses inn i et hull med H7 toleranse og bruker bolt med toleranse h9.
Figur 17,[3]
Figur 16,[3]
Vi fikk gjennom ASI Automatikk A/S i Drammen en prøve på 6 stk lager av typen
GFM-2023-21 (vedlegg nr 10) som ble brukt til jiggen.
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4.2
Festing av knekkbom
For å få festet IGUS lagrene skikkelig valgte vi å sveise inn to boss i hovedbommen. Siden
det er brukt firkant rør med 4mm vegg ville dette ikke vært nok hold for lagrene. For å finne
en løsning på dette dreiet vi to boss på 30mm, boret tilsvarende hull i bom og sveiset inn
bossene i bommen. Bossene ble så maskinert opp til 23mm H7 og lagrene ble presset inn. Det
ble brukt 4 stk lager i hovedbommen, to i hvert boss.
Vi måtte også få inn lager i knekkbom, men her er det sveist på 10mm plater på begge sider
slik at det ble ansett som nok hold for lagrene. Hullet var 20mm fra før så disse ble bare
maskinert opp til 23mm H7 etter Igus spesifikasjon. Det ble her brukt 2 stk lager, et på hver
side. I figur 18 og 19 er det illustrert hvordan dette ble gjort og seende ut.
Figur 19
Figur 18
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4.3
Enkoder og potensiometerfester
Vi hadde en liten utfordring med tanke på festing av enkoder og potensiometer. Den gamle
løsningen gav ikke nødvendig nøyaktighet eller stabilitet, så en ny løsning måtte til. Det som
var vrient å få til, var å finne et fast punkt å måle mot som lå i senter av rotasjonsaksen. Vi
måtte også ha låsing på bolten slik at de ikke kunne komme til å gli ut under kjøring.
Det som først slo oss var å lage en tilsvarende løsning som vi har i bunnen, lage to akslinger
som skrus inn i bolten, men usikkerhet ved låsing av bolt ble til at vi forkastet dette.
Vi kom så opp med en ide om å lage en brakett med en aksling på, som er vist på figur 21.
Ved å gjøre det slik løste vi to problem i et, både det å få fast punkt i rotasjonsaksen og låsing
av bolt.
For å få festet enkoder og potensiometer bøyde vi til to vinkler som vi sveiset på
knekkbommen. Det ble så boret hull som lå helt i senter av rotasjonsaksen.
Vi festet så enkoder og potensiometer på knekkbommen.. Det vil da fungere slik at når
systemet roterer vil da også potensiometer og enkoder rotere mens akslingene står i ro. Vi
måtte også lage disse to ”akslingene” som skulle bli festet på hovedbom.
Dette systemet krever en god del nøyaktighet, det kreves at alt treffer i samme senter. For å få
dette til skikkelig ble alle hull og deler maskinert med CNC maskin.
Figur 21
Figur 20
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Side 36 av 81
4.4
Koblingsboks
Vi bestemte oss etter hvert som vi koblet opp ledninger, delefiltere og de andre elektriske
komponentene til jiggen, for å sette sammen en boks hvor vi kunne montere alt i..
Boksen ble satt sammen av sponplater som er letter å bruke en stål og som også er isolerende.
Så ble den malt hvit. Lokket ble kuttet ut i pleksiglass og hengslet til sponboksen. I lokket
monterte vi også en nødstopp bryteren. Det er gummi under kretsene slik at elektrisk støy ikke
skal påvirke kretsene.
Bilde 22
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Side 37 av 81
4.5
Monteringsbenk og tavle
Etter å ha funnet ut at jiggen ristet voldsomt under kjøring fant vi ut at vi var nødt til å komme
opp med en bedre løsning på hvordan den skulle festes.
Etter konsultasjon med labb personellet fant vi frem til en stor ståletralle som stammet fra et
gammelt hovedprosjekt. Det bestod av et hydraulisk aggregat montert på en stor stålramme
med hjul. Denne var i grunn perfekt til vårt formål, dette på grunn av størrelsen og fordi den
virker stabil.
Det er også god plass slik at vi enkelt kan monterer koblinger for det elektriske og eventuelt
andre ting av interesse. Den har også et rom under der man kan legge utstyr tilhørende jiggen.
Vi rensket så rammen får deler og unødvendige ting. Deretter boltet vi den fast. Vi monterte
tilslutt en tavle som vi kunne skrive på for å vise banekjøringen. Under følger et bilde av
hvordan det hele ble seende ut.
Bilde 23
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Side 38 av 81
4.6
Nødstoppen
På koblingsboksen har vi koblet opp en nødstopp for sikkerhetsmessige årsaker. Bryteren er
plassert hvor den lett blir sett, oppe på koblingsboksen. Nødstoppbryteren kutter +12V og 12V som går til strømstyringen for ventilene.
Siden nødstoppbryteren kun bryter en krets når den blir trykket inn, vil den bare stoppe en
retning. For å løse dette problemet satt vi inn et dobbelt relee slik at den kutter både + og –
samtidig. Releet er styrt av nødstoppbryteren. Dette i tur gjør att spolen inne i releet mister sitt
magnetiske felt, og bryteren som spolen holdt i på posisjon går nå i av posisjon. Dette kutter
da +12V og -12V og dermed stopper ventilene.
Det eneste problemet med å koble nødstoppen på denne måten er at når strømmen blir kuttet,
så fungerer ikke reguleringen til ventilene. Hovedbommen vil da sige. Dette er imidlertid ikke
så farlig fordi den siger kun med vekten av sin egen arm.
Et annet alternativ var å koble nødstoppbryteren via softwaren, men da er problemet at en er
nødt til å ha et program for at bryteren skal fungere. Vi følte at dette var et dårlig alternativ
med tanke på at man da er avhengig av programmet og om at noe da skulle skje, så kan man
ikke stoppe jiggen.
Nødstoppbryteren er meget viktig å ha, spesielt når en programmerer slik at man kan unngå
farlige situasjoner.
4.7
Flushing av oljesystem
Siden vi måtte demontere og bytte ut en del slanger og rør, var det fare for at en del partikler
var kommet inn i oljesystemet. MOOG ventilene vi bruker tåler så å si ingen partikler i olja,
dermed måtte vi rense/flushe systemet. For å få til dette måtte vi demontere ventilen og sette
på spesielt maskinerte plater som guider oljen i et kretsløp rett til tank. Det vil si at vi fjernet
selve ventilen, men lot den delen som utgangene sto på stå igjen. Oljen vil da passere
igjennom uten hindring. De platene som vi brukte til dette måtte vi designe selv etter
tegninger av ventilen som vi fant fra MOOG sin hjemmeside. Platene ble maskinert i CNC
maskin her på skolen av Roy Werner Folgerø. Vi brukte o-ringer i sporene for å holde det tett.
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Bilde 24
Etter vi hadde montert Flusheplatene måtte vi koble vekk sylindrene for at oljen kunne
sirkulere. Vi monterte inn hann-hann kobling som vi kjøpte på TESS, i stedet for sylindrene.
Ifølge spesifikasjonene til MOOG, skulle vi flushe systemet helt til all oljen hadde gått
gjennom systemet fra mellom 50-100 ganger. Det er viktig at man flusher lenge for å være
sikker på at alle partikler og alt støv er fjernet fra systemet.
4.8
Teststang
I enden av jiggen har vi sveiset på et firkantrør som står 90 grader på resten av jiggen. Videre
så lagt vi et firkantrør til i X retning, som står 90 grader på røret i Y retning.
Ideen bak disse stengene er at vi da her to baner å kjøre jiggen etter for å sjekke nøyaktighet
og måle avvik. De er også meget nyttige når det kommer til å demonstrere jiggen.
Videre er det også mulig å feste en tavle på stanga slik at vi kan bruke jiggen til å tegne
forskjellige objekter. Dette gir også en meget god ide om hvor nøyaktig regulatorene i jiggen
er.
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4.9
Endestoppbrytere
For sikkerhetsmessige grunner har vi valgt å bruke endestoppbrytere i enden av hver
retningsbane på jiggen. Dette er for å stoppe bevegelsen i fra å nå bunn av sylinder og for å
unngå kollisjon. Vi har bruket 4 av disse bryterne, en for hver retning for de to armene.
Endebryterene er relativt billige og vi ble enige om at vi ikke skulle bruke mye tid og resurser
på å lage disse. Vi kunne brukt en bryter pr arm slik det var fra før, men vi kom frem til at
dette ville blitt vanskelig å kalibrere og få nøyaktige referanseverdier.
Ved den nedre armen har vi laget to spacer slik at bommen treffer bryterne i de forskjellige
festepunktene. Disse kan fjernes lett, og er nødvendig fordi bommen har to festepunkter for
nedre sylinder. Dette resulterer i en vinkelforskjell mellom bom og bord. Bryterne er
seriekoblet. Dette er gjort fordi Crio ikke har nok digitale innganger.
4.10
Kalibrering/referansekjøring
Endebryterene er i tillegg til en sikkerhetsanretning laget for at vi skal kunne få kalibrert
jiggen.
Om vi skal bruke endebryterene til referansepunkt, det vil si at når en starter opp jiggen med
program, så vil programmet kjøre armene ut til endestoppbryterne som da vil bli aktivert. De
er da ved et kjent punkt og en kjent vinkel. Tellerne til enkoderne vil da resets til denne kjente
vinkelen. På denne måten vil vi ha et referansepunkt å kalibrere mot.
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5 Det elektriske
5.1
Nr
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Din skinne oversikt
Funksjon ut
Jord
Usuply
Usuply
Usuply
Styresignal til
ventil
Styresignal til
ventil
Enkoder signal
(oppe)
Enkoder signal
(oppe)
Enkoder signal
(nede)
Enkoder signal
(nede)
Endestopp signal
(Oppe)
Endestopp signal
(nede)
Potensiometer
signal (oppe)
Potensiometer
signal (nede)
(Tom)
Strømstyring
ventil
Farge ut
Svart
Rød
Gul
Blå
Mørk
lilla
Brun
Mørk
Blå
Blå
Svart
Svart
2X Gul
2X
Oranje
Brun
Grønn
18
20
Strømstyring
ventil
Strømstyring
ventil
Rød
Grønn
21
22
23
Strømstyring
ventil
Farge Inn
Svart
Rød
Gul
Blå
Hvit m/ brun strek
Rød
Signal ut
GRD
+5V
+12V
-12V
Brun
Blå
Hvit m/ blå stripe
Grønn
Hvit m/ grønn stripe
Hvit m/ oransje
stripe
Oranje
Digital
(0 og +5V)
Digital
(0 og +5V)
Digital
(0 og +5V)
Digital
(0 og +5V)
0,5 mA
0,5 mA
Analog
Grønn
17
19
Funksjon inn
Jord
Usuply
Usuply
Usuply
Signal fra
CompactRio
Signal fra
CompactRio
Signal fra
CompactRio
Signal fra
CompactRio
Signal fra
CompactRio
Signal fra
CompactRio
Signal fra
CompactRio
Signal fra
CompactRio
Analog
Ventil A signal
port A
Ventil A signal
port B
Ventil A signal
port C
Ventil A signal
port D
Ventil B signal
port A
Ventil B signal
port B
Ventil B signal
port C
Ventil B signal
port D
Grønn
+/-50mA
Hvit
Tegn: Svart 3x prikk
Svart
+/-50mA
+/-50mA
Rød
+/-50mA
Grønn
+/-50mA
Hvit
Tegn: svart 3x prikk
svart
+/-50mA
+/-50mA
Rød
+/-50mA
Får fullt koblingsskjema se vedlegg 1
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5.2
5.2.1
Elektriske komponenter
Servoventiler
Når vi skulle kjøre servoventilene måtte vi ha en spenning til strøm omformer. Dette siden vi
ut fra compact rio har ± 10V og at denne ikke kan levere ± 50mA som servoventilene krever.
For å løse dette kan en i utgangspunktet bruke en enkel krets som ser følgende ut:
Uinn fra compactRIO varierer fra ±10V. OP-amp regelen
sier da at samme spenningen som ligger på pluss inngang
også må ligge på minus inngang. For å få ± 50mA
gjennom ventilen til jord må vi bestemme hva R må være.
U = RI →
U
=R
I
10V
= 200Ω
0,05 A
Figur 25
Problemet med denne kretsen er at OP-ampen bare kan gi 20mA strøm dermed kan ikke
denne brukes direkte. Kretsen som brukes til å styre solenoidene er en mer avansert krets som
bruker samme prinsipp, men ved hjelp av to transistorer og to op-amper får vi en krets som
kan gi strømmen vi behøver.
Den første op-ampen er for å kunne justere nullpunket, dette er viktig med tanke på at når den
er null styrespenning skal det være null strøm gjennom kretsen. Den andre op-ampen er den
som styrer transistorene, den styrer hvor mye disse skal åpne etter hvor stor styre spenning det
går inn på pinne 5 (se tegning). For å justere inn kretsen brukte vi en 47Ω motstand som
skulle simulere Ventilen (ventilen har 56Ω motstand). Vi brukte Labview til å justere
styrespenningen som går inn på P5 (se tegning), og målte spenningen mellom P2 og P1.
P 2 = (47Ω + 62,9Ω) * 0,05 A = 5,5V
P 2 − P1 = 5,5V *
62,9Ω
= 5,5V − 3,15V = 2,35V
(62,9Ω + 47Ω)
Nullpunktet ble også justert slik at vi ved ingen styrespenning fikk null ut.
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Figur 26
5.2.2
Enkodere
Eltra
Da vi koblet til eltra enkoderen merket vi fort at denne ikke telte slik som den skulle. Det som
viste seg å være feilen var at det logiske høy signalet var for svakt for å kunne registreres i
compactRIO.
Vi måtte da legge inn to Pull-up motstander på 10KΩ. Disse blir da
koblet inn mellom 5V og enkoder utgangen. Disse fungerer slik at
når kanal A (S1 på tegning) er lav vil denne være koblet til jord det
vil også inngangen til compactRIO være. Når kanal A (S1 på
tegning) er høy vil den være koblet til 5V gjennom motstanden og
den vil være høy inn til kanal A går høy igjen.
Figur 27
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Hengstler
Det som var med enkoderen fra Hengstler var at denne trengte mellom 10-30V supply
spenning og dette er for mye spenning for CompactRIO. Vi måtte pga dette bruke en enkel
krets bestående av to 10KΩ motstander og to dioder.
Figur 28
Enkoderen har supply spenning på 12V dermed vil det ut fra Kanal A og B være 0 eller 12V.
Denne kretsen fungerer slik at når Kanal A er høy vil det stå 12V i sperreretning på dioden og
ingen strøm vil gå gjennom den. Dermed er Kanal a koblet til 5V gjennom motstanden altså
er denne høy. Når Kanal A er lav er denne koblet til jord dette tvinger Kanal a også til å være
jord altså er også Kanal a Lav.
Vi fikk etter hvert problemer med denne kretsen ved at lav signalet ikke gikk helt til null volt.
Dette var pga at ut fra enkoder når denne var lav var 0,6V, i tillegg legger det seg ca 0,6V
over dioden. Dermed var lav spenningen 1,2V og dette er helt i grenseland hva I/O kortet vil
registrer som lav/høy. I spesifikasjonene er 0-0,8V karakterisert som lav mens 2-24V er
karakterisert som høy. Dermed ligger denne spenningen midt i dødsonen. Det som skjedde
var at telleren på programmet telte helt av seg selv til tider, antagelig pga støy som vippet
spenningen mellom høy og lav.
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For å fikse dette ble vi nødt til å lage en ny krets bestående av to transistorer(IRF3415) og to
motstander på 10KΩ. Kretsen ble seende slik ut:
Denne funker slik at når kanal A INN er
lav vil kanal A UT være 5V og høy. Når
Kanal A INN er høy vil denne åpne
transistoren slik at Kanal A UT er koblet til
jord altså lav
Figur 29
5.2.3
Endestoppbrytere
På utgangene fra endestoppbrytere måtte vi også ha 10KΩ motstander slik at ikke det ble
kortsluttning i CompactRIO. Dermed vil det kun gå 0,5mA i kretsen.
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6 Ytelser og spesifikasjoner
6.1
Arbeidsområde
X= 327,93mm
Y= 1299,92mm
X= -1094,02mm
Y= 779,32mm
X= -40,64mm
Y= 806,81mm
X= 0mm
Y= 0mm
X= -767,12mm
Y= 253,20mm
Figur 30
Her er det kalkulert ut hvilke områder som er innenfor rekkevidde ved enden av knekkbom.
Der det hvite representerer arbeidsområdet.
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6.2
Regulering
Når vi har et oppsett med tilbakemelding som vi har nå, vil reguleringen spille en stor rolle for
hvordan systemet vil oppføre seg under kjøring. Ved å forandre settpunkt kan vi se hvordan
systemet reagerer på ulike innputs. Det vi har brukt er sprang i form av nye settpunkt for
posisjon. Verdiene vi da får fra enkoderne er da det vi kaller prosessvariablene. Disse
verdiene sammenlignes da med satt verdi (settpunkt), og systemet vil prøve å kompensere for
det avviket som oppstår. Det er hvordan denne kompenseringen skjer vi her mener med
regulering.
Denne kompenseringen kan vi tune ved hjelp av reguleringsteknikker. Om vi vil ha et veldig
kjapt system, eller et veldig nøyaktig med lite oversving, kan man prøve seg frem til ved å
stille på de forskjellige funksjonene i regulatoren. Det finnes egne teknikker på hvordan man
kan finne disse verdiene ved regning, men disse er ikke brukt her. Vi kan stille inn alle
reguleringsverdier på frontpanelet på ”host” som vist I figur 31.
Figur 31
I vårt system er det brukt en ren P(proporsjonal) regulator sammen med en PID (proporsjonal,
integral, derivasjon). Den rene P reguleringen skjer i programmet, og er ikke vist på
frontpanelet.
Grunnen til at vi har en ren P regulator i tillegg til PID`n er at det ikke er plass til mer enn et
16-bits tall i arrayene i labview. I og med at vi kan bruke et tall som er høyere enn dette, må
vi da forsterke signalet med en P etter PID`en. Vi får da i praksis et forsterket signal inn i
forsterkeren. P(proporsjonal) ganger rett og slett avviket med den innsatte verdi for P.
Reguleringen er nå satt opp med høy P verdi, liten I samt liten D. Grunnen til dette oppsettet
er for det første at systemet er såpass nøyaktig at vi ikke trenger å bruke i-regulering for å
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Side 48 av 81
fjerne feilmargin. Det var også problem å finne en I verdi som gav et stabilt system. D leddet
er heller ikke i bruk sånn det er satt op nå, og det er fordi det rett og slett ikke gav så mye
utslag.
Så derfor endte vi opp med en helt ordinær P regulering som da er forsterket to ganger. Jiggen
oppfører seg forskjellig med forskjellig trykk og er dermed litt vanskelig å stille inn og krever
litt tuning ved forskjellig kjøring. Under kan man se responsen til systemet ved sprang på 100,
ved 150 bars trykk.
Vi fant at følgende verdier fungerte best på begge sylindere
P = 32768
I=0
D=0
Nedre sylinder
Sprangrespons
1150
1100
Posisjon
1050
1000
Serie1
Serie2
950
900
850
800
1
15
29
43 57
71
85
99 113 127 141 155 169
Tid, 0,1s
Figur 32
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Side 49 av 81
Øvre Sylinder
Sprangrespons
1400
1200
Posisjon
1000
800
Serie1
Serie2
600
400
200
0
1
10
19
28
37
46
55
64
73
82
91 100 109
Tid: 0,1s
Figur 33
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Banefølging nedre vinkel
Ved steppsize 2
Øvre vinkelfølging
1100
1050
1000
Verdi
950
Settpunkt Verdi
900
Encoder Verdi
850
800
750
700
1
20 39 58 77 96 115 134 153 172 191 210 229 248 267 286 305
(t)
Figur 34
Nedre vinkelfølging
1400
1350
Encoder verdi
1300
1250
Settpunkt Verdi
Målt verdi
1200
1150
1100
1050
1000
1
20
39
58
77
96 115 134 153 172 191 210 229 248 267 286 305
(t)
Figur 35
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Side 51 av 81
Banefølging steppsize 1
Vinkel følging oppe
1100
1050
1000
Verdi
950
Settpunkt Verdi
Encoder Verdi
900
850
800
750
700
1
42 83 124 165 206 247 288 329 370 411 452 493 534 575 616
(t)
Figur 36
Vinkel følging nede
1400
1350
1300
Verdi
1250
Settpunkt verdi
Encoder Verdi
1200
1150
1100
1050
1000
1
41 81 121 161 201 241 281 321 361 401 441 481 521 561 601
(t)
Figur 37
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6.3
Posisjonsmålinger
Vi har foretatt en posisjonsmåling av jiggen som skal gi oss en ide om nøyaktigheten.
Nøyaktigheten er avhengig av regulatorene i programvaren, settpunkt, unøyaktigheter ved
måling og tilfeldige feil i systemet.
Om man ser på verdiene i tabellene vi har fått fram av målingen, så ser man at vi har både
systematisk og tilfeldige feil. De systematiske feilene har vi mulighet til å regulere vekk,
mens de tilfeldige er mulig å regulere så de blir mindre, men vi kan ikke få eliminert dem helt.
Måten vi gjennomførte posisjonstesten på var at vi sammenlignet settpunktverdi på
frontpanelet med et kjent punkt vi hadde regnet oss frem til. Når vi regnet punktet vi skulle
sammenligne med tok vi utgangspunkt i ”senter” av jigg og brukt de to teststengene.
De systematiske feilene vi har kan ha opphav i enten feil kalibrering eller feil nullpunkt. Dette
kan også komme av at målesystemet ikke er riktig kalibrert. Siden vi ikke hadde laser eller
høyoppløselig målesystem tilgjengelig skal det lite til for å få feil.
Hvis vi ser på de vertikale målingene ser vi at vi har systematiske feil. Typisk for denne
målingen er at målt verdi trekker litt den ene veien, vist i figur 39.
Man kan se at jo lenger ned man kommer, jo større blir avviket. Vi ser også at avvikene er i
samme retning hele tiden. Da vet vi at det er noe i systemet som ikke er helt korrekt. Denne
feilen kan komme av at avstanden fra senter av hovedarmen til den vertikale stangen, som vi
har sveiset på i enden av jiggen, ikke er helt korrekt. Den kan også komme av at stangen ikke
er 90 grader med jiggen. Men siden der er en systematisk feil har vi mulighet til å kalibrere
den vekk., så dette ser vi ikke på som noe stort problem.
Om vi ser på den horisontale målingen har vi også systematiske feil. Vi ser at målt verdi og
satt verdi er forskjøvet med ca 6 millimeter. Dette kan som nevnt over også skyldes feil på
måleutstyr eller kalibrering. Videre kan det skyldes at vi ikke har et fast punkt å måle ut fra.
Vi kan enkelt fjerne målefeilen ved å forskyve nullpunktet i programmet.
I tillegg til systematiske feil er det også tilfeldige feil. De tilfeldige feilene følger ikke noe
mønster. De gir en spredning av måleresultatene og yter seg statisk, disse feilene har vi både i
X og Y retning.
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En av grunnene til at vi har disse feilene er pga oppløsning til enkoder. Med det menes det at
vi kan ha en rotasjon på 0,078 grader uten at enkoder registrer dette. Dermed har vi teoretisk
feil på opp mot 1,49 millimeter i y retning og 1,058 millimeter i x-retning. Dette er illustrert i
figur 38. Dette er det ikke noe vi kan gjøre med uten å gjøre store endringer.
En annen grunn kan være at målingen ikke har vært nøyaktig nok.
Utfallet av målingene kunne kanskje sett annerledes ut ved bruk av mer nøyaktig måleutstyr,
men det gir en pekepinn på hvor presist systemet er. Vi er godt fornøyd med tanke på at det
meste på jiggen er håndlaget og at presisjonsinstrumenter ikke er brukt.
.
Figur 38
Oppløsningen på enkoderen er 360˚/4096=0,078.
Formelen for å finne feilen i denne posisjonen er:
L=√(X²+Y²)
Den totale målefeilen vi finner er:
Y=1,49mm
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Side 54 av 81
X=1.058mm
Denne målefeilen er når begge armene er strekt ut maksimalt, så dette er hvor vi finner høyest
målefeil.
I diagrammene under så ser vi hvordan de forskjellige måleverdiene er i forhold til
settpunktet.
For vertikal måling, x verdi:
365
405
445
485
525
565
605
645
685
725
765
805
845
885
-831,5
905
-831
-832
-832,5
-833
målepunkt
-833,5
settpunkt
-834
-834,5
-835
-835,5
-836
Figur 39
Middelverdien til X er
X1+X2+X3..............+Xn/n
som gir verdien Xmiddel = - 833,72
Så har vi videre regnet ut d1 = X1-Xmiddel, d2=X2-Xmiddel, dn=Xn-Xmiddel
regner vi ut dette så kan vi finne variansen, formelen for varians er:
d1²+d2²+..........dn²/n-1
variansen blir da 0,814
formelen for standardaviket er S = √((Xn-Xmiddel)²/n-1)
Standardaviket = 0,902
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For horisontal måling, y verdi:
732
730
728
måleverdi
726
settpunkt
724
722
-5
20
-5
60
-6
40
-6
00
-6
80
-7
60
-7
20
-8
00
-8
80
-8
40
-9
20
-1
04
2
-1
00
0
-9
60
720
Figur 40
Middelverdien til Y er
Y1+Y2+Y3..............+Yn/n
som gir verdien Ymiddel= 725,4
Så har vi videre regnet ut d1= Y1-Ymiddel, d2=Y2-Ymiddel, dn=Yn-Ymiddel
regner vi ut dette så kan vi finne variansen, formelen for varians er:
d1²+d2²+..........dn²/n-1
variansen blir da 0,26
formelen for standardaviket er S= √((Xn-Xmiddel)²/n-1)
Standardaviket=0,51
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7 Programmering av CompactRIO
7.1
Sette opp et Real-time Project
For å kunne programmere CompactRIO må man lage et Real-Time prosjekt. Dette velges i
velkomst vinduet i Labview. Forutsatt at man har installert real-time modulen til labview.
Figur 41
I neste vindu skriver inn navn på prosjektet og hvor du vil lagre det.
Trykk Next
Det vil nå komme opp et vindu der du bestemmer hvilken arkitektur vi skal ha på prosjektet.
Her velger vi ”Two loops”. Vi huker av for ”Include user interface” og velger ”Host VI”.
Trykk Next
Figur 42
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I dette vinduet er der vi skal finne/få kontakt med en eksisterende Real-Time enhet.
Trykk Browse
Velg ”Existing target or device” og “Real-Time CompactRIO”.
Dersom den ikke finner noen enhet, velg ”Existing device on remote subnet” og skriv inn IPadressen til enheten.
Trykk OK.
Figur 43
Trykk ”Next” og så ”Finish”
Vi må nå sette opp Fpga Modulen.
Høyre klikk på CompactRIO (eller hvilket navn den har fått) og velg New og Targets and
Devices. Velg her FPGA target og velg enheten som kommer opp.
Trykk OK.
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Figur 44
Vi må nå initialisere I/O modulene som sitter i RIO chassiset.
Høyre klikk på FPGA target og velg ”New” og ”C series modules”.
Merk alle modulene og trykk OK.
Figur 45
For å velge hvilke inn og utganger vi skal bruke høyreklikker vi på ”FPGA Target og velger
New” og ”FPGA I/O”. Så kan vi legge til de inn og utganger vi skal bruke. Dette kan lett
endres på senere så det er ikke nødvendig å få med alt med en gang.
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Figur 46
Nå har vi satt opp CompactRIO systemet og det kan begynnes å lage programmer.
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7.2
Bruk av Shared variable
Når vi skal programmere på 3 nivåer er det viktig at vi kan kommuniserer mellom nivåene,
dette gjøres med noe som heter shared varible. Disse variablene gjør at forskjellige VI’er eller
forskjellige nivåer i samme VI kan skrive eller lese til en variabel når som helst. Og dermed
går kommunikasjonen mellom RT og host smertefritt. Denne kommunikasjonen er ikke like
rask som løkkene i VI’en, dermed er det ikke all type kommunikasjon som egner seg da det
vil bli litt forsinkelse i signalene.
Vi må ha to variabler til hver funksjon. Grunnen til dette er at vi trenger en variabel som
kommuniserer mellom host og RT, deretter har vi en variabel som kommuniserer mellom de
to løkkene på RT. Dette for å sikre determinisme i RT.
Figur 47
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7.2.1
Lage nye variabler
For å sette opp en shared variable går vi inn i ”project” og høyre klikker på ”variables – new
– variable”. Deretter kommer vi inn i et vindu der vi kan velge hvilken variabel vi skal ha.
Skriv inn navnet på variabelen og data typen variabelen skal brukes til, dette er viktig da
denne variabelen kun kan brukes til valgt datatype.
Her velger vi network-published for nettverks variabelen og single process for RT variabelen.
Ved oppsett av RT variabelen går vi også inn på ”Real-Time FIFO” og aktiverer denne.
NB! Ved aktivering av FIFO er det viktig å vite antall elementer som blir brukt i
bestemt array. Skal man legge til flere elementer i array må antallet endres i variabel
innstillingene.
Figur 48
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7.2.2
Variabler brukt i vårt prosjekt:
Stop – RT
Stop – network
Enkel boolean som stopper alle løkkene ved trykk på stopp knapp(Host, RT og FPGA)
Settpnkt – RT
Settpnkt – network
Et array av ”double” med 5 elementer.
Element nr:
0 – Kalibreringsverdi mot endebryter nede.
1 – Kalibreringsverdi mot endebryter oppe.
2 – Fart joystick styring.
3 – Settpunkt nede eller X verdi. (Avhengig av funksjon 1 eller 2)
4 – Settpunkt oppe eller Y verdi. (Avhengig av funksjon 1 eller 2)
PID – RT
PID – network
Et array av ”Int16” med 6 elementer.
Element nr:
0 – Kp verdi regulator for sylinder oppe.
1 – Pi verdi regulator for sylinder oppe.
2 – Pd verdi regulator for sylinder oppe.
3 – Kp verdi regulator for sylinder nede.
4 – Pi verdi regulator for sylinder nede.
5 – Pd verdi regulator for sylinder nede.
Encoder verdi – RT
Encoder verdi – network
Et array av ”Int16” med 4 elementer.
Element nr:
0 – Encoder verdi oppe.
1 – Encoder verdi nede.
2 – Settpunkt oppe.
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3 – Settpunkt nede.
Boolean array – RT
Boolean array - network
En “Int8”. (Bruker her funksjon ”array to number” for å overføre boolean array)
Element nr:
0 – Kalibrere.
1 – Overstyring endestopp.
2 – Start banekjøring (Ved funksjon 3 – Banestyring)
3 – Pause banekjøring (Ved funksjon 3 – Banestyring)
4 – Reset banekjøring (Ved funksjon 3 – Banestyring)
Banearray X – RT
Banearray X – network
Et array av “Double” som lagrer alle x verdiene i generert bane.
Banearray Y – RT
Banearray Y – network
Et array av “Double” som lagrer alle y verdiene i generert bane.
Funksjon – RT
Funksjon – network
En ”Int8”.
Denne variabelen brukes til å velge vilken type styring vi vil bruke. Den styrer egentlig en
case løkke på RT der verdien 1-4 velger hvilken case som skal kjøres.
Med default menes at ved verdier utenfor 1-4, vil default alltid velges.
Verdi 1(default) – Settpunkt manuell kjøring etter encoder teller.
Verdi 2 – X og Y settpunkt manuell kjøring.
Verdi 3 – Banekjøring.
Verdi 4 – Joystick kjøring.
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7.3
FPGA program
- encoder.vi (vedlagt program)
For å lage et FPGA program høyre klikker vi på FPGA target og velger ”New VI”.
Nå kommer FPGA vi’en opp og denne kan programmeres som vanlig. Det eneste som er
forskjellig fra vanlig labview er mangelen på funksjoner. Vi kan heller ikke bruke annet en
max int16 som variabler. Dvs vi har kun heltall å jobbe med.
Vi skal her styre en sylinder ved bruk av enkoder og vi trenger da to digitale innganger til
enkoder og en analog utgang til å styre ventilen med. Disse settes opp i FPGA I/O som
beskrevet ovenfor. For å velge hvilke inn og utganger som skal brukes på blokk diagram kan
vi velge paletten ”I/O node”, denne ligger under ”FPGA I/O”.
Det første vi trenger er en tellekrets for enkoderen. Denne blir satt opp som en XOR krets (se
enkoder 2.2) med teller både på stigende og synkende flanke. Vi har også en
retningsbestemmer som teller opp eller ned i henhold til retning enkoder roteres.
Her er eksempel på en tellekrets programmert i labview. Her har vi to innganger fra en
enkoder med kanal A og B.
Figur 49
Nå må vi implementere PID regulatoren, og dette gjøres som følger. Vi har teller som prosess
variabel, et settpunkt og utgang som går til en FPGA utgang AO0. Denne styrer da strømmen
til ventilen, hvor mye den skal åpne. Vi har også lagt til en friksjons blokk, denne fungerer
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slik at den eliminerer friksjon i systemet. Vi har friksjon/dødgang i begge ventilene som må
elimineres ved hjelp av disse. Ventilene trenger henholdsvis 0,352V(Ventil B) og
0,198V(Ventil A) signal før de begynner å gå, dette tilsvarer tallverdien 1150 og 650 i FPGA.
Dette er pga at det ikke finnes komma i FPGA programmeringa.
Verdiene finnes ved at 32678 tilsvarer 10V og -32678 tilsvarer -10V.
Disse verdiene settes inn som offset i friksjonsblokka.
Det var også et problem at vi ikke fikk nok forsterkning på signalet i PID regulatoren,
løsningen på dette var å bruke forsterkning på friksjonsblokka i tillegg. Man må ha to av disse
kretsene, en til hver enkoder/ventil.
Figur 50
Vi har også lagt inn endestopp i programmet. Denne fungerer slik at når det kommer inn et
digitalt signal fra endestopp så settes utgangen til 0. Her er det også lagt inn en ”overstyring
endestopp” (boolean array, element 1) som bypasser endestopp men setter begrenser utgang
til ± 2500. Her er det viktig å endre ”settpunkt” (settpunkt array, element 3 og 4) til en gyldig
verdi slik at jiggen kjøres ut fra endestopper og ikke fortsetter i samme retning.
Vi har også implementert en kalibrerings funksjon, denne fungerer slik at når vi setter boolean
”kalibrere” (Boolean array, element 0) til høy så går jiggen med konstant fart mot endebryter,
når endebryter går høy vil utgang settes lik 0 og teller vil settes til kjent verdi (settpnkt,
element 0 og 1) ved endebryter.
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Endestopp bryter styrer denne funksjonen som
setter utgang til null dersom den er aktivert
Denne Funksjonen blir styrt av
”overstyring endestopp” og
funker slik at den bypasser
endestopp og begrenser utgang
til ±2500
Her har vi kalibrerings funksjonen. Hvis
”kalibrering” knapp er inne og endebryter er inne
får vi 0 ut. ”Kalibrering” knapp styrer også
funksjon som kobler ut PID regulator.
Figur 51
En siste funksjon som er lagt til i FPGA programmet er to analoge innganger som måler inn
signal fra en joystick.
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7.4
Real-Time – Program
Når man har startet et nytt prosjekt får man opp en mal om hvordan Real time programmet
skal settes opp. Denne heter target – multi rate – variables. Denne viser i grove trekk hvordan
systemet funker.
Vi har her to ”Timed loops” med forskjellig prioritet. Den løkka med høyest prioritet vil alltid
bli utført først og tildelt mest prosessorkraft. Her brukes den løkka med høyest prioritet til
datainnsamling og kode. Vi bruker ikke den deterministiske løkka til å kommunisere med host
gjennom nettverks variabelene. RT variabelen brukes til å kommunisere mellom de to
løkkene. Grunnen til at de settes opp slik er at vi skal beholde determinisme i den
deterministiske loopen. Dette fordi ethernet som brukes til å kommunisere mellom host og
real-time ikke er deterministisk, man har ingen måte å forutse bestemt når informasjon sendes
og mottas.
Figur 52
For å kunne kommunisere med FPGA program må vi sette opp programet som følger. I
”FPGA interface” paletten velger vi først ”open FPGA vi reference” og setter denne på
utsiden av løkka. Høyreklikker og velger FPGA vi som skal åpnes. Deretter velger vi
”read/write control” som plasseres inne i løkka. Her blir alle variabler definert som control
eller indicator i FPGA vi, mulig å lese fra eller skrive til. På andre side av løkka har vi ”close
FPGA vi reference”.
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Figur 53
7.5
Program maler
Vi har laget maler for forskjellige kjøremodus. FPGA programmet er det samme for alle
malene. Alle variablene er også de samme. Det er kun Host og RT programmene som er
forskjellige.
7.5.1
Program mal for posisjonering med 1 DOF
7.5.1.1 Program mal – Posisjon – RT – 1DOF.vi (vedlagt Program)
For å kunne kjøre med en sylinder med settpunkt posisjonering trenger vi et enkelt RT
program. Det eneste dette skal gjøre er å overføre variabler fra host til FPGA. Programmet
blir seende slik ut, der vi sender ned settpunkt fra host via variabler. Begge settpunktene er
samlet i et array og man kan ta ut ønsket element i array med funksjonen ”index array”. For
tilbakemelding om settpunkt og enkoder verdi har vi samlet dette i et array og inn i en
variabel. Dette leses ut igjen på host for å dokumentere følging.
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Figur 54
7.5.1.2 Program mal – Posisjon – Host – 1DOF.vi (vedlagt Program)
Host program brukes til variabel endringer og visuell inspeksjon av følging. Vi har også lagt
til en case funksjon der vi skriver til variablene dersom det er gjort en endring. Dette for å
begrense skriving til variablene til et minimum, da ethernet forbindelsen kan overbelastes ved
for mye utveksling av informasjon. Dette kan da føre til tidsforsinkelser i forbindelsen.
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Figur 55
7.5.2
Program mal for posisjonering med 2 DOF
7.5.2.1 Program mal – posisjon – RT – 2DOF.vi (vedlagt program)
Ved posisjonering med 2 DOF er det eneste som er forskjellig fra 1DOF invers kinematikk
(se sub vi invers kinematikk).
Denne vi’en blir lagt til i RT før inngang til FPGA som vist nedenfor. Vi har også en ”round
to nearest” funksjon fordi vi får ut vinklene som enkoder tikk per runde. Dermed er det ikke
mulig med noe annet en hele tikk.
Figur 56
7.5.2.2 Program mal – posisjon – Host – 2DOF.vi (vedlagt program)
Det eneste som her er forskjellig fra 1DOF er at settpunktene er skiftet ut med X og Y verdier.
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7.5.3
Program mal for banestyring med 2 DOF
7.5.3.1 Program mal – banestyring – Host – 2DOF.vi (vedlagt program)
For å generere en bane har vi brukt programmet Corel draw. Her kan man lagre det som
tegnes som HPGL fil. Dette er en type plotter format som deler opp tegningen i små
linjestykker med tilsvarende x og y verdier i start og stopp punkt. Man får dermed ut en fil
bestående av x og y verdier i tilegg til noen andre enkle komandoer.
Det som er nytt på dette programmet er innlesing av hpgl fil(se sub vi ”hpg to xy cord 2.vi”)
og interpolering av punkter(se sub vi ”interpolering”). Etter vi har laget de to arrayene med X
og Y verdier blir disse skrevet inn i en shared variable. Dette skjer når man aktiverer boolean
”les ned data”. Man må velge hpgl fil på frontpanelet før man trykker på last ned data. Man
har også tre nye boolean knapper(boolean array, element 2,3 og 4), som skriver til den delte
variabelen. Ellers er det samme oppsett som i de to foregående malene.
7.5.3.2 Program mal – banestyring – RT – 2DOF.vi (vedlagt program)
Etter at host har skrevet til de to variablene vil disse da inneholde da x og y verdier for en
bane. Disse går inn i en case, som boolean ”Start banekjøring” (shared variable: boolean
array, element 2) styrer.
Dersom denne settes til true vil følgende krets generere true annenhver gang loopen går. Når
denne kretsen er høy vil indexen på ”index array” funksjonen øke med en og peke på neste
element i array. Denne vil telle oppover helt til man er kommet til siste element, da vil den
settes til null og skrive samme bane om igjen (se flytdiagram). Vi har også pause og reset
funksjonen til denne telleren(shared variable: boolean array, element 3 og 4).
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Figur 57
Figur 58
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7.5.3.3 Flytdiagram RT:
Bane array X og Y
n=0
Xn
Yn
Lengde
Xm
Ym
n = n+1
n=0
n=m
nei
Element n
ja
X og Y verdier
Invers kinematikk
Settpunkt
Figur 59
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7.6
Sub vi’er
7.6.1 Invers kinematikk.vi
Dette er en sub-vi med en formula node. Den implementerer formlene fra invers kinematikk
for jiggen men den gjør også om vinklene fra radianer til antall tikk i encoderen. Måten dette
gjøres på er at vinkelen deles med
2π
der oppløsning på encoder nede er 4000 og
Oppløsning
oppe er 4096.
7.6.2 hpg to xy cord 2.vi
Denne VI leser inn en hpgl fil, der den tar streng for streng og sorterer ut X og Y verdiene.
Den legger så inn hver X verdi i et array og hver Y verdi et annet array. Dermed får vi ut to
array med X og Y verdiene til en forhånds tegnet bane som er lagret i HPGL. Den gjør også
om lengdene til millimeter da x og y verdiene i en hpgl fil er 1024/tommer(25,4mm). Dette
gjøres ved å gange verdiene med
25,4mm
= 0,025 .
1024
7.6.3 Interpolering.vi
Denne VI leser inn to array med henholdsvis X og Y verdier. Det er også en inngang som
heter lengde på stepp. Det første som skjer er at vi tar array X der element N+1 trekkes fra
element N. Dette for å finne lengden på linjestykkene i X retning. Samme prosessen gjøres
med Y arrayet.
Vi har nå to nye array som viser lengden på hver katet i en rettvinklet trekant. For å finne
lengden på hypotenus gjøres følgende X 2 + Y 2 , vi har nå lengden på hvert linjestykke.
Denne lengden deles så med lengde på stepp. Vi får så hvor mange interpolasjoner vi må ha.
Dette antallet blir da hvor mange ganger FOR loopen skal gå. Antall ganger loopen har gått
blir så delt på antall ganger den skal gå. Dette blir valg for hvor mellom to punkter vi skal få
et nytt punkt, vi får alltid et tall mellom 0 og 1 der 0,5 er et punkt midt mellom de to tallene.
Slik velger vi hvordan avstanden skal være
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Eks: Vi har to tall 0 og 100. Indeksen vil da vise hvor mellom disse tallene nytt punkt skal
ligge. 0 tilsvarer 0
0,1 tilsvarer 10
0,5 tilsvarer 50
1 tilsvarer 100
Vi får nå ut to nye array der maks avstand mellom settpunkt er lengde på stepp.
Figur 60
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7.7
Programmer brukt av gruppa
-
Hoved program – Host – Multi.vi (vedlagt program)
Det programmet vi har brukt er et program som syr sammen alle funksjonene til et program
ved hjelp av en case funksjon på RT. Vi har samme host program som banestyring men har i
tillegg noen ekstra funksjoner.
Det første er en variabel som heter funksjon (shared variable: funksjon). Denne styrer med
tallverdiene 1-4 hvilken case vi vil kjøre, der:
1 = Settpunkt kjøring (case 1)
2 = X og Y koordinat settpunkt(case 2)
3 = Banestyring (case 3)
4 = Joystick styring (case 4)
Vi har også implementert en logging funksjon som logger settpunkt og encoder teller verdi for
å dokumentere følgingen til systemet.
”Joystick fart” (shared variable: setpnkt, element 2) settes også på host.
Resten av systemet på host er forklart under program maler.
Figur 61
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-
Hoved program – RT – Multi.vi (vedlagt program)
Her er det også samme funksjonene som forklart i de forskjellige malene, men disse er blitt
laget i en case struktur som gjør at vi enkelt kan bytte mellom de forskjellige styringene.
Vi har også en joystick funksjon implementert, denne leser inn spenningen på AI0 og AI1 fra
FPGA og
Den joysticken vi bruker er satt opp av 2 potensiometer, en for hver akse.
Dermed gir den ut forskjellig spenning alt etter posisjon.
Joystick programmet fungerer slik at vi leser inn spenningen fra joystick, denne varierer fra 0
til 5 volt, eller 0 til 16384 i FPGA. Dersom spenningen er over 12000 vil x eller y settpunkt
telle oppover med ”fart joystick” (Shared variable: settpnkt, element 2). Dersom den er under
3000 vil det telle nedover. Settpunktet øker eller minsker med ”fart joystick” hver gang
”løkka” går. Dermed fungerer joysticken som en av på bryter og ikke proporsjonalt slik den
kan gjøre.
Her har vi case strukturen der joystick programmet er vist
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8 Oppsumering
8.1
Status
Alle nødvendige beregninger og utregninger er gjort og dokumentert. Det samme gjelder for
alle deler som er maskinert og kretser som er laget. Videre er alle program maler laget og er
fullstendige.
Jiggen er ferdigstilt og komplett slik den står pr idag. Den er fullstendig og klar for bruk.
Den er testet med gode resultater med alle programmaler. Videre oppfyller den alle krav satt
ved prosjektstart. Den er også nøyaktig og rask både ved joytsickkjøring, setpunktkjøring og
ved banekjøring. Det er også laget en enkel prosedyremappe slik at studenter kan gjøre seg
kjent med jiggen, kretsene og systemet før kjøring.
Jiggen er ikke lakkert, og dette er det siste som skulle bli gjort. Grunnen til det er at tiden ikke
strakk til da vi måtte prioritere testkjøring isteden.
8.2
Konklusjon
I forhold til oppgaven er føler vi den er besvart på en grundig og fyldig måte. Vi har fått
maskinert alle nødvendige deler og laget alle kretser.
Videre har vi laget alle program malene og programmer tilknyttet hovedprosjektet.
Prosjektets omfang har vært relativt stort, og det har blitt lagt ned mye tid og innsats. Særlig
mye av maskineringen og det designmessige i startfasen av prosjektet har tatt mye tid.
Alt i alt er vi veldig fornøyd med resultatet og føler oppgaven er besvart.
8.3
Erfaringer
Vi har gjort mange erfaringer gjennom dette prosjektet og lært mye om hvordan det er å jobbe
sammen i en gruppe. Vi har blant annet satt oss inn i både maskinering av deler, hydraulikk
og styresystem. Det har vært en bred oppgave som har inneholdt innslag fra veldig mange av
de forskjellige fag disiplinene vi har hatt opp i gjennom.
Til slutt vil vi si vi syns dette har vært en lærerik og spennende avsluting på utdannelsen vi
har fått her på Hia.
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9 Litteraturliste
- Morten Ottestad – MAS200 kompendie – Datainnsamling 2007.pdf
- Morten Ottestad – MAS104 kompendie – Hydraulikk kapittel 3 06 ventiler.pdf
- Morten Ottestad – MAS104 kompendie – Servo og proporsjonal ventiler.pdf
- Morten Ottestad – MAS200 kompendie – målefeil_2.pdf
- Finn Haugen – Regulering av dynamiske systemer.
- http://www.igus.de
- http://mechatronics.mech.northwestern.edu/design-ref/
- http://www.cs.utah.edu/classes/cs5310/chapter5.pdf
- http://www.ece.ucsb.edu/~roy/student_projects/RiehlFinal238.pdf
- http://www.ni.co
Bilder – referanser:
[1]
http://images.google.no/images?hl=no&q=encoder&btnG=S%C3%B8k+etter+bilder&gbv=2
[2] http://www.ee.ucl.ac.uk/~mflanaga/java/closedLoop.gif
[3] www.igus.de
[4] Datainnsamling
[5] servokompendiet
[6] Finn Haugen, dynregsys
[7] ottestad servo proposjoanl ventiler
[8] moog datablad
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10 Vedlegg
Vedlegg 1 - Koblingsskjema
Vedlegg 2 – Produksjons tegninger
Vedlegg 3 – Bourns potensiometer
Vedlegg 4 – Vishay potensiometer
Vedlegg 5 – Eltra Enkoder
Vedlegg 6 – Hengstler Enkoder
Vedlegg 7 – Moog servoforsterker
Vedlegg 8 – Moog servoventil
Vedlegg 9 – NI CompactRIO
Vedlegg 10 – IGUS Iglidur G
Vedlegg 11 – Statoil hydraway
Vedlegg 12 - Ni 9263
Vedlegg 13 – Ni 9411
Vedlegg 14 – Ni 9215
Vedlegg 15 – Ni 9237
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A
B
C
1
3,20
2
16,70
27
0
,5
15
2
6,30
37,30
2
80
,50
54
15
3
3
15,50
2
D
1
32,50
7
P-001-1
Part nr
2
4
3,20
Part name
Unless otherwise
specified:
dimensions are
in millimeters
46
5
6
1.5:1
Scale
A4
Format
1/2
Sheet
Material
Approved by: AM
European
Projection
Verified by: DF
03.06.2007
Dato
70
0
Rev nr
Aluminium
Flusheplate
32,50
Designed by: MS
Qty
21,40
A
B
C
1
A
2
SECTION A-A
2
3
3
A
6
A
B
C
D
1
10
Part name
4
Part nr
5
6
1:1
Scale
A4
Format
1/2
Sheet
Material
European
Projection
Approved by: AM
03.06.2007
Dato
Verified by: DF
0
Rev nr
Aluminium
Flusheplate
2
Designed by: MS
Qty
Unless otherwise
specified:
dimensions are
in millimeters
P-001-2
1,70
A
B
C
A
B
C
D
1
1
90
C
20
54
110
40
2
2
5
3
3
10
DETAIL C
SCALE 3 : 5
4
580
Part name
Material
5
B
90
+0,02
20 H7 0
DETAIL B
SCALE 3 : 5
3,30
6
Approved by: AM
European
Projection
A4
Format
1/2
Sheet
3 holes equaly
spaced, Ø30
+0,02
20 H7 0
03.06.2007
Dato
Verified by: DF
0
Rev nr
Carbon Steel 1:5
Scale
knekkbom
Part nr
P-002-1
1
Unless otherwise
specified:
dimensions are
in millimeters
Qty
Designed by: MS
22
A
B
C
2
40
1,50
1
30
6
70
2
7,50
3
10
A
B
C
D
1
6
6,50
3
3
4
Part name
Material
0
Rev nr
5
Verified by: DF
6
1/2
Sheet
A4
Format
European
Projection
Approved by: AM
03.06.2007
Dato
Carbon Steel 1:1
Scale
encoder aksling
Part nr
P-003-1
1
Unless otherwise
specified:
dimensions are
in millimeters
Qty
Designed by: MS
21
A
B
C
1
2
40
30
70
6,35
2
7,50
3
10
A
B
C
D
1
6
6,50
1,50
3
3
4
Part name
Material
0
Rev nr
5
Verified by: DF
6
1/2
Sheet
A4
Format
European
Projection
Approved by: AM
03.06.2007
Dato
Carbon Steel 1:1
Scale
Potmeter_aksling
Part nr
P-004-1
1
Unless otherwise
specified:
dimensions are
in millimeters
Qty
Designed by: MS
10
A
B
C
1
2
2
120
90
0
R3
10
3
3
57,33°
43
Part name
4
Part nr
Material
0
Rev nr
5
73
Verified by: DF
6
1/2
Sheet
A4
Format
European
Projection
Approved by: AM
03.06.2007
Dato
Carbon Steel 1:1
Scale
Brakett_potmeter
1
Designed by: MS
Qty
Unless otherwise
specified:
dimensions are
in millimeters
P-005-1
5
A
B
C
D
1
6
A
B
C
1
R3
0
2
2
22
120
90
3,50
6
A
B
C
D
1
6
3
3 holes equaly
spaced, Ø30
3
5
Part name
4
Part nr
73
Material
0
Rev nr
5
Verified by: DF
6
1/2
Sheet
A4
Format
European
Projection
Approved by: AM
03.06.2007
Dato
Carbon Steel 1:1
Scale
Brakett_encoder
1
Designed by: MS
Qty
Unless otherwise
specified:
dimensions are
in millimeters
P-006-1
43
A
B
C
1
3
4
24
10
A
B
C
D
1
25
2
2
40
61
5
3
3
10
4
Part name
5
6
2:1
Scale
A4
Format
1/2
Sheet
Material
European
Projection
Approved by: AM
03.06.2007
Dato
Verified by: DF
0
Rev nr
Aluminium
brakett_endebryter_oppe
Part nr
Designed by: MS
Qty
2
P-007-1
14
Unless otherwise
specified:
dimensions are
in millimeters
10
A
B
C
A
B
C
D
5
1
1
8
12
27
2
2
44
7
3
3
8
76
Unless otherwise
specified:
dimensions are
in millimeters
Part name
4
12
10
18
5
5
Material
Verified by: DF
0
Rev nr
24
6
1/2
Sheet
A4
Format
European
Projection
Approved by: AM
03.06.2007
Dato
Carbon Steel 1:1
Scale
Brakett_endebryter_nede1
4
Designed by: MS
Qty
1
Part nr
P-008-1
56
A
B
C
A
B
C
D
1
1
2
2
40
20
6,50
3
3
15
Part nr
P-010-1
Part name
boltplate
4
1
Unless otherwise
specified:
dimensions are
in millimeters
Qty
Designed by: MS
5
5
6
1/1
Sheet
A4
Format
European
Projection
Approved by: AM
03.06.2007
Dato
Carbon Steel 2:1
Scale
Material
0
Rev nr
Verified by: DF
A
B
C
PL
IA
NT
Features
CO
M
■
*R
oH
S
■
■
Bushing mount
Shaft supported by front sleeve bearing
Non-standard features and
specifications available
6657 - Precision Potentiometer
Electrical Characteristics1
Product Dimensions
Standard Resistance Range....................................................................................1 K to 100 K ohms
Total Resistance Tolerance .........................................................................................................±10 %
Independent Linearity ...................................................................................................................±1 %
Effective Electrical Angle .......................................................................................................340 ° ±3 °
End Voltage .................................................................................................................0.5 % maximum
Output Smoothness .....................................................................................................................0.1 %
Dielectric Withstanding Voltage (MIL-STD-202, Method 301)
Sea Level .............................................................................................................750 VAC minimum
Power Rating (Voltage Limited By Power Dissipation or 300 VAC, Whichever is Less)
+70 °C ................................................................................................................................1.5 watts
+125 °C....................................................................................................................................0 watt
Insulation Resistance (500 VDC)..................................................................1,000 megohms minimum
Resolution ................................................................................................................Essentially infinite
1.57
(.062)
10.317+.000/-.051
(.4062+.000/-.002)
DIA. SHAFT
16.46 ± .38
(.648 ± .015)
3/8 "-32 UNEF-2ATHD
6.345 +.000/-.008
(.2498 +.0000/-.0003)
DIA. SHAFT
33.34
(1-5/16)
DIA.
45 ° ± 5 °
.38
X
(.015)
CHAMFER
Environmental Characteristics1
9.53 ± .79
(3/8± 1/32)
Operating Temperature Range...................................................................................+1 °C to +125 °C
Storage Temperature Range.....................................................................................-65 °C to +125 °C
Temperature Coefficient Over Storage Temperature Range ...........................±500 ppm/°C maximum
Vibration .........................................................................................................................................15 G
Wiper Bounce ...........................................................................................0.1 millisecond maximum
Total Resistance Shift ..............................................................................................±5 % maximum
Voltage Ratio Shift ................................................................................................±0.5 % maximum
Shock .............................................................................................................................................50 G
Wiper Bounce ...........................................................................................0.1 millisecond maximum
Total Resistance Shift ..............................................................................................±5 % maximum
Voltage Ratio Shift ................................................................................................±0.5 % maximum
Load Life ............................................................................................................1,000 hours, 1.5 watts
Total Resistance Shift ............................................................................................±10 % maximum
Rotational Life (No Load) .........................................................................10,000,000 shaft revolutions
Total Resistance Shift ............................................................................................±10 % maximum
Moisture Resistance (MIL-STD-202, Method 106)
Total Resistance Shift ............................................................................................±15 % maximum
IP Rating ........................................................................................................................................IP 40
22.23 ± .79
(7/8 ± 1/32)
3.18
(1/8)
SHAFT SLOT
1.19
WIDE
(.047)
1.60
DEEP
X
(.063)
UR
BO NS
2
6.35
R
(.25)
CW
3
1
30 ° ± 3 °
TYP.
Mechanical Characteristics1
Mechanical Angle ................................................................................................................Continuous
Torque (Starting & Running) ..............................................................0.40 N-cm (0.5 oz.-in.) maximum
Mounting.............................................................................170-200 N-cm (15-18 lb.-in.) maximum
Shaft Runout................................................................................................0.025 mm (0.001 in.) T.I.R.
Shaft End Play ...............................................................................................0.13 mm (0.005 in.) T.I.R.
Shaft Radial Play ...........................................................................................0.13 mm (0.005 in.) T.I.R.
Backlash ........................................................................................................................0.1 ° maximum
Weight ..........................................................................................................................................32 gm
Terminals.......................................................................................................................Rear turret type
Soldering Condition....................Recommended hand soldering using Sn95/Ag5 no clean solder,
0.025 ” wire diameter. Maximum temperature 399 °C (750 °F) for 3 seconds.
No wash process to be used with no clean flux.
Marking ................................Manufacturer’s name and part number, resistance value and tolerance,
linearity tolerance, wiring diagram, and date code.
Ganging (Multiple Section Potentiometers) .................................................................1 cup maximum
Hardware ....................................................One lockwasher (H-37-2) and one mounting nut (H-38-2)
is shipped with each potentiometer.
TOLERANCES: EXCEPT WHERE NOTED
.51
.13
DECIMALS: .XX ±
.XXX ±
(.02),
(.005)
FRACTIONS: ±1/64
MM
DIMENSIONS:
(IN.)
2
CCW
WIPER
3
1
CW
CLOCKWISE
1
At room ambient: +25 °C nominal and 50 % relative humidity, except as noted.
Recommended Part Numbers
Part Number*
Resistance
(Ω)
6657S-1-102
6657S-1-202
6657S-1-502
6657S-1-103
1,000
2,000
5,000
10,000
BOLDFACE LISTINGS ARE IN STOCK AND READILY
AVAILABLE THROUGH DISTRIBUTION.
FOR OTHER OPTIONS CONSULT FACTORY.
REV. 06/06
*RoHS Directive 2002/95/EC Jan 27 2003 including Annex
Specifications are subject to change without notice.
Customers should verify actual device performance in their specific applications.
Application Notes
Potentiometers and Trimmers
2.9 - Terminal
An external contact that provides electrical connection to the
resistance element and wiper.
2.9.1 - Printed Circuit Terminal
Rigid non-insulated electrical conductor suitable for
printed circuit board
2.9.2 - Solder Lug Terminal
Rigid non-insulated electrical conductor suitable for
external lead attachment
2.9.3 - Leadwire Type
Flexible insulated conductor
2.10 - Stop clutch
A device that allows the wiper to idle at the ends of the
resistance element without damage while the adjustment
shaft continues to be actuated in the same direction.
2.11 - Stop
A positive limit to mechanical and electrical adjustment.
3. INPUT AND OUTPUT TERMS
3.1 Input terms
3.1.1 - Total Applied Voltage
(E) The total voltage applied between the designated input
terminals.
Note: When plus (+) and minus (-) voltages are applied to
the potentiometer, the total applied voltage (commonly called
peak-to-peak applied voltage) is equal to the sum of the two
voltages. Each individual voltage is referred to as
zero-to-peak applied voltage.
3.2 - Output terms
3.2.1 - Output Voltage
(e) The voltage between the wiper terminal and the
designated reference points. Unless otherwise
specified, the designated reference point is the
counter-clockwise (CCW) terminal.
3.2.2 - Output Voltage Adjustment Ratio
(e/E) The ratio of the output voltage to the designated
input reference voltage. Unless otherwise specified
the reference voltage is the total applied voltage.
3.2.3 - Output Resistance
The resistance measured between the wiper terminal
and the designated reference point. Unless otherwise
specified, the designated reference point is the CCW
terminal.
3.3 - Load terms
3.3.1 - Load Resistance
(R) The external resistance as seen by the output voltage
(connected between the wiper terminal and the designated
reference point).
Note: No load means an infinite load resistance.
Document Number: 51001
Revision: 01-Aug-06
Vishay
4. ELECTRICAL DEFINITIONS
4.1 - Power rating
The maximum power that can be dissipated across the total
resistance element, i.e., between terminals a (or 1) and c (or
3), at the specified ambient temperature. In practice this
dissipation is modified by the following conditions:
4.1.1 - For ambient temperatures higher than that specified,
reference should be made to the derating curve.
4.1.2 - For high values of resistance, the limiting element
voltage may prevent the maximum power rating from
being obtained.
4.1.3 - For situations when the power is dissipated in only
part of the resistance element, the maximum current
capacity of the element will prohibit maximum total
power dissipation.
4.2 - Resistance law
The relationship between the mechanical position of the
moving contact and the resistance value across terminals a
and b. (This may also be expressed as the relationship
between the position of the moving contact and the ratio
Vab/Vac). Typical available laws are indicated in Figure 2.
90 %
F
S
RL
Vs
% 50 %
Ve
A
W
20 %
L
10 %
50 %
15°
Electrical travel 270°
15°
31°
Electrical travel
with inter 238°
31°
Mechanical travel 300°
A
L
F
RL
W
Linear (A law)
Clockwise logarithmic 10 % (L law) (audio taper)
Inverse, clockwise, logarithmic (F law)
Counter-clockwise, logarithmic (RL law)
Clockwise logarithmic 20 % (W law)
4.3 - Conformity
This is a measure of the maximum deviation of the actual to
the correspondant theoretical voltage expressed as percent
of the total applied voltage.
4.4 - Linearity
The conformity where the theoretical resistance law is a
straight line.
For technical questions, contact: sfer@vishay.com
www.vishay.com
3
Application Notes
Potentiometers and Trimmers
Vishay
4.5 - Total resistance
The resistance value of the resistive element measured
between connections a and c or 1 and 3 in conditions defined
by CECC 41000:
Temperature: + 20 °C ± 1 °C
Relative humidity: 65 % ± 2 %
This value has to be included between limits of resistance
nominal value according to tolerance.
4.5.1 - Minimum Effective Resistance
The resistance value at each end of the effective
rotation between termination b (or 2) and the nearest
end termination, a or c (1 or 3).
4.13 - Limiting element voltage
The maximum voltage that may be applied across the
element of a potentiometer, provided that the power rating is
not exceeded.
4.14 - Insulation voltage
The maximum voltage which may be applied under
continuous
operating
conditions
between
any
potentiometer termination and other external conductive
parts connected together. The insulation voltage is not less
than 1.4 times the limiting element voltage.
4.6 - Effective resistance
The portion of the total resistance over which the resistance
changes in accordance with the declared resistance law. It is
the total resistance minus the sum of the two minimum
effective resistance values.
4.15 - Dielectric strength (voltage proof)
The maximum voltage which may be applied under 1 ATM
pressure for 60 s between any potentiometer termination and
any external conductive part without breakdown occuring.
Dielectric strength is not less than 1.4 times the insulation
voltage.
4.7 - End resistance
The resistance measured between termination a or c and
termination b when the moving contact is positioned at the
corresponding end of mechanical travel.
4.16 - Insulation resistance
The resistance measured between the terminals and other
external conductive parts (e.g., shaft, housing, or mounting),
when a specified D.C. voltage is applied.
4.8 - Contact resistance
The resistance appearing between the contact and the
resistive element when the shaft is rotated or translated. The
wiper of the potentiometer is excited by a specific current and
moved at a specified speed over a specified portion of the
actual electrical travel.
4.17 - Temperature coefficient of resistance (TCR)
The unit change in resistance per °C change from a
reference temperature, expressed in parts per million per
°C as follows:
R2 – R1
6
- × 10
TC = -----------------------------( T 2 – T 1 )R 1
Where :
POTENTIOMETER
UNDER TEST
R1 = Resistance in ohms, at reference temperature
R2 = Resistance in ohms, at test temperature
T1 = Reference temperature in °C
T2 = Test temperature in °C
CONSTANT
CURRENT
GENERATOR
5. ENVIRONMENTAL DEFINITIONS
OUTPUT OR
CONTACT
RESISTANCE
4.9 - Continuity
Continuity is the maintenance of continuous electrical
contact between the wiper and the resistive element over the
total mechanical travel in both directions.
4.10 - Setting stability
For a fixed setting of the adjustment shaft, the amount of
change in the output voltage due to the effects of an
environmental condition, (expressed as a percentage of the
total applied voltage).
4.11 - Setting ability
A measure of the ability for the user to adjust the wiper to any
particular voltage ratio or resistance output.
4.12 - Resolution
This term is used in the description of wirewound
potentiometers and is a measure of the sensitivity to which
the output ratio of the potentiometer may be set. The
theoretical resolution is the reciprocal of the number of turns
of the resistance winding in the actual electrical travel
multiplied by 100 i.e., (expressed as a percentage).
www.vishay.com
4
5.1 - Climatic category
The climatic category is defined in terms of the temperature
extremes (hot and cold) and number of days exposure to
dampness, heat, and steady-state conditions that the
component is designed to withstand.
The category is indicated by a series of three sets of digits,
separated by oblique strokes, as follows:
• First set: Two digits denoting the minimum ambient
temperature of operation (cold test).
• Second set: Three digits denoting the upper category
temperature (at that temperature the allowed dissipation
is at least 25 %).
The maximum allowable temperature with zero dissipation
is higher than the upper category temperature.
• Third set: Two digits denoting the number of days used
for the “dampness, heat, and steady-state” test.
Example: P13: 55/100/56
Cold: - 55 °C
Upper category temperature: + 100 °C
(maximum allowable temperature: + 125 °C)
Damp heat: 56 days.
5.2 - Classify materials
Plastic materials used are UL94 class VO and/or our
products are compliant with the flammability test of STD
UL746C § 17 and 52.
For technical questions, contact: sfer@vishay.com
Document Number: 51001
Revision: 01-Aug-06
Application Notes
Potentiometers and Trimmers
6. STORAGE RECOMMENDATIONS
Careful attention must be paid when the components are
stored. Because high and very low environmental
temperature, high humidity, corrosive gases, etc. might
affect the solderability of the terminals and the function of the
package. Listed below are notes to be observed:
• The recommended storage conditions are in between
+ 10 °C and 25 °C (room temperature) at a relative
humidity in between 35 % and 75 %.
• Do not store them within the vicinity of any corrosive gases
such as hydrogen sulphide, sulphurous acid, chlorine or
ammonium. The oxidation of the metals caused by such
toxic gases may affect solderability as well as the electrical
and mechanical performance of these products.
• Exposure to the direct sunlight and dust must be avoided
• Handle carefully to avoid deformation of terminals
• Keep parts in the original packages until just before use,
and unpack only the quantity needed. Always seal any
opened packages to protet them from oxidation and
contaminants.
• Moisture Sensitive Level (MSL) for applicable SMD
components, following storage conditions should be
applied.
MSL LEVEL
1
2
2A
3
4
5
5A
6
FLOOR LIFE
TIME
CONDITIONS
Unlimited
≤ 30 °C/85 % RH
1 year
≤ 30 °C/60 % RH
4 weeks
≤ 30 °C/60 % RH
168 hours
≤ 30 °C/60 % RH
72 hours
≤ 30 °C/60 % RH
48 hours
≤ 30 °C/60 % RH
24 hours
≤ 30 °C/60 % RH
Time on label (TOL)
≤ 30 °C/60 % RH
If any special storage conditions are applied (outside those
recommendations), it is the user’s responsibility.
7. SMD AND THROUGH HOLE COMPONENTS,
SOLDER AND CLEANING RECOMMENDATIONS
VISHAY Trimmers sealed surface mount components are
designed to withstand the processes related to Infrared, Hot
Air, Vapour Phase Reflow and Dual Wave soldering. They
are sealed against flux by means of an O-ring seal or press
fit and can withstand exposure to all commonly used
defluxing solvents. It is important to note before pre-heating
and soldering trimmers, make sure the position of the wiper
is not in contact with the end terminals (beginning or end of
the wiper mechanical travel) to avoid malfunction of
trimmers.
7.1 - Adhesive application (for SMD only)
When an assembly has to be wave soldered, an adhesive is
essential to bond the SMDs to the substrate. Under normal
conditions reflow, soldered substrates do not need adhesive
to maintain trimmer orientation, since the solder paste does
it. The amount of adhesive, the curing time and temperature
to use should be in accordance with adhesive
manufacturer’s recommendations. Otherwise, the adhesive
polymerization time & temperature have to also respect
trimmers soldering recommendations. (§3)
Document Number: 51001
Revision: 01-Aug-06
Vishay
Caution: The height and the volume of adhesive dots applied
are critical for two reasons: the dot must be high enough to
reach the SMD, and there must not be any excess adhesive,
since this can pollute the solder land and prevent the
formation of a good soldered joint.
7.2 - Flux and solder recommendations
SMD & Through hole components can be used with R & RA
(Rosin & Rosin Activated) type flux to OA (Organic Acid). It
is always advisable not to use a flux of an activity level
greater than that necessary to achieve optimum yields for
solder wetting. Fluxes of RA and OA activity levels are
corrosive and therefore must be removed. It is advisable that
all types of fluxes be removed by cleaning due to the
possibility of corrosion.
Caution: Avoid highly activated fluxes. Consult factory before
using OA.
Suggested Solder composition is:
⎫
⎪
⎪
⎬
• Lead (Pb)-free solder: ⎪
⎪
Sn96.5/Ag3/Cu0.5
⎭
• Tin Lead solder:
Sn63/Pb37
Typical solder paste print thickness
would be 0.8 to 1 mm thick
7.3 - Soldering recommendations
Normal preheating is required to activate flux and minimize
thermal shock to components. The maximum recommended
temperature for flow and reflow soldering profiles are
specified below. It is important to note temperature of those
profiles corresponds to parts temperature (and not PCB
temperature). The use of leaded solder process or lead
(Pb)-free solder process is specified under each series of
SMD or through hole products.
General Caution: User must always test and verify
pre-heating and soldering processes as well as other
production line assembly before final production.
Leaded solder process
Wave soldering (1 time max.)
Maximum temperature: 235 °C max.
Preeheating temperature: 130 °C
Room temperature
1 min max.
5 s max.
3 min max.
Infrared or Hot Air reflow soldering (2 times max.) (for SMD only)
Maximum temperature: 220 °C max.
210 °C
Preeheating temperature: 130 °C
Room temperature
For technical questions, contact: sfer@vishay.com
2 min max.
5 s max
40 s max
4 min max.
www.vishay.com
5
Application Notes
Potentiometers and Trimmers
Vishay
Lead (Pb)-free solder process
Wave soldering (1 time max.)
Maximum temperature: 260 °C max.
Preeheating temperature: 160 °C
Room temperature
1 min max.
10 s max.
3 min max.
Infrared or Hot Air reflow soldering (2 times max.) (for SMD only)
Maximum temperature: 260 °C max.
230 °C
Preeheating temperature: 150 °C
Room temperature
10 s max
3 min max.
50 s max
6 min max.
Vapor phase reflow: Vapour with 215 °C condensation
temperature for a period not more than 2 minutes
Soldering iron caution: Use the appropriate soldering iron
size, shape and heat capacity for soldering SMD trimmers.
Do not exceed the maximum time and temperature
parameters specified: 3 s at 350 °C. Never touch the body of
the trimmer or potentiometer with the soldering iron.
Infrared soldering caution: If the infrared radiation is the
heat source, the temperature increase of the SMD trimmers
should be carefully checked because the radiation
absorption rate depends on the color and the structure of the
material of trimmers.
7.4 - Washing recommendations (refer to protection
level of the component)
Cooling down time after soldering and before exposure to
defluxing solvents is required. The component body
temperature when exposed to cleaning should not exceed
60 °C. Cleaning spray rinse is recommended with pressures
of not greater than 60 psi (5.5 kg-cm2) for a period not to
exceed 15 - 20 seconds.
Appropriate defluxing solvent/Aqueous:
• Aqueous detergent solutions
• Terpene based semiaqueous
• Ester/Ether based solvents
• Methanol
• HAS - HCFC
Caution: • Avoid using cleaning solvents such as
Trichloroethane or Freon which endanger the
environment
• Ultrasonic may cause component damage or
failure
7.5 - Reworking recommendations
• General: Excessive and/or repeated high temperature heat
exposure may affect component performance and
reliability
• Recommended: Hot air reflow technique is the safest
method for SMD component
• Caution: Avoid use of a soldering iron or wave soldering as
a rework technique
7.6 - Adjustment recommendations
Adjustment of components should be done only after part
has reached ambient temperature and cleaning solvent has
evaporated (10 minutes).
PROTECTION LEVELS
FIRST DIGIT
PROTECTION AGAINST SOLID SUBSTANCES
SECOND DIGIT
PROTECTION AGAINST LIQUIDS
IP
Tests
IP
Tests
0
Without Protection
0
Without Protection
1
Protected against solid substances
(size > 50 mm)
1
Protected against water drops
(condensation)
2
Protected against solid substances
(size > 12 mm)
2
Protected against water drops from
up to 15 feet
3
Protected against solid substances
(size > 2.5 mm)
3
Protected against water drops from
up to 60 feet
4
Protected against solid substances
(size > 1 mm)
4
Protected against water drops from
above 60 feet
5
Protected against dust (> 0.1 mm < 1 mm)
5
Protected against splashes of water
in all directions
6
Fully protected against dust
6
Protected against projections of water
in all directions
7
Protected against action of immersion < 15 cm and
water jet pressure in all directions
8
Protected against long time action of immersion
< 1 meter and water jet pressure in all directions
Note: To symbolize the protection levels, we use IP letters followed by 2 digits.
www.vishay.com
6
For technical questions, contact: sfer@vishay.com
Document Number: 51001
Revision: 01-Aug-06
Incremental Encoders
ISO 9001:2000
EH-EL53A / B
INCREMENTAL ENCODERS
R
C
US
Incremental encoders
A series of encoders for the direct assembly on motors; the
incorporated elastic joint allows the compensation of radial
and axial slack.
- Resolutions up to 10000 imp/turn with zero for the EL series
and up to 1024 imp/turn for the EH series
- Different electronic configurations available with power supply
up to 28 Vdc for the EL series and up to 24 Vdc for the EH
series
- Max output frequency up to 300 KHz for the EL series and up
to 100KHz for the EH series.
- Output : cable and connector
- Different flanges available
- Speed rotation up to 6000 rpm
- Protection up to IP64
Ordering codes
In case of particular Customer
variant separate with a full stop
EL 53 A 1000 Z 5/28 N 6
X 6 M R
Special Customer variants
indicated by a progressive
number from 001 to 999
R = radial
A = axial
53 = body dimension
P=
standard output cable 0.5 m series EH53
standard output cable 1.5 m series EL53
M = connector MS3106E 16S-1S or 18-1S
J = connector JMSP 1607 F or 1610 F
Type of flanges
from 1 to 10000 imp./turn EL series
Resolutions
from 40 to 1024 imp./turn EH series
N.B.: For impulse availability contact directly our offices
S = without zero impulse
Z = with zero impulse
XXX
XXX =
EL = incremental encoder EL series
EH = incremental encoder EH series
A = mod.EH-EL53A
B = mod.EH-EL53B
.
Zero Impulse
5 ÷ 28 = power supply for the EL series
Encoder power supply (Vdc)
5 / 8 ÷ 24 = power supply for the EH series
N.B.: LINE DRIVER available only with 5 Vdc or 8 ÷ 24 Vdc power supply
6 = 6000
X=
standard IP54 EH53
standard IP64 EL53
6 = ø 6 mm
8 = ø 8 mm
10 = ø 10 mm
N = NPN
C = NPN OPEN COLLECTOR
P = PUSH PULL
L = LINE DRIVER
R.P.M.
Protection
Shaft diameter
Electronic output configuration
N.B.: For the optionals on the output configurations see the output incremental
connections card
13
Incremental Encoders
Electronic Characteristics EL series
EH53A
Resolutions
48
41
Nº3 ø3.2x120
Power supply
7
ø46.5h7
ø20/
ø23.5
ø30
ø53.5
1
1
80 mA
Max output
current
50 mA per channel
20 mA per channel with LINE DRIVER
Electronic output
configuration
NPN / NPN OPEN COLLECTOR /
PUSH PULL / LINE DRIVER
EL53A
76.5
52.5
30
7
1
ø23.5
ø46.5h7
ø53.5
17
20
Nº3 ø3.2x120°
STANDARD JOINTS
G23A10
G23A8/10
G23A6/10
15
7
Nº3 ø3.2x120°
15
ø46.5H7
ø45
ø44
ø53.5
ø30
6
1
Resolutions
Power
supply
F=
RPM x Resolution
60
From 40 to 1024 impulses /turn
5 Vdc / 8 ÷ 24 Vdc
N.B.: LINE DRIVER only of power supply 5 / 8 ÷ 24 Vdc
Current consumption
without load
50 mA bidirectional
100 mA bidirectrional with zero
Max commutable
current
50 mA per channel
20 mA per channel with LINE DRIVER
Electronic output
configuration
NPN / NPN OPEN COLLECTOR /
PUSH PULL / LINE DRIVER
Max output
frequency
Max 100 KHz
F=
RPM x Resolution
60
Mechanical Characteristics
Shaft diameter (mm.)
ø6 / 8 / 10 h7
Protection
EH53 : IP54 standard
EL53 : IP64 standard
R.P.M. Max
6000 continuous
Shock
50 G for 11 msec (with flexible disc)
20 G for 11 msec (with glass disc)
Vibrations
10G 10 ÷ 2000 Hz
Bearings life
10 revolutions
Bearings
n°2 ball bearings
Shaft material
Stainless steel AISI303
Body material
Alluminium D11S - UNI 9002/5
Cover material
Special plastic with glass fibre
Operating
temperature
0° ÷ +60°C
0,5
33
EH-EL53B Flange version
Max 300 KHz
Electronic Characteristics EH series
STANDARD JOINTS
G20A6
G23A6/8
G23A6/10
ø58
ø30
5 ÷ 28 Vdc
N.B.: LINE DRIVER only of power supply 5 / 8 ÷ 24 Vdc
Current consumption
without load
Max output
frequency
20
From 1 to 10000 impulses / turn
Storage temperature
-25° ÷ +70°C
EH53 : 150 g
EL53 : 350 g
IN004GB0803A
Weight
9
1.5 5
14
Via Monticello di Fara, 32 bis - Sarego (VI) - ITALY - Tel.+39 0444 436489 R.A. - Fax +39 0444 835335
http://www.eltra.it E-mail:eltra@eltra.it
ELTRA reserves the right to make any modifications without prior notice
Incremental Shaft Encoders
Industrial types
Type RI 58
Solid shaft
■
■
■
■
■
■
■
■
Universal industry standard encoder
Up to 40 000 steps with 10 000 pulses
High signal accuracy
Protection class up to IP67
Operating temperature up to 100 °C (RI 58-T)
Flexible due to many flange and configuration variants
Suitable for high shock ratings
Application e.g.: Machine tools, CNC axles, packing machines, motors/drives, injection
moulding machines, sawing machines, textile machines
■ For EX version, see RX 70-l
Synchro flange
Clamping flange
NUMBER OF PULSES
RI 58-O
1 / 2 / 3 / 4 / 5 / 10 / 15 / 20 / 25 / 30 / 35 / 40 / 45 / 50 / 60 / 64 / 70 / 72 / 80 / 100 / 125 / 128 /
144 / 150 / 180 / 200 / 230 / 250 / 256 / 300 / 314 / 350 / 360 / 375 / 400 / 460 /
480 / 500 / 512 / 600 / 625 / 635 / 720 / 750 / 900 / 1000 / 1024 / 1200 / 1250 / 1500 /
1600 / 1800 / 2000 / 2048 / 2500 / 3000 / 3480 / 3600 / 3750 / 3968 / 4000 / 4096 / 4800 / 5000 /
5400 / 6000 / 7200 / 7680 / 8000 / 8192 / 9000 / 10000
Other number of pulses on request
Preferably available versions are printed in bold type.
RI 58-T
(high temperature) as above, but only for the range from 4 … 2500 pulses
Other number of pulses on request
TECHNICAL DATA
mechanical
Shaft diameter
Absolute max. shaft load
Absolute max. speed
Torque
Moment of inertia
Protection class (EN 60529)
Operating temperature
Storage temperature
Vibration resistance (IEC 68-2-6)
Shock resistance (IEC 68-2-27)
Connection
Housing
Flange
Weight
1
54
6 mm / 6.35 mm / 7 mm/
12 mm / 10 mm / 9.52 mm
Ø 12 mm
radial 80 N/axial 60 N
Ø 7…10 mm
radial 60 N/axial 40 N
Ø 6 mm / 6.35 mm
radial 40 N/axial 20 N
10 000 min-1
≤ 0.5 Ncm, ≤ 1 Ncm (IP67)
Synchro flange approx. 14 gcm2
Clamping flange approx. 20 gcm2
Housing IP65, bearings IP64
Housing IP67, bearings IP67
RI 58-O: –10 … +70 °C; RI 58-T: -25 … +100 °C
RI 58-O: –25 … +85 °C; RI 58-T: -25 … +100 °C
100 m/s2 (10 … 2 000 Hz)
1 000 m/s2 (6 ms)
1.5 m cable 1 or connector, axial oder radial
Aluminium Ø 58 mm
S = synchro flange, K = clamping flange,
G, Q = square flange, M = synchro clamping flange
approx. 360 g
Other cable length on request
ENCODERS
COUNTERS
INDICATORS
RELAYS
PRINTERS
CUTTERS
Incremental Shaft Encoders
Industrial types
TECHNICAL DATA
electrical
General design
Supply voltage
(SELV)
Max. current w/o load
Standard
output versions 2
2
Cable PVC
(A, B)
Colour
red
yellow/red
white
white/brown
green
green/brown
yellow
yellow/brown
black
yellow/black
screen 2
2
Cable TPE
(E, F)
Colour
brown/green
blue
brown
green
grey
pink
red
black
white/green
violet (white) 1
screen 3
1
2
3
ENCODERS
COUNTERS
Output
RS 422
(R, T)
DC 5 / 10 - 30 V
Sense VCC
Channel A
Channel A
Channel B
Channel B
Channel N
Channel N
GND
Alarm /Sense GND 1
screen 2
push-pull
(K)
DC 10 - 30 V
Channel A
Channel B
Channel N
GND
Alarm
screen 2
push-pull
complementary (I)
DC 10 - 30 V
Sense VCC
Channel A
Channel A
Channel B
Channel B
Channel N
Channel N
GND
Alarm
screen 2
depending on ordering code
connected with encoder housing
1
PIN ASSIGNMENT
Cable TPE
as per DIN VDE 0160, protection class III,
Contamination level 2, over voltage level II
with RS 422 + Sense (T): DC 5 V ± 10 %
with RS 422 + Alarm (R): DC 5 V ± 10 % oder DC 10 - 30 V 1
with push-pull (K, I):
DC 10 - 30 V 1
40 mA (DC 5 V), 60 mA (DC 10 V), 30 mA (DC 24 V)
RS 422 (R):
A, B, N, A , B , N , Alarm
RS 422 (T):
A, B, N, A , B , N , Sense
push-pull (K):
A, B, N, Alarm
push-pull complementary (I): A, B, N, A , B , N , Alarm
Pole protection with supply voltage DC 10 - 30 V
Output description and technical data see chapter “Technical basics”
1
PIN ASSIGNMENT
Cable PVC
Type RI 58
Solid shaft
INDICATORS
Output
RS 422
(R, T)
DC 5 / 10 - 30 V
Sense VCC
Channel A
Channel A
Channel B
Channel B
Channel N
Channel N
GND
Alarm /Sense GND 2
screen 3
push-pull
(K)
DC 10 - 30 V
Channel A
Channel B
Channel N
GND
Alarm
screen 3
push-pull
complementary (I)
DC 10 - 30 V
Sense VCC
Channel A
Channel A
Channel B
Channel B
Channel N
Channel N
GND
Alarm
screen 3
white with RS 422 + Sense (T)
depending on ordering code
connected with encoder housing
RELAYS
PRINTERS
CUTTERS
55
Incremental Shaft Encoders
Industrial types
CONNECTOR 12 POLE (CONIN)
Pin RS 422 +
Sense (T)
1 Channel B
2 Sense VCC
3 Channel N
4 Channel N
5 Channel A
6 Channel A
7 N.C.
8 Channel B
9 N.C. 1
10 GND
11 Sense GND
12 DC 5 V
1
CONNECTOR 10 POLE (MIL)
56
push-pull
(K)
N.C.
N.C.
Channel N
N.C.
Channel A
N.C.
Alarm
Channel B
N.C. 1
GND
N.C.
DC 10 - 30 V
push-pull
complementary (I)
Channel B
Sense VCC
Channel N
Channel N
Channel A
Channel A
Alarm
Channel B
N.C. 1
GND
N.C.
DC 10 - 30 V
Pin assignment
connector counter
clockwise (CCW)
connector
clockwise (cw)
screen for cable with CONIN connector
Pin
1/A
2/B
3/C
4/D
5/E
6/F
7/G
8/H
9/I
10/J
CONNECTOR 6 POLE
(BINDER)
RS 422 +
Alarm (R)
Channel B
Sense VCC
Channel N
Channel N
Channel A
Channel A
Alarm
Channel B
N.C. 1
GND
N.C.
DC 5/10 - 30 V
Type RI 58
Solid shaft
Description RS 422/Euro-pinout
(Connection codes O and K)
Channel A
Channel B
Channel N
DC 5/10 - 30 V
Alarm
GND
Channel A
Channel B
Channel N
screen
Description (push-pull)
DC 10 - 30 V
Channel A
Channel N
Channel B
Alarm
GND
ENCODERS
COUNTERS
push-pull
Channel A
Channel B
Channel N
DC 10 - 30 V
Alarm
GND
screen
N.C.
N.C.
screen
push-pull
complementary
Channel A
Channel B
Channel N
DC 10 - 30 V
Alarm
GND
Channel A
Channel B
Channel N
screen
Pin (Stifte)
1
2
3
4
5
6
INDICATORS
RELAYS
PRINTERS
CUTTERS
Incremental Shaft Encoders
Industrial types
Type RI 58
Solid shaft
DIMENSIONAL DRAWINGS
Synchro flange, 58 mm
Connecting cable, axial/radial
Dimensions in mm
Connector 12 pole, axial/radial
R for alternating bending > 100 mm
R for permanent bending > 40 mm
Clamping flange, 58 mm
Connecting cable, axial/radial
Connecting cable 12 pole, axial, radial
R for alternating bending > 100 mm
R for permanent bending > 40 mm
Dimensions in mm
DIMENSIONS
Typ
Connection
Output
Synchro flange,
58 mm
cable
connector
Clamping flange,
58 mm
cable
connector
ENCODERS
COUNTERS
INDICATORS
RELAYS
PRINTERS
R (with UB = DC 5 V), T, K, I
axial L1
mm
51.5
radial L2
mm
41.5
R (with UB = DC 10 - 30 V)
R (with UB = DC 5 V), T, K, I
R (with UB = DC 10 - 30 V)
R (with UB = DC 5 V), T, K, I
56
57.5
57.5
45.5
56
51.5
56
35.5
R (with UB = DC 10 - 30 V)
R (with UB = DC 5 V), T, K, I
R (with UB = DC 10 - 30 V)
50
51.5
51.5
50
45.5
50
CUTTERS
57
Incremental Shaft Encoders
Industrial types
Type RI 58
Solid shaft
DIMENSIONAL DRAWINGS
Synchro clamping flange,
63.5 mm (2.5”)
screw thread
MIL
6 ... 10 pole
Dimensions in mm
Square flange,
63.5 x 63.5 mm (2.5” x 2.5”)
Dimensions in mm
Square flange, 80 x 80 mm
R for alternating bending > 100 mm
R for permanent bending > 40 mm
58
*Dimensions in mm; L1, L2 see clamping flange
ENCODERS
COUNTERS
INDICATORS
RELAYS
PRINTERS
CUTTERS
Incremental Shaft Encoders
Guide for selection
Type RI 58
Solid shaft
STANDARD VERSIONS
RI 58 - O
Version
Number
of pulses
1 ... 10 000
Type of
flange **
Protection class
housing/
bearings
Shaft
K = clamping flange
Ø 58
S = synchro flange
Ø 58
M = syn.clamping fl.
Ø 63.5
Q = square flange
63.5 x 63.5
G = square flange
80 x 80
4 = IP65/64
7 = IP67/67
4 = IP65/64
7 = IP67/67
4 = IP65/64
7 = IP67/67
4 = IP65/64
7 = IP67/67
4 = IP65/64
3* = 7 mm
6 = 9.52 mm
2 = 10 mm
7* = 12 mm
1 = 6 mm
5 = 6.35 mm
6 = 9.52 mm
6 = 9.52 mm
2 = 10 mm
Supply
voltage
Output
Connection
A = DC 5 V
T = RS 422 + Sense
E = DC 10 - 30 V
R = RS 422 + Alarm
A = cable PVC, axial
B = cable PVC, radial
C = Conin, axial, cw
D = Conin, radial, cw
E = cable TPE, axial
F = cable TPE, radial
G = Conin, axial, ccw
H = Conin, radial, ccw
3 = 7 mm
I = push-pull
complementary
A = cable PVC, axial
B = cable PVC, radial
C = Conin, axial, cw
D = Conin, radial, cw
E = cable TPE, axial
F = cable TPE, radial
G = Conin, axial, ccw
H = Conin, radial, ccw
K* = MIL 10 pole, radial
O* = MIL 10 pole, axial
R = RS 422 + Alarm
A = cable PVC, axial
B = cable PVC, radial
C = Conin, axial, cw
D = Conin, radial, cw
E = cable TPE, axial
F = cable TPE, radial
G = Conin, axial, ccw
H = Conin, radial, ccw
K* = MIL 10 pole, radial
O* = MIL 10 pole, axial
K = push-pull
A = cable PVC, axial
B = cable PVC, radial
C = Conin, axial, cw
D = Conin, radial, cw
E = cable TPE, axial
F = cable TPE, radial
G = Conin, axial, ccw
H = Conin, radial, ccw
J = Binder 6 pole, radial
N = Binder 6 pole, axial
K* = MIL 10 pole, radial
O* = MIL 10 pole, axial
* not for IP67
** other flange versions can be realized by combination of clamping flange + flange adapter (see Accessories)
e.g. RI58 with synchro flange and 10 mm-shaft: version clamping flange with 10 mm-shaft + synchro flange adapter (1 522 328)
ENCODERS
COUNTERS
INDICATORS
RELAYS
PRINTERS
CUTTERS
59
Incremental Shaft Encoders
Guide for selection
Type RI 58
Solid shaft
STANDARD VERSIONS
100 °C max. operation temperature
RI 58 - T
Version
Number
of pulses
Type of
flange **
Protection class
housing/
bearings
Shaft
4 ... 2500
K = clamping flange
Ø 58
S = Synchro flange
Ø 58
M = Syn.clamping fl.
Ø 63.5
Q = square flange
63.5 x 63.5
G = square flange
80 x 80
4 = IP65/64
7 = IP67/67
4 = IP65/64
7 = IP67/67
4 = IP65/64
7 = IP67/67
4 = IP65/64
7 = IP67/67
4 = IP65/64
3* = 7 mm
6 = 9.52 mm
2 = 10 mm
7* = 12 mm
1 = 6 mm
5 = 6.35 mm
6 = 9.52 mm
6 = 9.52 mm
2 = 10 mm
Supply
voltage
Output
Connection
3 = 7 mm
A = DC 5 V
T = RS 422 + Alarm
E = DC 10 - 30 V
R = RS 422 +Sense
C = Conin, axial, cw
D = Conin, radial, cw
E = cable TPE, axial
F = cable TPE, radial
G = Conin, axial, ccw
H = Conin, radial, ccw
K* = MIL 10 pole, radial
O* = MIL 10 pole, axial
C = Conin, axial, cw
D = Conin, radial, cw
E = cable TPE, axial
F = cable TPE, radial
G = Conin, axial, ccw
H = Conin, radial, ccw
K = push-pull
C = Conin, axial, cw
D = Conin, radial, cw
E = cable TPE, axial
F = cable TPE, radial
G = Conin, axial, ccw
G = Conin, radial, ccw
J = Binder 6 pole, radial
N= Binder 6 pole, axial
K* = MIL 10 pole, radial
O* = MIL 10 pole, axial
* not for IP67
** other flange versions can be realized by combination of clamping flange + flange adapter (see Accessories)
e.g. RI58 with synchro flange and 10 mm-shaft: version clamping flange with 10 mm-shaft + synchro flange adapter (1 522 328)
Further versions on request
60
ENCODERS
COUNTERS
INDICATORS
RELAYS
PRINTERS
CUTTERS
Incremental Shaft Encoders
Industrial types
ORDERING INFORMATION
Please check „selection guide” on previous pages
as not all combinations are possible!
Number
of pulses
Supply
voltage
Type
Model
RI58-
O Standard RI58-O:
1 … 10 000
T High
temperature
RI58-T:
4 … 2 500
1
2
3
Type RI 58
Solid shaft
Flange, Protection 1, Shaft
2
Output
K.43 Clamping Ø58 , IP65/64, 7 mm
K.46 Clamping Ø58 , IP65/64, 9.52 mm
K.42 Clamping Ø58 , IP65/64, 10 mm
K.47 Clamping Ø58 , IP65/64, 12 mm
K.76 Clamping Ø58 , IP67/67, 9.52 mm
K.72 Clamping Ø58 , IP67/67, 10 mm
S.41 Synchro Ø58 , IP65/64, 6 mm
S.45 Synchro Ø58 , IP65/64, 6.35 mm
S.71 Synchro Ø58 , IP67/67, 6 mm
S.75 Synchro Ø58 , IP67/67, 6.35 mm
M.46 Syn.clamping Ø63.5, IP65/64, 9.52 mm
M.76 Syn.clamping Ø63.5, IP67/67, 9.52 mm
Q.46 Square 63.5 x 63.5, IP65/64, 9.52 mm
Q.42 Square 63.5 x 63.5, IP65/64, 10 mm
Q.76 Square 63.5 x 63.5, IP67/67, 9.52 mm
Q.72 Square 63.5 x 63.5, IP67/67, 10 mm
G.43 Square 80 x 80, IP67/67, 7 mm
A DC 5 V
E DC
10 - 30 V
(only with
push-pull)
T RS 422 + Sense
K push-pull, short
circuit proof
I push-pull
complementary
R RS 422 + Alarm
Connection
PVC cable, axial
PVC cable, radial
CONIN 3, axial, cw
CONIN 3, radial, cw
TPE cable, axial
TPE cable, radial
CONIN 3, axial, ccw
CONIN 3, radial, ccw
BINDER 3 , 6 pole,
radial
N BINDER 3 , 6 pole,
axial
O MIL MS 3 , 10 pole,
axial
K MIL MS 3 , 10 pole,
radial
A
B
C
D
E
F
G
H
J
Housing/ bearings
other flange versions can be realized by combination of clamping flange + flange adapter (see Accessories)
e.g. RI58 with synchro flange and 10 mm-shaft: version clamping flange with 10 mm-shaft + synchro flange adapter (1 522 328)
encoder connector with pins
ACCESSORIES
Clamping eccentric (set of three)
Ordering code 0 070 655
Spring washer coupling
hole 6/6 mm
Ordering code 3 520 081
hole 10/10 mm
Ordering code 3 520 088
Cable plug connector
for connector (CONIN),
cw (type of connection C, D)
Ordering code 3 539 202
for connector (CONIN),
ccw (type of connection G, H)
Ordering code 3 539 229
Mounting spanner
for CONIN connectors
Ordering code 3 539 343
Extension cables
(TPE)
12 pole plug (socket) on one end
clockwise (C,D)
counter clockwise (G,H)
Ordering code
Ordering code
L=3m
1 522 348
1 522 394
L=5m
1 522 349
1 522 395
L = 10 m
1 522 350
1 522 396
TPE cable (not made up with connectors) 3 280 112 + state requied length
For more detailed specifications and other accessories see chapter “Accessories”
ENCODERS
COUNTERS
INDICATORS
RELAYS
PRINTERS
CUTTERS
61
Application Notes
Vishay
Potentiometers and Trimmers
These application notes are valid unless otherwise specified in the data sheets
1. GENERAL DEFINITIONS
1.1 - Potentiometer
A potentiometer is a mechanically actuated variable resistor
with three terminals. Two of the terminals are linked to the
ends of the resistive element and the third is connected to a
mobile contact moving over the resistive track. The output
voltage becomes a function of the position of this contact.
Potentiometer is advised to be used as a voltage divider.
1.2 - Trimming potentiometer (trimmer)
A potentiometer designed for relatively
adjustments
TOTAL MECHANICAL ROTATION
ANGLE OF EFFECTIVE ROTATION
ANGLES OF
INEFECTIVE
ROTATION
infrequent
1.3 - Multi-ganged potentiometer
A potentiometer with two or more sections, each electrically
independent, operated by a common spindle.
a b c
(or 1) (or 2) (or 3)
END STOP
1.4 - Multi-turn potentiometer
A potentiometer with a shaft rotation of more than 360° from
one end of the resistive element to the other. Multi-turn types
are usually trimming or precision potentiometers.
1.5 - Sealed potentiometers
Two levels of sealing are usually recognized. The less
severe one provides protection only against dust and
cleaning processes (solvent splashes and vapors). For
definition of sealing, see table “Protection Levels” at the end
of these Application Notes. Hermetic sealing is more
rigorous and protects the product against environmental
pressure. (Not applicable for trimmers and potentiometers)
1.6 - Panel seal
This is used to seal the cut-out hole through which the
potentiometer is mounted.
1.7 - Spindle seal
One or more O-rings are used to seal the spindle/case joint.
2. MECHANICAL DEFINITIONS
2.1 - Mechanical travel
The full extent of travel between the end stops of the spindle
(Fig. 1). In potentiometers fitted with a slipping clutch, the
position of the end stops is defined as those points where the
clutch starts to slip at each end of the travel of the moving
contact.
2.2 - Actual electrical travel
The angle of rotation of the spindle throughout which the
resistance changes in the manner prescribed by the
specified resistance law. (Fig. 1)
2.3 - End stop torque
The maximum torque that may be applied to the spindle
when set against either end stop without causing any
damage.
www.vishay.com
2
END STOP
Fig. 1
2.4 - Operating torque
The necessary torque to move the contact in either direction
from a random position away from end stops.
2.5 - Locking torque
The torque that may be applied to the shaft of a
potentiometer fitted with a locking device without causing
shaft rotation.
2.6 - Rotational life
The minimum number of cycles of operations obtainable
under specified operating conditions while performance
parameters (e.g., resistance rotational noise, torque, etc.)
remain within specifications. A cycle is defined as the travel
of the moving contact from end to end of the resistance
element, and back.
2.7 - Direction of rotation
Rotation is defined as clockwise or counter-clockwise when
viewing the surface of the potentiometer which, includes the
means of actuation.
2.8 - Adjustment shaft
The mechanical input member of a potentiometer which,
when rotated, causes the wiper to travel the resistance
element resulting in a change in output voltage or resistance.
2.8.2 - Single-turn Adjustment
Requires 360° or less mechanical input to cause the
wiper to travel the total resistance element.
2.8.2 - Multi-turn Adjustment
Requires more than 360° mechanical input to cause
the wiper to travel the total resistance element.
For technical questions, contact: sfer@vishay.com
Document Number: 51001
Revision: 01-Aug-06
P-I Servoamplifier
G122-824-002
Application Notes
1 Scope
These Application Notes are a guide to applying the
G122-824-002 P-I Servoamplifier. These Application Notes
can be used to:
Cover
release
tab (4)
Top vents
25
26
27
28
29
30
31
32
17
18
19
20
21
22
23
24
Screw
terminals
17 - 32
Determine the closed loop structure for your application.
Select the G122-824-002 for your application. Refer also
to data sheet G122-824.
DIN rail
MOOG
Use these Application Notes to determine your system
configuration.
feedback
gain
inp.1
Install and commission your system.
2 Description
The G122-824-002 is a general purpose, user configurable,
P-I servoamplifier. Selector switches inside the amplifier enable
either proportional control, integral control, or both to be
selected. Many aspects of the amplifier’s characteristics can be
adjusted with front panel pots or selected with internal
switches. This enables one amplifier to be used in many
different applications. Refer also to data sheet G122-824.
enable
zero
Draw your wiring diagram.
Aspects, such as hydraulic design, actuator selection, feedback
transducer selection, performance estimation etc. are not
covered by this application note. The G122-202 Application
Notes (part no C31015) cover some of these aspects. Moog
Application Engineers can provide more detailed assistance,
if required.
valve
dither
Vs
in posn.
scale
P
gain
I
gain
bias
controller
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Bottom
vents
Screw
terminals
1 - 16
DIN rail
release
clip
Cooling
airflow
3 Installation
3.1 Placement
A horizontal DIN rail, mounted on the vertical rear surface
of an industrial steel enclosure, is the intended method of
mounting. The rail release clip of the G122-824-002 should
face down, so the front panel and terminal identifications
are readable and so the internal electronics receive a cooling
airflow.
An important consideration for the placement of the module is
electro magnetic interference (EMI) from other equipment in
the enclosure. For instance, VF and AC servo drives can
produce high levels of EMI. Always check the EMC compliance
of other equipment before placing the G122-824-002 close by.
3.2 Cooling
Vents in the top and bottom sides of the G122-824-002 case
provide cooling for the electronics inside. These vents should
be left clear. It is important to ensure that equipment below
does not produce hot exhaust air that heats up the G122-824.
Page 1 of 6: C31881 Rev F 01.06
5 Set-up adjustments
3.3 Wiring
The use of crimp “boot lace ferrules” is recommended for the
screw terminals. Allow sufficient cable length so the circuit
card can be withdrawn from its case with the wires still
connected. This enables switch changes on the circuit card
to be made while the card is still connected and operating.
An extra 100mm, for cables going outside the enclosure,
as well as wires connecting to adjacent DIN rail units,
is adequate.
The screw terminals will accommodate wire sizes from 0.2mm2
to 2.5mm2 (24AWG to 12AWG). One Amp rated, 0.2mm2
should be adequate for all applications.
Enclosure
Wires
Grounded EMI
cable gland
100mm Loop
To access the circuit card switches, the circuit card must be
withdrawn from the case. See paragraph 17.
Switch positions
Cable
ON
Radial screen
termination
shown in on position
shown in off position
Preferred Wiring
Enclosure
Cable
Cable gland
100mm Loop
Cable
Wire soldered
to screen
or
Drain wire.
(Heat shrink to
cover the screen)
Alternative Wiring
3.4 EMC
The G122-824-002 emits radiation well below the level called
for in its CE mark test. Therefore, no special precautions are
required for suppression of emissions. However, immunity from
external interfering radiation is dependent on careful wiring
techniques. The accepted method is to use screened cables for
all connections and to radially terminate the cable screens, in
an appropriate grounded cable gland, at the point of entry into
the industrial steel enclosure. If this is not possible, chassis
ground screw terminals are provided on the G122-824-002.
Exposed wires should be kept to a minimum length. Connect
the screens at both ends of the cable to chassis ground.
4 Power supply
24V DC nominal, 22 to 28V
75mA @ 24V without a load, 200mA @ 100mA load.
If an unregulated supply is used the bottom of the ripple
waveform is not to fall below 22V.
It is recommended that an M205, 250mA T (slow blow) fuse,
compliant to IEC127-2 sheet 3, be placed in series with the
+24V input to protect the electronic circuit.
Trimpots are all 15 turns.
Plug-in resistors are all “quarter watt” 1% metal film. Two
suitable types are Beyschlag MBB0207 and Roderstein
MK20207.
The amplifier is shipped in the following default state.
top board switches
SW 1
1 I lim
off
2 INT
off
3 PROP
on
4 5mA
off
5 10mA
off
6 20mA
off
7 30mA
off
8 50mA
on
SW 3
1 4-20mA
off
2 ±10V
on
3 4-20mA
off
4 4-20mA
off
SW 2
1 CMD LAG
off
2 Iin = E
on
3 Iin = P
off
4 V
off
5 V
off
6 V
off
7 I
on
8 I
on
bottom board switches
SW 1
1 spare
off
2 ENABLE
on
3 DITHER
off
4 4-20mA
on
Page 2 of 6: C31881 Rev F 01.06
R17:
R34:
R33:
R16:
100k (P gain range 1 to 20)
100k (input 2 to error amp)
not fitted (input 2 to output amp)
not fitted (feedback derivative)
Feedback gain and zero pots: configured for 4-20mA input
Dither level pot: fully counter clockwise (FCCW)
Scale pot: FCCW
P gain pot: FCCW
I gain pot: FCW (prior to S.N. M1084, was FCCW)
Note that FCW is min. I gain = longest integrator time.
Bias pot: 0V
Caution
If you intend to use the feedback amplifier adjusted for
4-20mA, don’t change the feedback gain or zero.
They are already adjusted for 4-20mA
To re-adjust for 4-20mA takes a little time, needs test
equipment and is tedious to do in the field.
6 Input configuration
All three inputs can be used for feedback or command.
Care needs to be taken in selecting signal polarity to achieve
negative feedback for the overall closed loop. Since the input
error amplifier sums the signals, the transducer feedback signal
needs to be the opposite polarity of the command. This can be
achieved in two ways:
Arrange for an opposite polarity feedback transducer signal
and connect it to input 1, input 2 or the positive feedback
amplifier input.
If the feedback transducer signal is the same polarity as the
command, you only have one option: Connect it to the
negative input of the feedback amplifier.
6.1 Feedback input
The feedback amplifier is the best choice for the feedback
signal, for five reasons:
It leaves input 1 available for command. See 6.2 below.
It has inverting (negative) and non-inverting (positive) inputs.
It has zero and gain adjustment pots. This enables a signal
that does not go to zero volts and has less span than the
command, to be scaled up to the command. While this is
not essential, it helps when setting up and trouble-shooting.
There is a front panel test point for the zeroed and amplified
signal. This is very convenient (essential) for setting up and
trouble-shooting.
There is the option of a plug-in resistor, R16, to give a
feedback derivative (lead or D) in the output of the feedback
amplifier.
Default
The feedback amplifier default set-up is 4-20mA flowing into
terminal 18 and out of terminal 17, producing an output of
0 to -10V. Reversing the terminals, and hence the current flow,
will not result in a 0 to +10V output. The feedback gain and
zero must be adjusted for this arrangement.
6.2 Input 1
Input 1 is well suited to be a command because of these two
features. If input 1 is used for feedback, be sure the lag is
switched off. Input resistance after the scale pot is 94k Ohms.
6.3 Input 2
This input is non-inverting. It is switch selectable between
4-20mA and ±10V. The 4-20mA converter produces 0 to +10V
for 4 to 20mA input. R34 connects from the output of the
converter to the input of the servo amp when 4-20mA is
selected. Plug-in input resistor R34, of 100k Ohms, gives a
nominal 0 to 10V input signal range when V rather than
4-20mA is selected. Input 2 is suitable for command or
feedback. R34 can be increased to give a larger input range.
7 Output configuration
Select the output to match the input requirements of the valve.
When voltage (V) is selected, ±10V is available into a minimum
load of 200 Ohm. When current (I) is selected, the current level
switches enable ±5 to ±100mA to be selected. The switch
selections sum, so, if for instance 45mA is required, select
30,10 and 5. The output can drive all known Moog valves up
to ±100mA. The maximum load at I (Amp) output is:
11V – 39 Ohm
RL max =
I (Amp)
eg. at 50mA RL max is 181 Ohm
The output amplifier is limited to approximately 105% of the
selected full scale output. If both the proportional and
integrator stages are saturated, the output will not be twice
the selected full scale but still only 105% of full scale.
(
)
8 Step push button
The step push button injects -50% valve drive disturbance
into the output. When released, the valve drive reverts to its
original level. This feature is useful for closed loop gain
optimisation.
9 P-I selection
For position closed loops, initially select only P. For pressure or
velocity loops select I initially and then P. See paragraph 12
below for more detail. For a complete discussion of P and I
control, see the G122-202 servoamplifier Application Notes
(part no C31015).
10 Integrator input
The servoamplifier has a unity gain input error amplifier
followed by two parallel stages, one a proportional amplifier
and the other an integrator. The outputs of these two stages
can be switched to the output power amplifier (see paragraph
7 above) which then drives the valve.
The input to the integrator stage can be switch selected from
either the output of the error amplifier, I in = E, or the output
of the proportional stage, I in = P. The latter arrangement is
used in the G122-202. It is beyond the scope of these
Application Notes to detail the benefits of each arrangement.
If you have experience with the G122-202, I in = P would
seem to be an easy choice.
This input is ±10V non-inverting and has two important
features:
It has a scale pot on its input that enables large inputs to be
scaled down to match smaller signals on other inputs. Scale
range is 10 to 100%. Set fully clockwise (FCW), an input of
100V can match a 10V signal on the other inputs.
It has a switch selectable lag of 55mS that can be used to
remove transients from the input signal that could cause
unwanted rapid movement in the output.
Page 3 of 6: C31881 Rev F 01.06
11 P only gain
16 In position
For position loops select only P control. Input a step
disturbance of 50% valve current with the step push button.
Adjust the P gain for the required stability, while monitoring
the front panel valve test point, or the feedback signal. The
gain range of the proportional amplifier can be moved by
changing the plug-in resistor R17. The value loaded when
shipped is 100k Ohms, which gives a 1 to 20 range. Selecting
200k Ohms will give 2 to 40. The circuit will function correctly
with the value of R17 between 100k Ohms and 10M Ohms.
When the valve drive signal falls below ±10% of the selected
full scale signal, the “in position” signal goes true and provides
an opto-isolated current path between the + and – terminals.
This can be connected to a PLC to initiate the next step in a
control sequence. Do not apply more than 40V to the +
terminal and ensure the load on the – terminal is less than
20mA.
Note that as P gain is increased, the movement due to the step
push button decreases.
17 Withdrawing the circuit card
from its case
12 P and I gains together
The circuit card needs to be withdrawn from its case to set the
selector switches and operate the step push button.
If you are inexperienced with integral control the following
set-up method is a good starting point.
I in = E: Initially select only I. Press the step push button.
Increase I gain until one overshoot in the feedback signal
is observed.
Next select P and I together and increase the P gain to reduce
the overshoot.
The “in position” signal is not relevant for a velocity loop.
To do this, push one tab (item 4) with a pen or screwdriver,
while gently pulling on the top cover on that side. The cover
will release approximately one mm. Repeat on the second tab
on that side. Repeat on the other side and then withdraw the
cover and circuit card until the required switches are exposed.
The rigidity of the connecting wires will hold the circuit card
in position while the switches are set.
For the I in = E arrangement the P and I sequence could be
reversed. i.e.: adjust P first, followed by I.
I in = P: For an I in = P arrangement, only the “P followed
by I” sequence of adjustment can be used.
For a more thorough discussion see G122-202 Application
Notes (part no C31015).
13 I limit
The contribution from the integrator to the output amplifier
can be reduced by selecting I limit on. When this switch is on
the integrator contribution is reduced to approximately 15% of
the level when it is off. This feature is useful in a position loop
that may require integral control to achieve the required steady
state accuracy. The limited integral control removes valve null
error when the final position is reached. It is also useful in a
pressure loop to limit overshoot, if the valve drive saturates.
14 Dither
The dither frequency is fixed at 200Hz and the level is
adjustable with the front panel pot to ±10% of valve drive,
regardless of the type and level of valve drive selected. Dither
is seldom needed in a position loop but can be beneficial in
pressure or velocity loops. Increase dither until it can just be
detected in the controlled variable, such as pressure or velocity.
Dither can compromise valve life, so it should be kept to
a minimum.
15 Enable
A relay on the circuit card needs to be energised to connect
the output stage to its screw terminal and to un-clamp the
integrator. The clamp prevents integrator wind-up when the
loop is not operating. Supply 24V to the appropriate terminal
to energise the relay. The enable switch on the circuit card can
be set to permanently energise the relay and provide a
permanent enable.
Page 4 of 6: C31881 Rev F 01.06
18 Specifications
19 Internet
Function:
Input 1:
www.moog.com/dinmodules
P, I, or P & I, switch selectable
Scaled to 95V max with switch
selectable lag of 55mS.
Input 2:
4-20mA 240R load, for 0 to +10V on R34.
Or 0 to ±10V direct onto R34.
R34 is plug-in, 100K nominal.
Feedback input:
Differential 4-20mA or ±10V, switch
selectable
±15V max.
R in 100k – ±10V
R in 240R – 4-20mA
Feedback amp:
Zero, ±10V.
Gain, 1 to 10.
Derivative (velocity) feedback via
plug-in resistor and fixed capacitor.
Transducer excitation: +10V @ 10mA max.
Error amp:
Unity gain.
Bias ±1.5V.
Proportional amp gain: 1 to 20.
Integrator gain:
1 to 45 per second.
Integrator input:
Switch selectable from output of unity
gain error amp or proportional gain amp
Enable:
Relay, +24V @ 8mA, 17 to 32V.
Output amp:
Switch selectable voltage or current, single
ended output, return to ground.
V. ±10V, minimum load = 200 Ohm
I. ±5, 10, 20, 30, 50mA to a maximum
of ±100mA
11V – 39 Ohm
max load =
I (Amp)
Step push button:
-50% valve drive disturbance.
Valve supply:
Pin 14, 300mA max.
In position:
±10% of valve drive. 20mA and 40V max
output to PLC.
Front panel
Vs, internal supply – green
indicators:
Valve drive positive – red
negative – green
Enable – yellow
In position – green
Front panel
Valve ±10V (regardless of output
test points:
signal selection)
Feedback amplifier output
signal 0V
Front panel
Input 1 scale
trimpots:
Error amp bias
(15 turns)
P gain
I gain
Dither level
Feedback amp gain
Feedback amp zero
Dither:
200 Hz fixed frequency.
±10% valve drive. Switch selectable on/off
Supply:
24V nominal, 22 to 28V
75mA @ 24V, no load,
200mA @ 100mA load
Wire size range:
0.2mm2 to 2.5mm2
(24AWG to 12AWG)
Recommended
M205, 250mA T (slow blow) fuse
supply protection:
compliant to IEC127-2 sheet 3
Mounting:
DIN rail
IP 20
Temperature:
0 to +40ºC
Dimensions:
100W x 108H x 45D
Weight:
180g
CE mark:
EN50081.1 emission
EN61000-6-2 immunity
C tick:
AS4251.1 emission
(
)
Page 5 of 6: C31881 Rev F 01.06
0V
+24V
see note 1
0Vref
Feedback Input
Typical
linear pot
feedback
4-20mA
100K
25
26
18 240R 100K
17
100K
4-20mA
V
+24V
gain
TP
feedback
100K
47K
zero
R33
N.F.
cmd lag
47K
Feedback Amp
100K
1K
10K
scale
240R
R34
100K
4-20mA
Converter
4-20mA
Power Supply
+
bias
+
R17
100K
in =E
dither
V
valve
LED
Av=10
TP
valve
39R
Output Amp
limit
V
on
+24V
enable
12
11
100R
+24V
-15V
+15V
13
8
7
6
5
15
14
28
32
30
10
4
3
In Position
Comparator
+24V
see note 1
see note 1
+
Note: 3. Switches shown in default shipping mode.
V
20R 50mA
33R 30mA
51R 20mA
100R 10mA
200R 5mA
V= 1V
P on
LED
enable
Note: 2. Connect spool (pin F) to terminal 7 if current,
to terminal 8 if voltage.
dither
on
Step P.B.
Dither
Oscillator
-50%
P gain
P Gain Amp
in =P
gain
Integrator
TP
Integrator input
select
-15V
+15V
feedback lead
2.2uF
R16
N.F.
Av=1
Error Amp
+
Vs LED
Additions to -001: input2 4-20mA option, step push button.
Note: 1. Connect cable screen to enclosure cable gland
or chassis ground terminal on G122-824-002.
+
27
20
0V
+10V
Transducer
Excitation
29
22
21
31
24
23
19
see note 1
see note 1
see note 1
9
2
1
+10V
0Vref
signal
Input 1
0Vref
signal
Input 2
250mA
T fuse
4-20mA
Supply
F
E
D
B
A
Connect to
pins 5 & 6.
mfb Valve
spool
see note 2
Typical D66X
Prop. valve
efb Valve
In position
+24V
Enable
+24V
PLC
20 Block-wiring diagram
Industrial Controls Division. Moog Inc., East Aurora, NY 14052-0018. Telephone: 716/652-3000. Fax: 716/655-1803. Toll Free 1-800-272-MOOG.
Moog GmbH. Germany. Telephone: 07031-622-0. Fax: 07031-622-100.
Moog Sarl. France. Telephone: 01 45 60 70 00. Fax: 01 45 60 70 01.
Moog Australia Pty. Ltd. Telephone: 03 9561 6044. Fax: 03 9562 0246.
Moog pursues a policy of continuous development and reserves the right to alter designs and specifications without prior notice. Information contained herein is for guidance only and does not form part of a contract.
~
Paulo Denmark: Birkerød England: Tewkesbury Finland: Espoo France: Rungis Germany: Böblingen, Dusseldorf Hong Kong: Shatin India: Bangalore
Australia: Melbourne, Sydney, Brisbane Austria: Vienna Brazil: Sao
Ireland: Ringaskiddy Italy: Malnate (VA) Japan: Hiratsuka Korea: Kwangju-Kun Philippines: Baguio City Singapore: Singapore Sweden: Askim USA: East Aurora (NY)
Page 6 of 6: C31881 Rev F 01.06
D631 Series
Servo Control Valves
ISO 4401 Size 05
GENERAL
SECTION
D
PAGE
MOOG SERVO- AND PROPORTIONAL CONTROL VALVES
General
2
Benefits and Function
3
General technical dates, Symbols
4
Electrical Connection
5
For over 50 years Moog has manufactured proportional control valves with integrated electronics. During this time more
than 200,000 valves have been delivered. These servo control
valves have been proven to provide reliable control including
injection and blow molding equipment, die casting machines,
presses, heavy industry equipment, paper and lumber processing and other applications.
Technical Data
7
D631 SERIES SERVO VALVE
Ordering Information
11
The servo control valves D631 Series are throttle valves for 3and preferably 4-way applications. According to the requirements of the application, the user can select either the standard version (P) or the high response version (H). The main features of the high response valves are short stroke related
improved dynamics and a more precise axis null cut.
DESCRIPTION
The proportional valves D631 Series consist of an electromechanical transformer (torque motor), a hydraulic amplifier
(nozzle/flapper principle), a spool in a bushing and a cantilever
feedback spring. The torque motor contains coils, pole pieces,
permanent magnets and an armature. The armature is connected to a flexible tube which allows a limited rotation of the
armature and at the same time seals the electromagnetic components against the hydraulic fluid.
The hydraulic amplifier is a full bridge arrangement with two
upstream fixed orifices and two downstream variable orifices
Valves available with intrinsically protection to EN 50.020 class
EEx ia IIc T6. Special data sheet on request.
NOTICE
Before installation of the valve into the system the complete
hydraulic system must be flushed.
Our quality management system conforms to DIN EN ISO 9001.
2
Moog • D631 Series
created by two nozzles and a flapper between them. The flapper is connected at its upper end to the centre of the armature and extends downward through the flexure tube to the
nozzles. A deflection of the flapper between the nozzles changes the size of the variable orifices in opposite sense.
The 4-way spool controls fluid flow from pressure port to one
of the load ports and also from the other load port to return.
Deflection of the feedback spring due to spool displacement
produces a torque which is fed back to the torquemotor.
BENEFITS AND FUNCTION
D
BENEFTITS OF SERVO VALVES
Operational features
2-stage version with dry torque motor
Low friction double nozzle pilot stage
High spool control forces
Mechanical feedback
Protection filter easy to replace
SERVO CONTROL VALVE OPERATING PRINCIPLE
An electrical current (command or input signal) is applied to
the coils of the torquemotor and produces depending on the
current polarity a clockwise or counter clockwise torque to the
armature. The thereby deflected nozzle flapper system creates
a pressure difference across the drive areas of the spool and
effects its movement. The feedback spring connected to the
armature engages with its lower end into a bore of the spool
and is thus deflected by spool displacement. The motion of the
spool stops when feedback torque and electromagnetic torque
are in equilibrium. Then the flapper is again in hydraulic centre position (approximately). Thus the position of the spool is
proportional to the electrical command signal.
Null adjust cover plug
D631 Series
two stage servo control valves
A
B
P
T
Torque motor
Locking screw
Centering spring
Hydraulical
amplifier
Spool
Bushing
Moog • D631 Series
3
GENERAL TECHNICAL DATA
SYMBOLS
D
PERFORMANCE SPECIFICATIONS FOR STANDARD MODELS
Pilot stage: regular version
with dropping orifice
Temperature range
Ambient
Fluid
Seal material
Operating fluid
4-WAY FUNCTION
up to 315 bar (4500 psi)
20% of pilot pressure,
max. 100 bar (1450 psi)
15 to 210 bar
(200 to 3000 psi)
25 to 315 bar
(350 to 4500 psi)
–20 °C to +80 °C
(-4 °F to +170 °F)
–20 °C to +80 °C
(-4 °F to +170 °F)
NBR, FPM,
others on request
Mineral oil based hydraulic
fluid (DIN 51524, part 1 to
3), other fluids on request
15 to 100 mm2/s (cSt)
Viscosity, recommended
System filtration
High pressure filter (without bypass, but with dirt alarm) mounted in the main flow and if possible directly upstream of the
valve.
Class of cleanliness
The cleanliness of the hydraulic fluid greatly effects the performance (spool positioning, high resolution) and wear (metering edges, pressure gain, leakage) of the valve.
Recommended cleanliness class
for normal operation:
ISO 4406:1999 < 19/16 /13
for longer life:
ISO 4406:1999 < 17/14 /11
Filter rating recommended
for normal operation:
ß15 ≥ 75 (15 µm absolute)
for longer life:
ß10 ≥ 75 (10 µm absolute)
Installation options
any position,
fixed or movable
Vibration
30 g (0.7 Ibs), 3 axes
Mass
2.2 kg (4.9 Ibs)
Degree of protection
EN 60529: class IP 65, with
mating connector mounted
Shipping plate
Delivered with an oil sealed
shipping plate
4
Moog • D631 Series
A
B
P
T
M707
Operating pressure range
Main stage:
ports P, A and B
port T
4-way version
optional X external
Flow control (throttle valve) in port A and port B
For 3-way fuction close port A or port B of the manifold
Spools with exact axis cut, 1.5 to 3% or 10% overlap
available
VALVE FLOW CALCULATIONS
D
The actual flow depends on the electrical command signal and
the valve pressure drop, and may be calculated using the square root function for a sharp-edged orifice.
Flow rate Q / l/min
VALVE FLOW CALCULATIONS
100
80
pm)
.9 g
7
(
n
)
/mi
gpm
30 l
(6.3
n
i
/m
)
24 l
gpm
(4.2
n
i
m
/
16 l
50
30
Q / l/min
QN / l/min
∆p / bar
∆pN / bar
=
=
=
=
calculated flow
rated flow
actual valve pressure drop
rated valve pressure drop
If large flow rates with high valve pressure drops are required,
an appropriate higher pilot pressure has to be chosen to overcome the flow forces. An approximate value can be calculated
as follows:
20
15
pm)
.1 g
(2
/min
8l
10
8
pm)
.1 g
(1
/min
4l
5
pm)
.5 g
3
2
n (0
l/mi
2
1,5
Q / l/min
∆p / bar
AK / cm2
pX / bar
=
=
=
=
max. flow
valve pressure drop with Q
spool drive area
pilot pressure
1
5
10
20
30
50
70
100
Valve pressure drop ∆p / bar
The pilot pressure pX has to be at least 15 bar (200 psi), with
throttle valve 25 bar (350 psi) above the return pressure of the
pilot stage.
Moog • D631 Series
5
ELECTRICAL CONNECTION
D
ELECTRICAL CONNECTION WITH 4-POLE CONNECTOR TO MIL C5015/14S-2
The torque motor has 2 coils. The leads of the coils are single
connected to the pins. For operation in parallel, series or single
coil mode the corresponding wiring must be done in the mating
connector.
Optional two types of coils are available:
Coil R with 28 Ω per coil
Coil Q with 300 Ω per coil
Connector
Mil C5015/14S-2
Parallel wiring
A
Coil type
Input resistance (at 25°C)1) / Ω
Rated current / mA
Inductance (at 60 Hz) / H
Electrical power / W
Connections for valve
opening P B, A T
Series wiring
BC
R
14
± 100
0.2
0.14
D
A
Q
150
± 30
1.8
0.14
R
56
± 50
0.8
0.14
A and C (+)
B and D (–)
The torque motor has 2 coils. The coils are connected in parallel inside the valve.
Two types of coils are available:
Coil R with 28 Ω
Coil Q with 300 Ω
Parallel wiring
1
Coil type
Input resistance (at 25°C)1) / Ω
Rated current / mA
Inductance (at 60 Hz) / H
Electrical power / W
Connections for valve
opening P B, A T
1)
6
65 °F
Moog • D631 Series
R
14
± 100
0.2
0.14
D
A
Q
600
± 15
7.0
0.14
R
28
± 100
0.25
0.28
A (+), D (–)
B and C connected
ELECTRICAL CONNECTION WITH CONNECTOR TO DIN 43650
Connector
DIN 43650
BC
Single coils
2
3
Q
150
± 30
1.8
0.14
1 (+) and 3 (–)
BC
D
Q
300
± 30
2.0
0.27
A (+), B (–)
or C (+), D (–)
TECHNICAL DATA
D
PERFORMANCE SPECIFICATIONS FOR STANDARD MODELS
Model ... Type
D631-... P...
Mounting pattern
Valve body version
Pilot stage
Pilot connection
Rated flow (± 10%)
ISO 4401-05-05-0-94
4-way, 2-stage with bushing-spool assembly
Standard
Highresponse
X
X
2 / 4 / 8 / 16 / 24 / 30
0.5 / 1.1 / 2.1 / 4.2 / 6.3 / 7.9
25
13
<1
<1
<5
<3
<5
<4
< 2.5 to 4.2 (0.7 to 1.1)
< 2.5 to 4.2 (0.7 to 1.1)
1.4 (0.4)
1.7 (0.5)
depending on hydraulic bridge 0.5 to 1 (0.1 to 0.3)
± 2.54 (0.1)
± 1.3 (0.05)
0.75 (0.3)
0.75 (0.3)
Nozzle / flapper
optional, internal or external
at ∆pN= 5 bar per land
at ∆pN= 73 psi per land
Response time1)
Threshold1)
Hysteresis1)
Null shift
Null leakage flow1)
Pilot leakage flow1)
Pilot flow1) max.,
Spool stroke
Spool drive area
1)
without dither
at ∆T = 55 K
total, max.
Tare
for 100% step input
l/min
gpm
ms
%
%
%
l/min (gpm)
l/min (gpm)
l/min (gpm)
mm (inch)
cm2 (inch2)
D631-... H...
measured at 210 bar (3045 psi) pilot or operating pressure, respectively, fluid viscosity of 32 mm2/s (0.05 in2/s)
and fluid temperature of 40 °C (104 °F)
Moog • D631 Series
7
TECHNICAL DATA
D
Step response standard valve
Step response high response valve
Spool stroke / %
Spool stroke / %
TYPICAL CHARACTERISTIC CURVES MEASURED WITHOUT DROPPING ORIFICE
measured at 210 bar (3045 psi) pilot or operating pressure, respectively,
fluid viscosity of 32 mm2/s (0.05 in2/s) and fluid temperature of 40 °C (104 °F)
100
1)
210 bar
140 bar 2)
75
70 bar 3)
100
70 bar 3)
50
25
25
0
10
20
30
40
50
Time / ms
0
Frequency response standard valve
Amplitude ratio / dB
0
-2
-6
-8
-90
-70
±100%
-50
-30
-10
1
2
3 4 5
1)
210 bar = 3045 psi
140 bar = 2030 psi
3)
70 bar = 1015 psi
2)
Moog • D631 Series
10
20 30 50
Frequency / Hz
Phasne lag / degrees
-110
±25%
20
30
Time / ms
Frequency response high response valve
+2
-4
10
+2
0
-2
-4
-110
±25%
-6
-90
±100%
-8
-70
-50
-30
-10
1
2
3 4 5
10
20 30 50
Frequency / Hz
Phase lag / degrees
0
Amplitude ratio / dB
140 bar 2)
75
50
0
8
210 bar1)
TECHNICAL DATA
D
INSTALLATION DRAWING
Extension connector
Mil C5015/14S-2
Extension space
20 (0.8)
A
B
107 (4.2)
C
Ø11 (0.7) (4x)
Ø6.5 (0.3)
Name plate
1.5 (0.06)
1.5 (0.06)
98 (3.9)
Filter element
58 (2.3)
D
120 (4.7)
Two-way connector
128 (5.1)
Mechanical null adjustment
(under locking screw)
Ø15.7 (0.6)
3 (0.1)
70 (2.8)
77.5 (3.1)
Ø11.7 (0.5)
Locking screw for
control oil internal
or external
M 4 x 6 DIN EN ISO 4788
with seal ring
ID 4.5 / AD 7
62 2.5)
136 (5.4)
Extension connector DIN 43650
100 (4.0)
10.6 (0.4)
23 (0.9)
75 3.0)
13 (0.5)
19 (0.8)
fill assembly area
131 (5.2)
9.9 (0.4)
O-seal cut-in
in valve body
Mechanical override manually operated
(special design)
102 (4.0)
(optional)
Mounting pattern
ISO 4401-05-05-0-94, without X-Connection
mm
inch
P
A
B
T
X1)
F1
Ø11.5 Ø11.5 Ø11.5 Ø11.5 Ø 6.3 M6
F2
M6
F3
M6
1)
F4
M6
P
A
B
T
X
F1
Ø0.45 Ø0.45 Ø0.45 Ø0.45 Ø0.25 M6
x
27
16.7
37.3
3.2
-9
0
54
54
0
x
1.07
0.66
1.47 0.13 -0.36
0
y
6.3
21.4
21.4 32.5
6.3
0
0
46
46
y
0.25
0.85
0.85 1.28 0.25
0
F2
M6
F3
M6
2.13 2.13
0
F4
M6
0
1.82 1.82
The mounting manifold must conform to
ISO 4401-05-05-0-94 1).
1)
Note: Location of X port in valve body does not correspond
to ISO standards.
Mounting surface needs to be flat within 0.02 mm (0.0008 inch).
Average surface finish value, Ra, better than 0.8 µm.
Moog • D631 Series
9
TECHNICAL DATA
D
SPARE PARTS AND ACCESSORIES
O-rings (included in delivery)
for P, T, T2, A, B
for X
1)
ID 12 x Ø 2 (ID 0.47 x Ø 0.08)
ID 8 x Ø 2 (ID 0.31 x Ø 0.08)
NBR 85 Shore
-66117-012-020
-66117-008-020
Mating connector, waterproof IP 65 (not included in delivery)
4-pole Mil C50515/14S-2S
for cable dia
min. Ø 6,5 mm, max. Ø 9,5 mm
min. Ø 0.25 in, max. Ø 0.37 in
Flushing plate
for P, A, B, T, T2, X, Y
B67728-001
for P, T, T2, X, Y
B67728-002
Mounting manifolds
see special data sheet
Mounting bolts (not included in delivery)
M 6 x 70 DIN EN ISO 4762-10.9 4 pieces
Replaceable filter
required torque 13 Nm (115 Ib in)
100 µm nominal
A03665-060-070
A67999 100 1)
O-rings for filter replacement
for filter
for filter cover
Screw plug port X
Seal for screw plug
ID 13 x Ø 1,5 (ID 0.51 x Ø 0.06)
ID 17 x Ø 2 (ID 0.67 x Ø 0.08)
M 4 x 6 DIN EN ISO 4762-8.8
ID 4,5 / AD 7 (ID 0.18 / AD 0.28)
NBR 85 Shore
-66117-013-015
-66117-017-020
-66098-040-006
A25528-040
For standard models, others on request
10
5 pieces
1 piece
Moog • D631 Series
1 piece
1 piece
1 piece
1 piece
FPM 85 Shore
A25163-012-020
A25163-008-020
B46744-004
for P, T, T2, und X, Y
B67728-003
FPM 85 Shore
A25163-013-015
A25163-017-020
ORDERING INFORMATION
D
ORDERING INFORMATION
Model number
D631 . . . . . .
Type designation
. . . . . . . . . . . .
Special equipment
no
M Mechanical override
Specification status
–
E
Z
K
Series specification
Preseries specification
Special specification
Intrinsically safe valve
Signals for 100% spool stroke
Command
for rated flow QN
Q ±15 mA Series
± 22,5 mA Series
R ± 50 mA Series
± 75 mA Series
Y others on request
Model designation
assigned at the factory
Factory identification
Valve Typ P
05 to 80
–
05 to 80
–
Valve Typ H
05 to 60
80
05 to 60
80
assigned at the factory
Valve connector
Valve version
B Mil C5015/14S-2P
G DIN 43650
P Standard valve
H High response valve
Seal material
Rated flow
∆pN = 5 bar per land
(∆pN = 73 psi per land)
05
10
20
40
60
80
N NBR (Buna)
V FPM (Viton)
X others on request
QN / l/min bei ∆pN = 35 bar
(QN / gpm at ∆pN = 500 psi)
2 (0.5)
4 (1.1)
8 (2.1)
16 (4.2)
24 (6.3)
30 (7.9)
5 (1.3)
10 (2.6)
20 (5.3)
40 (10.6)
60 (15.8)
75 (19.8)
Pilot connections and pressure
A
C
E
G
210 bar
J 315 bar
internal supply
external supply
internal supply
external supply
Spool position without electrical signal P1)
Maximum operating pressure
F
15 to 210 bar (217 to 3045 psi)
15 to 210 bar (217 to 3045 psi)
25 to 315 bar (363 to 4565 psi)
25 to 315 bar (363 to 4565 psi)
At pX ≤ 210 bar (3045 psi) (X external) operating pressure
A P ➧ B, A ➧ T
B P ➧ A, B ➧ T
M Mid position
in port P, A and B up to 315 bar possible 315 bar (4566 psi)
(with dropping orifice)
Bushing spool type
Pilot stage
0 Axis cut, linear characteristic
D ± 10% overlap, linear characteristic
X others on request
F Standard response for valve version "P"
G Highresponse for valve version "H"
1)
Control pressure
Preferred configurations are highlighted.
All combinations may not be available.
Options may increase price.
Technical changes are reserved.
Moog • D631 Series
11
Moog GmbH
Hanns-Klemm-Straße 28
71034 Böblingen
email: sales@moog.de
www.moog.de
Telefon (0 70 31) 622-0
Telefax (0 70 31) 622-191
D631.en.09.02
Ksis / Wacker / 1000
Ireland
Italy
Japan
Korea
Luxembourg
Norway
Philippines
Russia
Singapore
Spain
Sweden
United Kingdom
USA
Änderungen vorbehalten
Argentina
Australia
Austria
Brazil
China
Finland
France
Germany
India
CompactRIO
Features
Contents
Overview ....................................................................................366
Configuration Guide....................................................................371
Reconfigurable Embedded Systems
NEW! Real-Time Controllers....................................................372
NEW! Reconfigurable Chassis ..................................................373
R Series Expansion Systems
NEW! R Series Expansion Chassis............................................374
Input/Output Modules
NEW! Analog Input ..................................................................375
NEW! Analog Output................................................................376
NEW! Digital Input ..................................................................377
NEW! Digital Output ................................................................378
Typical System Specifications ..................................................379
Accessories................................................................................380
Ordering Information ..................................................................381
CompactRIO
Contents and Overview
Overview
National Instruments CompactRIO is an advanced reconfigurable
embedded control and acquisition system powered by NI RIO
technology for ultrahigh performance, user customization, and
reconfigurability. It is designed to perform in the harshest
industrial environments.
11
Figure 1. CompactRIO Architecture
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366
• Small, rugged, industrial control and acquisition system
• Powered by reconfigurable I/O (RIO) FPGA technology
for ultrahigh performance and customization
• Low-cost architecture with open access to low-level
hardware resources
• High-productivity LabVIEW graphical programming
tools for rapid development
• Real-time processor and reconfigurable FPGA for reliable
stand-alone embedded or distributed applications
• Hot-swappable industrial I/O modules with built-in signal
conditioning for direct connection to sensors and actuators
• Design your own custom control or acquisition circuitry
in silicon with 25 ns timing/triggering resolution
• NI CompactRIO Extreme Industrial Certifications
and Ratings
• -40 to 70 °C (-40 to 158 °F) operating temperature
• Up to 2,300 Vrms isolation (withstand)
• 50 g shock rating
• International safety, EMC, and environmental certifications
• Class I, Division 2 rating for hazardous locations
• Dual 11-30 VDC supply inputs, low power
For ordering information, see page 381.
CompactRIO Overview
With NI CompactRIO, you can rapidly build embedded control or
acquisition systems that rival the performance and optimization of
custom-designed hardware circuitry. Now LabVIEW programmers
can take advantage of reconfigurable FPGA technology to
automatically synthesize a highly optimized electrical circuit
implementation of their input/output, communication, or control
applications. Field-programmable gate array (FPGA) devices are
widely used by control and acquisition system vendors for their
performance, reconfigurability, small size, and low engineering
development costs. FPGA-based devices were traditionally vendor
defined rather than user defined because of the complexity of the
electronic design tools. Now you can take advantage of userprogrammable FPGAs to create highly optimized reconfigurable
control and acquisition systems with no knowledge of specialized
hardware design languages such as VHDL.
drive, differential/TTL digital inputs with 5 V regulated supply
output for encoders, and 250 Vrms universal digital inputs. Because
the modules contain built-in signal conditioning for extended
voltage ranges or industrial signal types, you can usually make your
wiring connections directly from the CompactRIO module to your
sensors/actuators. Visit ni.com/compactrio for the latest information
on module availability.
Real-Time Processor
The CompactRIO embedded system features an industrial 200 MHz
Pentium class processor that reliably and deterministically executes
your LabVIEW Real-Time applications. Choose from thousands of
built-in LabVIEW functions to build your multithreaded embedded
system for real-time control, analysis, data logging, and
communication. The controller also features a 10/100 Mb/s Ethernet
port for programmatic communication over the network (including
email) and built in Web (HTTP) and file (FTP) servers. Using the
remote panel Web server, you can automatically publish the frontpanel graphical user interface of your embedded application for
multiclient remote monitoring or control. The real-time processor
also features dual 11 to 30 VDC supply inputs, a user DIP switch,
LED status indicators, a real-time clock, watchdog timers, and other
high-reliability features.
CompactRIO
Overview
Low-Cost Open Architecture
CompactRIO combines a low power consumption real-time
embedded processor with a high-performance RIO FPGA chipset.
The RIO core has built-in data transfer mechanisms to pass data to
the embedded processor for real-time analysis, postprocessing, data
logging, or communication to a networked host computer.
CompactRIO provides direct hardware access to the input/output
circuitry of each I/O module using LabVIEW FPGA elemental I/O
functions. Each I/O module includes built-in connectivity, signal
conditioning, conversion circuitry (ADC or DAC), and an optional
isolation barrier. This represents a low-cost architecture with open
access to low-level hardware resources.
I/O Modules
Each CompactRIO I/O module contains built-in signal conditioning
and screw terminal, BNC, or D-Sub connectors. By integrating the
connector junction box into the
modules, the CompactRIO system
significantly reduces the space
requirements and cost of field wiring. A
variety of I/O types are available
including ±80 mV thermocouple inputs,
±10 V simultaneous sampling analog
inputs/outputs, 24 V industrial digital I/O with up to 1 A of current
Source: XILINX
11
Performance
Using the LabVIEW FPGA Module and reconfigurable hardware
technology, you can create ultrahigh performance control and
acquisition systems with CompactRIO. The FPGA circuitry is a
parallel processing reconfigurable computing engine that executes
your LabVIEW application in silicon circuitry on a chip. The
LabVIEW FPGA Module features built-in functions for analog
closed-loop PID control, fifth-order FIR filters, 1D look-up tables,
linear interpolation, zero crossing detection, and direct digital
synthesis of sine waves. Using the embedded RIO FPGA hardware,
you can implement multiloop analog PID control systems at loop
rates exceeding 100 kS/s. Digital control systems can be implemented
at loop rates up to 1 MS/s. Multiple rungs of Boolean logic can be
evaluated using single-cycle while loops at 40 MHz (25 ns). Because
of the parallel nature of the RIO core, adding additional
computation does not necessarily reduce the speed of the FPGA
application. CompactRIO offers 4 and 8-slot chassis with options for
FPGA chips with either 1 million or 3 million gates.
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367
CompactRIO Overview
Size and Weight
CompactRIO is designed for applications in harsh environments
and small places. Size, weight, and I/O channel density are critical
design requirements in many such embedded applications.
By taking advantage of the
extreme performance, small
size, and lower power
consumption of FPGA devices,
CompactRIO is able to deliver
unprecedented control and
acquisition capabilities in a compact, rugged package.
A 4-slot embedded system measures 179.6 by 88.1 by 88.1 mm
(7.07 by 3.47 by 3.47 in.) and weighs just 1.58 kg (3.47 lb). An 8-slot
system filled with 32-channel I/O modules delivers a mass channel
density of 9.7 g/ch (0.34 oz/ch), and a volumetric channel density of
8.2 cm3/ch (0.50 in.3/ch).
Key Developer Tools
The LabVIEW development environment, including the LabVIEW
FPGA Module and LabVIEW Real-Time Module, provides an array
of tools and technologies to accelerate the development of reliable
reconfigurable embedded systems.
CompactRIO
Overview
NI CompactRIO Extreme Industrial
Certifications and Ratings
CompactRIO is a reconfigurable embedded system that combines
reliable stand-alone embedded capability with extreme industrial
certifications and ratings for operation in harsh industrial
environments. CompactRIO is rated for a -40 to 70 °C (-40 to 158 °F)
temperature range, 50 g shock, and hazardous locations or
potentially explosive environments (Class I, Div 2). Most I/O
modules feature up to 2,300 Vrms isolation (withstand), and 250 Vrms
isolation (continuous). Each component comes with a variety of
international safety, electromagnetic compatibility (EMC), and
environmental certifications and ratings.
Host Interface
FPGA Application
Embedded Project Manager
• FPGA hardware target configuration and automatic
module discovery
• CompactRIO module and I/O channel alias name management
• FPGA application flash memory download and
autoload configuration
11
Hazardous Locations
Description
Electromagnetic Compatibility
(EMC)
Product Safety
Hazardous Locations,
Class I, Division 2
Shock and Vibration
Mean Time Before Failure
(MTBF)
(pending)
Standard
89/336/EEC
EN 55011 Class A at 10 m
FCC Part 15A above 1 GHz
Industrial levels per EN 61326-1:1997
+ A2:2001, Table A.1
CE, C-Tick, and FCC Part 15 (Class A) Compliant
73/23/EEC
EN 61010-1, IEC 61010-1
UL 61010-1
CAN/CSA C22.2 No. 61010-1
Class I, Division 2, Groups A, B, C, D, T4;
Class I, Zone 2, AEx nC IIC T4,
EEx nC IIC T4
IEC 60068-2-64, IEC 60068-2-27,IEC 60068-2-6
Bellcore Issue 6, Method 1, Case 3
MIL-HDBK-217F
Typical Certifications – Actual specifications vary from product to product.
Visit ni.com/certification for details.
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368
LabVIEW FPGA Development Environment
• FPGA device I/O for analog input/output, digital input/output,
and I/O property nodes/methods
• Interrupt request (IRQ) generation and synchronization functions
• 40 MHz single-cycle timed loop for LabVIEW code execution
in 25 ns timing interval
• Parallel processing with while loop, sequence, case, for loop,
and other execution control structures
• FPGA FIFO data buffering and memory read/write
• Boolean logic, comparison, numeric math, saturation arithmetic
functions, and bitwise data manipulation functions
CompactRIO Overview
• HDL interface node for integration of non-LabVIEW IP cores
• Nonlinear system and discrete linear control functions
including PID and fifth-order FIR filter
• 1D look-up table, linear interpolation, zero-crossing detection,
and direct digital synthesis sine generator
LabVIEW Real-Time Development Environment
• Web browser remote panel graphical user interface plug-in for
remote control/monitoring (Windows, Linux, Mac OS X, Solaris)
• Express spectral signal analysis, distortion/tone, amplitude/level,
timing/transition, convolution/correlation, mask/limit,
histogram functions
• Local or remote database connectivity, text/HTML/DIAdem
report generation
• Handheld mobile/portable PDA user interface/
remote control (LabVIEW PDA Module)
The CompactRIO Platform is available in
two configurations:
CompactRIO Embedded System
In this configuration, CompactRIO is a complete reconfigurable
embedded system for rugged stand-alone or networked control and
acquisition applications. The reconfigurable embedded system consists
of a real-time controller, a reconfigurable chassis containing the userprogrammable RIO FPGA, and a variety of hot-swappable industrial
I/O modules.
CompactRIO
Overview
• Target configuration options including start-up application
execution settings and development, Web, remote panel,
and file server access
• Open FPGA VI Reference function for programmatic
bit-stream download, communication interface reference,
and application start
• Deterministic real-time while loop thread synchronization
with FPGA-generated IRQ
• FPGA front panel control/indicator read/write for data transfer
• Data scaling/mapping functions for integer to floating-point
engineering units conversion
• Real-Time FIFO data buffering for multithread communication
• Timed-loop structure for multirate deterministic control
• Floating-point PID, set-point profiling, gain scheduling,
and rate limiter functions
• Point-by-point signal generation, time-domain analysis,
frequency-domain transforms and spectrum analysis, filters,
statistics, curve fitting/interpolation, linear algebra,
array/vector operations
• SMTP E-mail, TCP/IP, UDP, IrDA, DataSocket, and VISA
RS232 serial programmatic server/client communication
(including 802.11 wireless Ethernet)
• Binary and text file I/O for embedded data logging and retrieval
LabVIEW Networked Host Application Development
11
HALO Productions Photographer -– Douglas J. Nesbit
Application Modules and Toolkits
• LabVIEW PDA Module, LabVIEW Enterprise Connectivity
Toolkit, LabVIEW Remote Panel License
• LabVIEW Execution Trace Toolkit
• LabVIEW Order Analysis Toolkit, LabVIEW Sound and
Vibration Toolkit, LabVIEW Signal Processing Toolkit
• LabVIEW Simulation Module, LabVIEW Control Design Toolkit,
LabVIEW System Identification Toolkit, LabVIEW Simulation
Interface Toolkit, LabVIEW State Diagram Toolkit
• NI SoftMotion Development Module for LabVIEW
CompactRIO R Series Expansion System
In this configuration, a CompactRIO expansion chassis connects to
the digital port on a PCI or PXI R Series FPGA device. The R Series
device can be installed in any desktop PC, industrial PC (IPC), or
ruggedized PXI/CompactPCI computer system running Windows or
one of the LabVIEW Real-Time OSs. The RIO FPGA resides on the
R Series device while CompactRIO converts a digital port on the
R Series device into a high-performance expansion I/O and signal
conditioning system.
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369
CompactRIO Overview
HALO Productions Freefall Cameraman – Joao Tambor
CompactRIO
Overview
Application Examples
11
Photo courtesy of NASA
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Due to its low cost, reliability, and suitability for high-volume
embedded measurement and control applications, CompactRIO can
be adapted to solve the needs of a wide variety of industries and
applications. Examples include heavy industrial machine control,
in-vehicle data acquisition, machine condition monitoring, and
rapid control prototyping (RCP):
• Batch control
• Discrete control
• Motion control
• In-vehicle data acquisition
• Machine condition monitoring
• Rapid control prototyping (RCP)
• Industrial data acquisition
• Distributed data acquisition and control
• Mobile/portable noise, vibration, and harshness
(NVH) analysis
CompactRIO
Configuration Guide
Build your CompactRIO reconfigurable control and acquisition
system in three easy steps:
Step 1. Choose your CompactRIO real-time embedded controller, PXI controller, or industrial PC.
Type of Controller
Standard real-time
Premium real-time
Windows PXI
Windows PCI
PCI real-time (ETS)
Reconfigurable Embedded System
cRIO-9002 embedded controller, 64 MB storage
cRIO-9004 embedded controller, 512 MB storage
R Series Expansion System
PXI-8145 RT, PXI-1031 (real-time PXI)
PXI-8186 RT, PXI-1031 (real-time PXI)
NI PXI-8186, PXI-1031
Any desktop or industrial PC
Certified desktop PC (Dell Optiplex, model GX270)
or industrial PC
Step 2. Select a reconfigurable chassis or R Series device and expansion chassis.
Type of Chassis
Standard real-time
Premium real-time
Reconfigurable Embedded System
cRIO-9101 4-slot 1 M gate RIO chassis
cRIO-9102 8-slot 1 M gate RIO chassis
cRIO-9103 4-slot 3 M gate RIO chassis
cRIO-9104 8-slot 3 M gate RIO chassis
R Series Expansion System
PXI-7831R or PXI-7811R, and
cRIO-9151 expansion chassis
PXI-7831R or PXI-7811R, and
cRIO-9151 expansion chassis
PXI-7831R or PXI-7811R and
cRIO-9151 expansion chassis
PCI-7831R and
cRIO-9151 expansion chassis
PCI-7831R and
cRIO-9151 expansion chassis
Windows PXI
Windows PCI
PCI real-time (ETS)
Type of Signal
Analog Input
Signal
Thermocouple
IEPE2 (±5 V)
Small voltage (±80 mV)
Medium voltage (±10 V)
Analog Output
Digital Input
High voltage (±60 V)
Medium voltage (±10 V)
24 V sinking
Digital Output
250 AC/DC universal
Differential or TTL
24 V sourcing
Relay Output
Counter, Pulse
Form A (SPST)
Counter/timer (24 V)
Counter/timer (TTL)
Quadrature encoder (differential)
PWM
Module
cRIO-9211
cRIO-9233
cRIO-9211
cRIO-9215
cRIO-9201
cRIO-9221
cRIO-9263
cRIO-9421
cRIO-9423
cRIO-9435
cRIO-9411
cRIO-9472
cRIO-9474
cRIO-9481
cRIO-9423
cRIO-9411
cRIO-9411
cRIO-9474
Channels
4
4
4
4
8
8
4
8
8
4
6
8
8
4
8
6
6
8
Special Features1
24-bit delta-sigma, 15 S/s, differential (J, K, R, S, T, N, E, and B thermocouple types)
24-bit delta-sigma, 50 kS/s per ch, simultaneous, antialiasing, nonisolated, TEDS
24-bit, 15 S/s, differential
16-bit, 100 kS/s per ch, simultaneous, differential
12-bit, 800 kS/s
12-bit, 800 kS/s
16-bit, 100 kS/s per ch, simultaneous
100 µs, 24 V logic, 40 V protection
1 µs, high-speed, 24 V logic, 35 V protection
3 ms, ±5 to 250 VDC, 10 to 250 VAC, universal, sink/source
1 µs, ±5 to 24 V, single-ended TTL or differential, regulated 5 V supply output
100 µs, 24 V logic, 750 mA max per ch, 30 V protection, short-circuit-proof
1 µs, high-speed, 24 V logic, 1 A max per ch, 30 V protection, short-circuit-proof
1 s, 30 VDC (2 A), 60 VDC (1 A), 250 VAC (2 A) electromechanical form A (SPST)
1 µs, high-speed, 24 V logic, 35 V protection
1 µs, ±5 to 24 V, single-ended TTL or differential, regulated 5 V supply output
1 µs, ±5 to 24 V, single-ended TTL or differential, regulated 5 V supply output
1 µs, high-speed, 24 V logic, (5 to 30 V)1 A max per ch, 30 V protection,short-circuit-proof
CompactRIO
Configuration Guide
Step 3. Choose your I/O modules.
11
1
NI CompactRIO Extreme Industrial Certifications and Ratings. All modules except cRIO-9233 feature 2,300 Vrms withstand isolation, 250 Vrms continuous isolation channel-to-earth ground.
Integrated electronic piezoelectric (IEPE) sensors include accelerometers, strain gages, load cells, and microphones.
2
BUY ONLINE or CALL (866) 265-9891! Visit ni.com
371
CompactRIO
Reconfigurable Chassis
NI cRIO-910x NEW!
• Design hardware using LabVIEW
programming skills
• 4 or 8-slot chassis for any
CompactRIO I/O modules
• 1 M or 3 M gate RIO FPGA core
for normal or extended RIO
processing power
• DIN-rail mounting, 19 in. rack
mount, and panel mounting options
• NI CompactRIO Extreme Industrial
Certifications and Ratings1
Product
cRIO-9101
cRIO-9102
cRIO-9103
cRIO-9104
Module Slots
4
8
4
8
• Program in easy-to-use
LabVIEW FPGA graphical
development environment
to automatically synthesize
an optimized highperformance electrical
circuit implementation
of your application
• RIO FPGA core executes
LabVIEW control logic at
rates up to 40 MS/s using
single-cycle timed loops
FPGA System Gates
1M
1M
3M
3M
RAM (KB)
82
82
196
196
Overview and Applications
Maximum Power Consumption (W)
2.3
2.3
3
3
Built-In
Panel Mounting Holes
3
3
3
3
3. Develop the real-time controller application to add
floating-point control, signal processing, data logging,
and communication
Key Features
• Create any local or multichassis timing, triggering, and
synchronization scheme with 25 ns resolution
• Use multiple while loops to create a parallel processing application
for high-performance signal processing or multirate control systems
• Built-in PID control functions for control system loop rates
greater than 100 kHz
• Generate waveforms or implement nonlinear look-up tables
(LUTs) using LabVIEW FPGA express VIs
• Integrate widely available third-party HDL cores using the
LabVIEW FPGA Module HDL Node
• Enforce critical logic and interlocks in silicon hardware circuitry, or
use the parallel RIO architecture to create dual, triple, or quadruple
redundant systems
Visit ni.com/compactrio for example programs, application notes,
and other developer tools.
CompactRIO
Reconfigurable Chassis
The National Instruments CompactRIO reconfigurable chassis are
the heart of the CompactRIO system because they contain the
reconfigurable I/O (RIO) core. The RIO FPGA core, which has an
individual connection to each I/O module, is programmed with easyto-use elemental I/O functions to read or write signal information
from each module. Because there is no shared communication bus
between the RIO FPGA core and the I/O modules, I/O operations on
each module can be precisely synchronized with 25 ns resolution. The
RIO core can perform local integer-based signal processing and
decision-making and directly pass signals from one module to another.
The RIO core is also connected to the CompactRIO real-time
controller through a local PCI bus interface. The real-time controller
can retrieve data from any control or indicator on the front-panel of
the RIO FPGA application through an easy-to-use FPGA Read/Write
function. The RIO FPGA can also generate interrupt requests (IRQs)
to synchronize the real-time software execution with the RIO FPGA.
Typically, the real-time controller is used to convert the integer based
I/O data to scaled floating-point numbers. In addition, the real-time
controller typically performs single-point control, waveform analysis,
data logging, and Ethernet/serial communication.
The reconfigurable chassis, real-time controller, and I/O modules
combine to create a complete stand-alone embedded system.
Application development consists of three steps:
1. Target the reconfigurable chassis to automatically detect the
I/O modules and develop the RIO FPGA application,
2. Compile the RIO application to automatically synthesize
an optimized high-performance electrical circuit implementation
of your application,
Default Timebase (MHz)
40
40
40
40
11
For ordering information, see page 381.
North American
Hazardous Locations
(pending)
For more information, see page 379.
1
See CompactRIO Overview on page 366 for details.
BUY ONLINE or CALL (866) 265-9891! Visit ni.com
373
CompactRIO – Real-Time Embedded Controllers
NI cRIO-900x
• Small, rugged, high-reliability embedded
real-time processor for intelligent standalone operation
• Executes powerful floating-point
algorithms with deterministic real-time
performance
• Low power consumption with dual DC
supply inputs for redundancy
• 10/100BaseT Ethernet port with built-in
LabVIEW remote panel Web server and
FTP file sharing server
• RS232 serial port for peripheral devices
Operating System
• LabVIEW Real-Time (ETS)
Development Environment
• LabVIEW Full or Professional
Development System for Windows
• LabVIEW Reconfigurable I/O
Software Development Kit (includes
LabVIEW Real-Time, LabVIEW FPGA
Modules and developer toolkits)
Driver Software
• NI-RIO for reconfigurable
embedded systems
DRAM
Internal Nonvolatile 10/100BaseTX
RS232
Product Memory (MB)
Storage (MB)
Ethernet Port Serial Port
cRIO-9002
32
64
3
3
cRIO-9004
64
512
3
3
LEDs
4
DIP
Switches
5
Power Supply
Input Range
9 to 35 VDC
Power
Consumption
7 W max
4
5
9 to 35 VDC
7 W max
Backup
Power Input
Remote Panel
Web Server
FTP
Server
3
3
3
3
3
3
Overview and Applications
Embedded Software
National Instruments cRIO-900x real-time embedded controllers offer
powerful stand-alone embedded execution for deterministic LabVIEW
Real-Time applications. The NI cRIO-9002 includes 32 MB of DRAM
memory and 64 MB of nonvolatile flash storage for file storage. The
cRIO-9004 includes 64 MB of DRAM memory and 512 MB of nonvolatile
flash storage for data-logging applications. Both controllers are designed
for extreme ruggedness, reliability, and low power consumption with
dual 9 to 35 VDC supply inputs that deliver isolated power to the
CompactRIO chassis/modules and a -40 to 70 °C temperature range.
A 200 MHz industrial processor balances low power consumption with
powerful real-time floating-point signal processing and analysis
capabilities for deterministic control loops exceeding 1 kHz.
Embedded code execution can be synchronized to an FPGA-generated
interrupt request (IRQ) or an internal millisecond real-time clock source.
The LabVIEW Real-Time ETS OS provides reliability and simplifies the
development of complete embedded applications that include time-critical
control and acquisition loops in addition to lower priority loops for
postprocessing, data logging,
and Ethernet/serial
communication. Built-in
elemental I/O functions such as
the FPGA Read/Write function
provide a communication
interface to the highly optimized reconfigurable FPGA circuitry. Data
values are read from the FPGA in integer format, and then converted to
scaled engineering units in the controller.
+
Built-In Servers
System Configuration
The CompactRIO real-time controller connects to any 4 or 8-slot
CompactRIO reconfigurable chassis. The user-defined FPGA circuitry in
the chassis controls each I/O module and passes data to the controller
through a local PCI bus, using built-in communication functions.
In addition to programmatic communication via TCP/IP, UDP, Modbus/TCP,
IrDA, and serial protocols, the CompactRIO controllers also include built-in
servers for VISA, HTTP, and FTP. The VISA server provides remote
download and communication access to the RIO FPGA over Ethernet.
The HTTP server provides a Web browser user interface to HTML pages,
files, and the user interface of embedded LabVIEW applications through
a Web browser plug-in. The FTP server provides access to logged data or
configuration files.
North American Hazardous Locations
CompactRIO – Real-Time Embedded Controllers
Environmental
Specifications
cRIO-900x controllers are intended for indoor use only. For outdoor use,
mount the CompactRIO system in a suitably rated enclosure.
Network
Network interface............................... 10BaseT and 100BaseTX Ethernet
Compatibility ....................................... IEEE 802.3
Communication rates.......................... 10 Mb/s, 100 Mb/s,
autonegotiated
Maximum cabling distance................. 100 m/segment
Memory
cRIO-9002
Nonvolatile .....................................
DRAM .............................................
cRIO-9004
Nonvolatile .....................................
DRAM .............................................
64 MB
32 MB
512 MB
64 MB
Power Requirements
You must use a National Electric Code (NEC) Class 2 power source with
the cRIO-9002/9004.
Recommended power supply................
Power consumption
Controller only ................................
Controller supplying power to
8 CompactRIO modules..............
Power supply
On power-up ...................................
After power-up ...............................
48 W secondary, 18 VDC to 24 VDC
7 W max
17 W
9 to 35 V
6 to 35 V
Physical Characteristics
Screw-terminal wiring ........................ 12 to 24 AWG copper conductor
wire with 10 mm (0.39 in.) of
insulation stripped from the end
Torque for screw terminals................. 0.5 to 0.6 N • m (4.4 to 5.3 lb • in.)
Weight................................................. Approx. 488 g (17.2 oz)
Safety
Safety Voltages
Connect only voltages that are within these limits.
Operating temperature
(IEC 60068-2-1, IEC 60068-2-2) ...... -40 to 70 °C
Note: To meet this operating temperature range, follow the guidelines in
the installation instructions for your CompactRIO system.
Storage temperature
(IEC 60068-2-1, IEC 60068-2-2) ......
Ingress protection ...............................
Operating relative humidity
(IEC 60068-2-56) .............................
Storage relative humidity
(IEC 60068-2-56) .............................
Maximum altitude...............................
Pollution Degree (IEC 60664) ..............
-40 to 85 °C
IP 40
10 to 90%, noncondensing
5 to 95%, noncondensing
2,000 m
2
Shock and Vibration
To meet these specifications, you must panel mount the CompactRIO
system and affix ferrules to the end of the terminal wires.
Operating vibration, random
(IEC 60068-2-64) ............................. 5 grms, 10 to 500 Hz
Operating shock
(IEC 60068-2-27) ............................. 30 g, 11 ms half sine
50 g, 3 ms half sine,
18 shocks at 6 orientations
Operating vibration, sinusoidal
(IEC 60068-2-6) ............................... 5 g, 10 to 500 Hz
Electromagnetic Compatibility
Emissions ............................................ EN 55011 Class A at 10 m
FCC Part 15A above 1 GHz
Immunity.............................................. Industrial levels per EN
61326:1997 + A2:2001, Table A.1
EMC/EMI............................................. CE, C-Tick, and FCC Part 15
(Class A) Compliant
Note: For EMC compliance, operate this device with shielded cabling.
V-to-C .................................................. 30 V max, Installation Category I
FCC Compliance
Safety Standards
Go to ni.com/info and enter rdcriofcc for information on using this
product in compliance with FCC regulations.
The cRIO-9002/9004 is designed to meet the requirements of the
following standards of safety for electrical equipment for measurement,
control, and laboratory use:
• EN 61010-1, IEC 61010-1
• UL 61010-1
• CAN/CSA-C22.2 No. 61010-1
Hazardous Locations
U.S. (UL) .............................................. Class I, Division 2, Groups A, B,
C, D, T4; Class I, Zone 2, AEx nC
IIC T4
Canada (C-UL) ..................................... Class I, Division 2, Groups A, B, C,
D, T4; Class I, Zone 2, Ex nC IIC T4
Europe (DEMKO) ................................. EEx nC IIC T4
CE Compliance
This product meets the essential requirements of applicable European
directives, as amended for CE marking, as follows:
Low-voltage directive (safety) ............ 73/23/EEC
Electromagnetic compatibility
directive (EMC) ............................... 89/336/EEC
Note: Refer to the Declaration of Conformity (DoC) for this product for
any additional regulatory compliance information. To obtain the DoC
for this product, and for UL and other safety certifications, visit
ni.com/certification.
BUY ONLINE at ni.com or CALL (800) 813 3693 (U.S.)
2
C Series Analog Input Modules
NI 9201, NI 921x, NI 9221, NI 923x NEW!
• Signal conditioning for high voltage
(±60 V), thermocouples, RTDs,
accelerometers, microphones,
strain gages, current inputs
• Advanced features such as smart TEDS
sensor capability, antialiasing filters,
open-thermocouple detection
• ±80 mV, ±10 V, or ±60 V analog
input ranges
• 12, 16, or 24-bit (delta-sigma)
resolution
Model
NI 9201
NI 9203
NI 9205
NI 9206
NI 9211
NI 9215
NI 9217
NI 9221
NI 9233
NI 9237
• Up to 800 kS/s multiplexed or up to
100 kS/s simultaneous-sampling
analog-to-digital converter (ADC)
• Up to 32 channels per module
• Up to 2,300 Vrms isolation (withstand),
up to 250 Vrms isolation (continuous)
• NIST-traceable calibration certificate
for guaranteed accuracy
Compatibility
CompactRIO NI CompactDAQ
Signal Type
Channels Resolution (bits)
–
Voltage
8
12
3
–
Current
8
16
3
Voltage
32 SE/16 DI
16
3
3
Cat I Isolated Voltage
16 DI
16
3
3
Thermocouple
4
24
3
3
Voltage
4
16
3
3
–
RTD
4
24
3
–
Voltage
8
12
3
IEPE
4
24
3
3
Bridge
4
24
3
3
Max Sampling
Rate (S/s)
500 k
200 k
250 k
250 k
15
100 k/ch
400
800 k
50 k/ch
50 k/ch
Signal
Input Ranges
±10 V
±20 mA, 0-20 mA
±10 V, ±5 V, ±1, ±0.2
±10 V, ±5 V, ±1, ±0.2
±80 mV
±10 V
0 to 400 Ω
±60 V
±5 V
±250 mV
Simultaneous
Sampling
–
–
–
–
–
3
–
–
3
3
Antialiasing
Filters
–
–
–
–
3
–
3
–
3
3
Isolation
3
3
3
3
3
3
3
3
–
3
Connector Options
Screw Terminal, D-Sub
Screw Terminal
Spring Terminal, D-Sub
Spring Terminal
Screw Terminal
Screw Terminal, BNC
Screw Terminal
Screw Terminal, D-Sub
BNC
RJ50
Table 1. C Series Analog Input Modules Selection Guide
Overview
High-accuracy C Series analog input modules for National Instruments
CompactRIO and NI CompactDAQ provide high-performance
measurements for a wide variety of industrial, in-vehicle, and laboratory
sensors and signal types. Each module includes built-in signal conditioning
and an integrated connector with screw terminal or cable options for
flexible and low-cost signal wiring. All modules feature NI CompactRIO
Extreme Industrial Certifications and Ratings.
System Compatibility
NI C Series modules can be used in multiple system types depending
on available software. Please see the table above for CompactRIO and
NI CompactDAQ module compatibility because not all modules will work
with both systems. Many of the advanced features described apply only to
reconfigurable I/O systems and not to NI CompactDAQ.
Advanced Features
When used with CompactRIO, NI C Series analog input modules
connect directly to reconfigurable I/O (RIO) FPGA hardware to create
high-performance embedded systems. The reconfigurable FPGA
hardware within CompactRIO provides a variety of options for custom
timing, triggering, synchronization, filtering, signal processing and high
speed decision making for all C Series analog modules. For instance,
with CompactRIO you can implement custom triggering for any analog
sensor type on a per-channel basis using the flexibility and performance
of the FPGA and the numerous arithmetic and comparision function
blocks built into LabVIEW FPGA.
Key Features
• High-accuracy, high-performance analog measurements for any
CompactRIO embedded system, R Series expansion chassis, or
NI CompactDAQ chassis
• Screw terminals, BNC, D-Sub, spring terminals, strain relief, highvoltage, cable, solder cup backshell, and other connectivity options
• Available channel-to-earth ground double-isolation barrier for safety,
noise immunity, and high common-mode voltage range
• NI CompactRIO Extreme Industrial Certifications and Ratings
• Built-in signal conditioning for direct connection to sensors and
industrial devices
Visit ni.com/compactrio or ni.com/compactdaq for up-to-date
information on module availability, example programs, application notes,
and other developer tools.
North American
Hazardous Locations
C Series Module Accessories
Connectivity Accessories
CompactRIO and NI CompactDAQ systems are designed to provide
flexible options for low-cost field wiring and cabling. Most C Series
modules have a unique connector block option that offers secure and
safe connections to your C Series system. The table below contains
all of the connector blocks available for C Series I/O modules.
Accessory
NI 9932
NI 9933
NI 9934
NI 9935
NI 9936
NI 9939
The NI 9934 includes a screw-terminal connector with strain relief
as well as a D-Sub solder cup backshell for creating custom cable
assemblies for any module with a 25-pin D-Sub connector.
Description
10-position strain relief and high-voltage screw-terminal connector kit
37-pin D-Sub connector kit with strain relief and D-Sub shell
25-pin D-Sub connector kit with strain relief and D-Sub shell
15-pin D-Sub connector kit with strain relief and D-Sub shell
10-position screw-terminal plugs (quantity 10)
16-position connector kit with strain relief
Note: To meet shock and vibration requirements, you must affix ferrules to the ends of the wires on all screw-terminal connectors.
The table below lists the recommended connector block accessories for
each C Series analog input module.
C Series Analog Input Module
NI 9201
NI 9201 with D-Sub
NI 9211
NI 9215
NI 9217
NI 9221
NI 9221 with D-Sub
Figure 3. NI 9934 25-Pin D-Sub Connector Kit with Strain Relief and D-Sub Shell
The NI 9935 includes a screw-terminal connector with strain relief as
well as a D-Sub solder cup backshell for creating custom cable
assemblies for any module with a 15-pin D-Sub connector.
Recommended Module Accessory
NI 9932, NI 9936
NI 99341
NI 9932, NI 9936
NI 9932, NI 9936
NI 9939
NI 9932, NI 9936
NI 99341
1Requires a 25-pin D-Sub connector such as the NI 9934 accessory kit.
The NI 9932 kit provides strain relief and operator protection from
high-voltage signals for any 10-position screw-terminal module.
Figure 4. NI 9935 15-Pin D-Sub Connector Kit with Strain Relief and D-Sub Shell
The NI 9936 consists of 10-position screw-terminal plugs for any
10-position screw-terminal module.
Figure 1. NI 9932 10-Position
Strain Relief and High-Voltage Screw-Terminal Connector Kit
The NI 9933 includes a screw-terminal connector with strain relief
as well as a D-Sub solder cup backshell for creating custom cable
assemblies for any module with a 37-pin D-Sub connector.
Figure 5. NI 9936 10-Position Screw-Terminal Plugs
Visit ni.com/compactrio or ni.com/compactdaq for up-to-date
information on availability of accessories.
Figure 2. NI 9933 37-Pin D-Sub Connector Kit with Strain Relief and D-Sub Shell
BUY ONLINE at ni.com or CALL (800) 813 3693 (U.S.)
2
51127 Cologne
Fax
iglidur® G – Flange Bearing – Type F
iglidur® G – Thrust Washer – Type T
d13
d3
4.0
25.0
h13
b1
1.0
1.0
1.0
1.0
-0.14
b2
GFM-8590-100
GFM-8085-100
GFM-7580-50
GFM-7075-50
GFM-6570-50
85.0
80.0
75.0
70.0
65.0
GFM-606580-62 60.0
90.0
85.0
80.0
75.0
70.0
65.0
98.0 100.0
93.0 100.0
88.0
83.0
78.0
80.0
d13
d3
50.0
50.0
50.0
62.0
h13
b1
2.5
2.5
2.0
2.0
2.0
2.0
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b2
Type
Dimen.
d1
d2
Structure – Part No.
25.0
6.0
1.0
Dimensions according to ISO
26.0
11.0
1.0
d1-Tol.*
19.0
26.0
12.0
2.5
d2
20.0
26.0
17.0
95.0 103.0 100.0
d1
17.0
20.0
26.0
90.0
2.5
Part No.
18.0
20.0
26.0
GFM-9095-100
2.5
d1-Tol.*
GFM-1719-25
18.0
20.0
GFM-95100-100 95.0 100.0 108.0 100.0
2.5
d2
GFM-1820-04
18.0
20.0
1.0
GFM-100105-100100.0 105.0 113.0 100.0
d1
GFM-1820-06
18.0
22.0
1.0
GFM-110115-100110.0 115.0 123.0 100.0
Part No.
GFM-1820-11
18.0
26.0
30.0
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s
GFM-1820-12
20.0
26.0
6.0
32.0
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GFM-1820-17
18.0
20.0
22.0
26.0
3547-1 and special dimensions
GFM-1820-22
18.0
20.0
20.0
GFM-2527-48
GFM-2526-25
GFM-2427-10
GFM-2427-07
GFM-2023-11
GFM-2023-07
GFM-2021-20
GFM-1822-28
25.0
24.0
24.0
GFM-202326-21 20.0
GFM-2023-16
25.0
GFM-202328-15 20.0
GFM-2023-21
25.0
20.0
20.0
20.0
20.0
20.0
18.0
28.0
28.0
27.0
26.0
27.0
27.0
23.0
23.0
23.0
23.0
23.0
23.0
21.0
20.0
35.0
35.0
35.0
32.0
30.0
32.0
32.0
28.0
26.0
30.0
30.0
30.0
30.0
25.0
26.0
21.5
16.5
11.5
48.0
25.0
10.0
7.0
15.0
21.0
21.5
16.5
11.5
7.0
20.0
28.0
1.5
1.5
1.5
1.0
0.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
0.5
2.0
GFM-150155-100150.0 155.0 163.0 100.0
GFM-140145-100140.0 145.0 153.0 100.0
GFM-130135-100130.0 135.0 143.0 100.0
GFM-125130-100125.0 130.0 138.0 100.0
GFM-120125-100120.0 125.0 133.0 100.0
2.5
2.5
2.5
2.5
2.5
GTM-1522-008
GTM-1426-015
GTM-1420-015
GTM-1224-015
GTM-1018-020
GTM-1018-010
GTM-0918-015
GTM-0818-015
GTM-0818-010
GTM-0815-015
GTM-0815-005
GTM-0713-005
GTM-0620-015
GTM-0615-015
GTM-0509-006
15.0
14.0
14.0
12.0
10.0
10.0
9.0
8.0
8.0
8.0
8.0
7.0
6.0
6.0
5.0
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d1
22.0
26.0
20.0
24.0
18.0
18.0
18.0
18.0
18.0
15.0
15.0
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d2
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1.5
1.5
1.5
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1.5
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0.5
0.5
1.5
1.5
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18
18
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GFM-1820-30
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GFM-2528-11
25.0
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GFM-1820-32
Part No.
GFM-182022-06 18.0
GFM-2528-16
25.0
GFM-3034-37
GFM-3034-26
GFM-3034-20
GFM-3034-16
GFM-3032-22
GFM-3032-17
GFM-3032-12
GFM-3031-30
GFM-3031-20
30.0
30.0
30.0
30.0
30.0
30.0
30.0
30.0
30.0
GFM-283239-20 28.0
GFM-2830-36
32.0
36.0
34.0
34.0
34.0
34.0
32.0
32.0
32.0
31.0
31.0
32.0
30.0
40.0
42.0
42.0
42.0
42.0
37.0
37.0
37.0
35.0
36.0
39.0
35.0
16.0
37.0
26.0
20.0
16.0
22.0
17.5
12.0
30.0
20.0
20.0
36.0
2.0
2.0
2.0
2.0
2.0
1.0
1.0
1.0
0.5
0.5
2.0
1.0
GTM-3862-015
GTM-3254-015
GTM-2848-015
GTM-2835-005
GTM-2644-015
GTM-2442-015
GTM-2238-015
GTM-2036-015
GTM-1832-015
GTM-1630-015
GTM-1524-0275
GTM-1524-015
38.0
32.0
28.0
28.0
26.0
24.0
22.0
20.0
18.0
16.0
15.0
15.0
62.0
54.0
48.0
35.0
44.0
42.0
38.0
36.0
32.0
30.0
24.0
24.0
1.5
1.5
1.5
0.5
1.5
1.5
1.5
1.5
1.5
1.5
2.75
1.5
54.0
50.0
43.0
38.0
*
35.0
33.0
30.0
28.0
25.0
23.0
*
19.5
4.0
4.0
4.0
4.0
*
3.0
3.0
3.0
3.0
2.0
2.0
*
1.5
1.0
1.0
1.0
1.0
0.2
1.0
1.0
1.0
1.0
1.0
1.0
2.0
1.0
74
66
62
54
48
35
44
42
38
36
32
30
24
24
28.0
GFM-2528-21
GFM-3236-16
1.5
81
90
66.0
1.5
1.5
42.0
*
4.0
GTM-4266-015
*
76.0
2.0
2.0
26.0
2.0
40.0
90.0
36.0
81.0
32.0
62.0
GFM-3236-26
68.0
78
GTM-6290-020
1.5
GTM-6881-020
1.5
2.0
4.0
2.0
4.0
16.0
2.0
61.0
26.0
2.0
65.0
47.0
22.0
2.0
2.0
47.0
14.0
2.0
2.0
39.0
54.0
30.0
2.0
74.0
39.0
52.0
40.0
2.0
78.0
GFM-3539-058
35.0
42.0
52.0
50.0
2.0
48.0
GFM-3539-16
35.0
44.0
52.0
19.0
2.0
52.0
GFM-3539-26
38.0
44.0
52.0
30.0
2.0
GTM-4874-020
GFM-3842-22
40.0
44.0
53.0
50.0
2.0
GTM-5278-020
GFM-4044-14
40.0
44.0
58.0
10.0
2.0
2.0
GFM-4044-30
40.0
46.0
58.0
40.0
2.0
2.0
GFM-4044-40
40.0
50.0
63.0
50.0
2.0
5.8
GFM-4044-50
42.0
50.0
63.0
30.0
35.0
GFM-4246-19
45.0
55.0
63.0
50.0
47.0
GFM-4550-30
45.0
55.0
73.0
50.0
GFM-4550-50
50.0
55.0
73.0
39.0
GFM-5055-10
50.0
65.0
38.0
GFM-5055-40
50.0
65.0
35.0
GFM-5055-50
60.0
www.igus.de/en/g
60.0
Lifetime calculation, CAD files and much more support
GFM-6065-30
GFM-343850-35 34.0
www.igus.de/en/g
GFM-6065-50
Lifetime calculation, CAD files and much more support
G
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mm
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G
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56
igus® GmbH
iglidur® G
Phone +49- (0) 22 03-96 49-145
iglidur® G
+49- (0) 22 03-96 49-334
Internet: www.igus.de
Phone +49- (0) 22 03-96 49-145
iglidur®
E-mail: info@igus.de
51127 Cologne
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Plain Bearings
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38
together homogeneously. The advantage of this design is clear once
to this principle, and likewise a number of maintenance free bearings,
iglidur® plain bearings: Exactly the
right bearing for every application
The traditional solution, bearing shells
made of layers with lubricants and/or coating.
iglidur® plain bearings are homogeneously structured. Base
polymer, bonding materials and solid lubricants mutually
complement each other.
iglidur® – Plain Bearings – High Performance
you explain the requirements made on the surface bearing:
iglidur® – Plain Bearings – High Performance
iglidur® – plain bearings made
from high performance polymers
These components are not applied in layers, but instead are mixed
Excellent polymers, improved by precise additions of reinforcing
the surface of the bearing, should be as small as possible.
that are equipped with special slide layers. However, this soft slide
The radial pressure, with which the bearings are loaded, is received
®
iglidur
Plain Bearings
1. The coefficient of the friction, which is determined especially by
2. The surface may not be removed by forces that act on the bearing
Fit it and forget it
layer is not strong enough. For high loads, compression across edges
The base polymers are responsible for the resistance to wear
The solid lubricants are, as microscopically small particles, embedded
by the polymer base material. In the contact area, this material provides
Left: Base polymers with fibres and solid lubricants, magnified
200 times, dyed. Right: Base polymers without reinforcing
materials with solid lubricants, magnified 50 times, dyed.
Fax
materials and lubricants, tested a thousand times and proven a
hundred new plastic compounds and test maintenance free plain
Based on the results of several thousand empirical tests, we are
or oscillations, it becomes removed.
Fibres and filling materials reinforce the bearing so that high
in millions of tiny chambers of the mostly fibre reinforced material.
Both in material development as well as in the design of bearings,
shaft support. The polymer base material ensures the lubricants do
linear curve. In this phase, the coefficients of friction continue to change,
iglidur®
million times. Each year, igus® engineers develop more than one
3. The wearing force acts especially on the surface of the bearing,
for this the bearing must be capable of high resistance.
bearings in more than 2,500 experiments per year. That’s how in recent
There is no such thing as a single, universal material that performs all
years they built an extensive database of the tribological properties
of polymers. This database makes it possible for us to better assess
of these functions well.
The traditional solution is:
the overwhelming number of applications in advance, to calculate
the expected service life, and provide our customer with confidence
now able to provide you with reliable answers to almost all inquiries
Hard shells with soft coating. Each lubricated bearing works according
about the service life of iglidur ® plain bearings. We can also
First class materials in the
injection molding process
forces or edge loads are possible
Plain bearings do last a long time at low cost
From these chambers, the plain bearings release tiny amounts of solid
former disadvantages of plastics can be greatly reduced. Thus iglidur®
not receive a surface pressure that is too high. The base material is
until finally assuming a value that is for the most part constant.
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39
mm
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during use.
Every designer’s dream: A calculable plain
iglidur® plain bearings function differently
Very few basic materials can be modified and adapted as well as
the bearing:
thermoplastics. Thermoplastics can be produced with lubricants,
friction of the system.
Solid lubricants, lubricate the bearing independently and prevent
One component of the iglidur® materials acts for each function of
they can be reinforced mechanically by the addition of technical
igus ® develops materials that are wellsuited to the different
lubricants during movement. The solid lubricants help to lower the
Self lubrication
requirements of maintenance free plain bearings:
coefficient of friction of the iglidur® bearing. Since they are embedded
in the tiny chambers, they cannot be pressed out. They are always
there as soon as the bearing or the shaft is set in motion.
plain bearings are thin walled and some materials have especially
also reinforced by technical fibres or filling materials. These additional
Base polymers and technical fibres
high thermal conductivity. Both features help to rapidly dissipate
The start-up phase
materials stabilize the bearing especially for cases of continuous stress.
Above and beyond the general properties, each iglidur® bearing material
mated to one another. During this phase, the surfaces of both materials
are fitted to each other. The specific loading of the system drops since
In the starting phase, the shaft and the iglidur® plain bearing become
the contact surfaces of the shaft and bearing expand during the start-
has a series of particular properties that create its suitability for certain
materials in the following chapters along with a complete list of existing
The self lubricating effect
Base polymer
composed of:
Time
www.igus.de/en/iglidur
During the start-up phase, the rate of wear drops greatly.
Lifetime calculation, CAD files and much more support
The high performance polymers of the iglidur ® plain bearing are
up. At the same time, the rate of wear decreases and approaches a
dimensions.
applications and requirements. You’ll find a detailed description of the
Properties of iglidur® bearings
heat and thus directly increase the load capacity of the bearing.
that they can be used for a long time.
3. Their wear resistance should ensure
should have low coefficients of friction.
2. Maintenance free plain bearings
over many years, receive high loads.
1. Plain bearings must, at times
in regard to friction and wear behaviour.
fibres, or they can be varied by additional filling materials, especially
from our testing database.
recommend the most appropriate shaft material using the results
bearing made of high performance polymers
Plain bearing laboratory
Testing the properties of polymer bearings
Fibres and filling materials
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Solid lubricants
Lifetime calculation, CAD files and much more support
Wear
®
igus® GmbH
iglidur
Internet: www.igus.de
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iglidur®
E-mail: info@igus.de
51127 Cologne
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Plain Bearings
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40
80
80
100
100
120
120
140
140
160
160
in MPa. For this purpose, the radial load is determined on the projected
The load of a plain bearing is expressed by the surface pressure (p)
Compressive strength
the shaft and the bearing.The surface speed is expressed in metres
rotational speed is not decisive, instead it’s the relative speed between
For plain bearings, the revolution speeds always matter. The absolute
Surface speed
=
d1 =
frequency in Hertz
shaft diameter [mm]
This is also the reason why different running speeds can occur for the
Rotating
1.5
1.5
Oscillating
4
4
Linear
Table 41.1: Surface speeds (constant) of the plain bearing [m/s]
3
100
1
10
iglidur ® G
iglidur ® P
Load [MPa]
0,1
0,25
100
1
10
iglidur ® A290
iglidur ® A200
Load [MPa]
0,1
0,25
100
1
10
0,75
0,75
iglidur ® Q
iglidur ® W300
iglidur ® M250
iglidur ® D
iglidur ® H
0,75
iglidur ® H370
iglidur ® Q
30
iglidur ® X
15
iglidur ® H2
iglidur ® G
Load [MPa]
5
Load [MPa]
0,1
0,25
100
10
1
2
2
2
iglidur ® J
iglidur ® Z
iglidur ® F
iglidur ® Z
5
5
5
50
iglidur® C
iglidur® B
iglidur® A500
iglidur® A290
iglidur® A200
iglidur® J
iglidur® M250
iglidur® X
iglidur® W300
iglidur® G
Material
3
1.5
1
1
2
1.5
3
2
3.5
2.5
2
Rotating
3
1.5
1
1
2
1.5
3
2
4
3
2.5
Oscillating
10
3
3
2
4
4
10
5
10
6
5
Linear
iglidur® H2
iglidur® H
1.5
1.5
1
1.5
1.5
1.5
1.5
1.5
1.5
2
6
4
3
15
2
5
3
4
3
iglidur® H370
1.5
2.5
2
5
iglidur® H4
1.5
2
3
1
iglidur® J200
2
1
1.5
iglidur® L250
2
1.5
3
3
1
iglidur® P
1
1.5
1.5
iglidur® Q
1.5
1
iglidur® F
iglidur® T220
1.5
4
iglidur® GLW
iglidur® D
Table 41.2: Surface speeds (short term) of the plain bearing [m/s]
45
Graph 41.1: Wear of iglidur® plain bearings under different loads
iglidur® – Plain Bearings – High Performance
surface of the bearing.
per second and calculated from the rotational speed with the adjacent
load in N
f
angle of motion per cycle [°]
different movement types. For linear movements, more heat can be
1
1.5
5
iglidur® UW
1.3
®
iglidur
Plain Bearings
Radial bearing: p = F / d1 x b1
v = n x d1 x π / 60 x 1000 [m/s]
formula.
Rotations:
bearing inner diameter in mm
p = F / (d22 - d12) x π / 4
For thrust bearings, the load is produced accordingly.
Axial bearing:
F
bearing length in mm
=
Permissible surface speeds
ß
v = d1 x π x ß / 360 x f/1000 [m/s]
d1
ß
in the process:
Oscillating movements:
b1
outer diameter of the bearing in mm
in this process:
d2
iglidur® plain bearings were primarily developed for low to average
RPM
A comparative value of the iglidur® material is the permissible average
running speeds in continuous operation. Tables 41.1 and 41.2 show
=
static surface pressure (p) at 20°C. The values of the individual iglidur®
the permissible surface speed of iglidur® plain bearings for rotating,
n
plain bearings differ greatly on this point. The value (p) indicates the
Permissible average surface pressure
limit of the load of a plain bearing. The plain bearing can carry this
Pressure and temperature
dissipated via the shaft, since the bearing uses a longer surface area
Material
1
1
1
iglidur® UW500
3.5
Fax
iglidur® – Plain Bearings – High Performance
60
60
The graphs 40.2 and 40.3 show the permissible static surface pressure
on the shaft.
presented by the predictability of the iglidur® plain bearing to record
iglidur® G
125
iglidur® P
1
iglidur® V400
6
iglidur® Z
iglidur®
Graph 40.1: Permissible average static surface pressure at 20°C
40
40
values assuming minimum pressure loading of the bearing. In practice,
20
20
these limit values are rarely reached due to an inverse relationship
00
iglidur ® G
iglidur ® W300
iglidur ® X
iglidur ® M250
iglidur ® J
iglidur ® Q
iglidur ® H370
iglidur ® H
iglidur ® Z
iglidur ® P
iglidur ® F
iglidur ® A200
iglidur ® A290
iglidur ® H2
iglidur ® D
iglidur ® GLW
iglidur ® A500
iglidur ® L250
iglidur ® V400
iglidur ® H4
iglidur ® J200
iglidur ® C
iglidur ® B
iglidur ® T220
iglidur ® UW
iglidur ® UW500
operation, only very slow speeds up to 0.01 m/s are tolerated under
MPa
this load. Higher loads than those indicated are possible if the duration
oscillating, and linear movements. These surface speeds are limit
Graph 40.2: Compression resistance of iglidur®
load permanently without damage. The given value applies to static
plain bearings as a function of temperature
between load and speed. Each increase of the pressure load leads
(p) of the iglidur® plain bearing versus the temperature. When using
these effects in advance, or determine the effective temperatures in
iglidur® W300
ambient temperature, due to friction. Take advantage of the opportunity
the plain bearing, the bearing temperature can be higher than the
versa. The limit of the speed is measured by the bearing temperature.
unavoidably to a reduction of the allowable surface speeds and vice
140
140
of the load is short. For a few minutes, the load can be more than
100
100
doubled, depending on the material. Please call us if you have questions.
100
100
80
80
60
60
40
40
20
20
00
60
60
Temperature [°C]
the test.
5
20
20
iglidur® P
3
iglidur® Z
1.5
8
2.5
iglidur® J
iglidur® X
0.8
iglidur® G
Pressure and speed
1.5
iglidur® F
0.8
iglidur® A200
1.5
iglidur® Q
iglidur® M250
iglidur® H370
iglidur® J
iglidur® W300
With decreasing radial load on the plain bearing, the permissible surface
iglidur® X
speed increases. The product of the load (p) and the speed (v) can
iglidur® H
2.5
iglidur® A290
0.75
iglidur® M250
0.75
2
iglidur® A200
2
be understood as a measurement for the frictional heat of the bearing.
0.6
8
3
1
1
0.7
1.5
1
1
0.6
iglidur® B
1.5
1
iglidur® C
0.6
iglidur® D
iglidur® A290
Pressure and wear
3
iglidur® A500
The load of the plain bearing has an effect on the wear of the bearing.
2.5
3
1
1.5
2.5
1
1
1.2
1
4
0.8
iglidur® H
0.9
1
1.25
0.8
iglidur® H2
1
1.2
iglidur® F
iglidur® H370
iglidur® GLW
plain bearing available.
iglidur® H4
materials. It is easily recognized that for each load, there is an optimal
This relationship is shown by the p x v graph that is the first in the
160
160
140
140
120
120
100
100
Pressure and coefficient of friction
80
80
With increasing load, the coefficient of friction of the plain bearing
60
60
20
20
40
40
75
iglidur ® V400
iglidur® Q
page 44
1
00
iglidur ® L250
iglidur ® B
1
iglidur ® H4
iglidur ® A500
iglidur ® C
2
Temperature [°C]
iglidur ® J200
0.4
2
0.5
2
0.4
0.8
5
0.5
0.8
3
0.8
iglidur® T220
0.9
iglidur® UW
iglidur® UW500
1.5
iglidur ® UW500
iglidur® V400
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41
mm
+49- (0) 22 03-96 49-334
Wear [µm/km]
Wear [µm/km]
Wear [µm/km]
Wear [µm/km]
Lifetime calculation, CAD files and much more support
iglidur® Z
iglidur ® UW
Lifetime calculation, CAD files and much more support
www.igus.de/en/iglidur
iglidur ® T220
also significant. Coefficients of friction
2
The following graphs show the wear behaviour of the iglidur® bearing
respective chapter for each iglidur® material.
200
200
Graph 40.3: Compression resistance of iglidur®
175
175
1
150
150
1
125
1
100
100
1
75
iglidur® J200
50
50
iglidur® L250
25
25
typically decreases. In this context, shaft materials and surfaces are
0
0
plain bearings as a function of temperature
Compressive strength [MPa]
Compressive strength [MPa]
®
igus® GmbH
iglidur
Internet: www.igus.de
Phone +49- (0) 22 03-96 49-145
iglidur®
E-mail: info@igus.de
51127 Cologne
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Plain Bearings
Temperatures
Material
Table 43.1: Lower application temperature limit of the iglidur® materials
iglidur® – Plain Bearings – High Performance
Plain bearings made of high-performance polymers are usually
- 40
iglidur® – Plain Bearings – High Performance
Surface speed and wear
iglidur® H
- 40
0,41
Temp. limit [°C]
- 40
Temp. limit [°C]
Application temperatures
iglidur® D
iglidur® C
iglidur® B
- 40
- 40
- 50
- 40
- 40
iglidur® Z
iglidur® V400
iglidur® T220
- 40
iglidur® UW500 - 100
iglidur® UW
- 100
- 50
- 40
iglidur® H2
iglidur® H
120
120
pauses make a greater contribution to re-cooling. The different curves
Temperature and load
by changing bore design or additionally securing the bearing.
to ensure that the bearing cannot slide out of the bore. This is achieved
iglidur® D
iglidur® C
iglidur® B
iglidur® A500
iglidur® A290
iglidur® A200
100
130
60
50
50
140
130
60
iglidur® Z
iglidur® V400
iglidur® T220
iglidur® Q
iglidur® P
iglidur® L250
100
iglidur® UW500 150
iglidur® UW
160
60
60
90
60
120
of graph 42.2 represent different ratios (3x means that the pause lasts
The compressive strength of plain bearings decreases as temperature
iglidur® F
Coefficient of thermal expansion
iglidur® G
Material
315
200
220
iglidur® J200
iglidur® H4
iglidur® H370
iglidur® H2
iglidur® H
200
200
140
260
260
260
260
Table 43.3: Maximum ambient temperature, short term, without loading
Thermal conduc-
Material
16
Material
303 Stainless
tivity [W/m x k]
46
ambient temp [°C]
ambient temp [°C]
Max. Long term [°C]
®
iglidur
Plain Bearings
Lower application
Considerations about the permissible surface speeds should also
- 40
iglidur® H2
- 40
The minimum application temperature is the temperature below which
iglidur® F
120
iglidur® H370
three times longer than the operating time).
increases. During this process, the materials react very differently from
iglidur® GLW
The thermal expansion of polymers is approximately 10 to 20 times
iglidur® W300
200
iglidur® L250
200
Steel
Max. Short term [°C]
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Material
Graph 42.1: Coefficients of friction of iglidur® materials for different
underestimated at higher temperatures. Who would believe that bearings
iglidur® G
- 40
iglidur® H370
- 50
the material is so rigid and hard that it becomes too brittle for standard
iglidur® GLW
- 40
p x v-value
applications. The maximum continuous application temperature is the
iglidur® Q
For plain bearings, the product is given a new value depending on
temperature which the material can endure without the properties
Table 43.2: Temperature at which additional securing
- 100
the specific load (p) and the surface speed. The p x v value can be
changing considerably. The maximum, short-term application temperature
iglidur® A500
considered a measure of the frictional heat and can be used as an
is the temperature above which the material becomes so soft, that it
70
Lubrication
another. iglidur® X for example still accepts loads of 52 MPa even at
higher when compared to metals. In addition to this, it also acts non-
iglidur® X
140
iglidur® P
170
1.4
iglidur ® UW500
Ceramics
iglidur ® B
204
iglidur ® UW
Aluminum
iglidur ® C
iglidur®
Lower application
surface speeds
include the wear resistance of the plain bearing. High running speeds
made of plastic could be used up to over 300°C? Data is often found
iglidur® W300
- 100
iglidur® H4
- 40
0,2
0,16
0,18
0,2
0,18
0,3 m/s
in the literature about the continuous use temperature. The continuous
iglidur® X
- 40
iglidur® J200
- 40
0,15 m/s
automatically bring correspondingly high wear rates with them.
use temperature is the highest temperature, which the plastic can
iglidur® M250
- 50
iglidur® L250
0,3
analytical tool to answer questions concerning the proper application
of the iglidur ® plain bearing is required
iglidur® G
170
(K1 = 0.5, K2 = 0.042)
constant for heat dissipation
Although iglidur® plain bearings are designed to run dry, they are quite
temperatures of 200°C.
linearly in plastics. The coefficient of thermal expansion of the iglidur®
iglidur®M250
200
iglidur® Q
140
iglidur ® T220
0.24
iglidur ® H4
Plastics
iglidur ® J200
58
iglidur ® V400
Grey cast iron
iglidur ® D
Phone +49- (0) 22 03-96 49-145
0,33
0,28
Surface speed and coefficient of friction
withstand for a period of time without a reduction in the tensile strength
iglidur® J
- 40
0,24
0,26
In practice the coefficient of friction of plain bearings is a result of the
of the material above or below a prespecified value. Please note, these
iglidur® A200
iglidur® P
0,4
0,45
0,55
surface speed in practice. High surface speeds have a higher coefficient
standard test results have limited applications, since bearings are almost
- 40
0,37
0,42
of friction, than low surface speeds. Graph 42.1 shows this relationship
iglidur® A290
0,6
of a plain bearing. For this purpose, the actual p x v value is a
can only withstand small external loads. “Short term” is defined as a
Securing mecha-
function of the shaft material, the ambient temperature and the
pressfit. In these cases, axial securing of the bearing is necessary in
iglidur® W300
nism provided
addition to the pressfit. Table 43.3 shows the maximum ambient
iglidur® X
60
100
nism provided
Correction factor
temperatures to which the plain bearings canbe exposed for a short-
iglidur® H4
Material
Material
Securing mecha-
time period of a few minutes. If the plain bearings are moved axially or
The tolerated p x v value can be increased in intermittent operation if
term. If these temperatures are realised, the bearings may not be
60
starting at [°C]
the bearing temperature never reaches the maximum limit because
iglidur® M250
bearing wall thickness [mm]
compatible with standard oils and greases. A single lubrication during
starting at [°C]
of the short operating time. Tests have shown that this is true for
additionally loaded. In fact, a relaxation of the bearings can occur at
axial forces occur, there is more opportunity for the bearing to lose
operating time.
30 and 0.7 MPa.
always under load.
0,55
in the example of a Cold Rolled Steel shaft with a load of (Cf53) with
0,19
0,15
0,15
0,21
0,17
0,20
0,41
0,38
0,49
0,45
0,4
0,38
0,21
0,2
0,22
0,18
0,24
0,33
0,35
0,36
0,37
operating times below 10 minutes. An important qualifier here is the
iglidur® J200
=
bearing length [mm]
the installation improves the start-up behaviour and the coefficient of
plain bearing is a significant reason for the required play in the bearing.
iglidur® J
230
iglidur® T220
315
iglidur ® L250
43
mm
+49- (0) 22 03-96 49-334
0,27
0,23
0,25
0,41
0,23
0,22
0,22
0,16
0,23
0,30
0,33
0,33
0,28
x 10-3
70
K1, K2
=
coefficient of friction
thermal conductivity of the shaft
thermal conductivity of the bearing
friction, thus reducing the frictional heat. Due to this effect, the
)
iglidur® J
s
=
(Ta - Tu)
(K1 x π x λk x ∆T) (K2 x π x λs x ∆T)
+
µxs
µ x b1 x 2
these temperatures, even without an additional load. Thus it is necessary
b1
=
=
=
ambient temperature
(
iglidur ® G
iglidur ® W300
iglidur ® X
iglidur ® M250
iglidur ® J
iglidur ® Q
iglidur ® H370
iglidur ® H
iglidur ® Z
iglidur ® P
iglidur ® F
iglidur ® A200
iglidur ® A290
iglidur ® H2
iglidur ® D
iglidur ® GLW
iglidur ® A500
iglidur ® L250
iglidur ® V400
iglidur ® H4
iglidur ® J200
iglidur ® C
iglidur ® B
iglidur ® T220
iglidur ® UW
iglidur ® UW500
p x v perm. =
ratio of the operating time and pause intervals. It is known that long
µ
λs
λk
=
=
where:
∆T
At the given application temperature, seizing of the bearing to the
iglidur® A200
315
iglidur® UW
250
iglidur ® H2
max., short term
shaft does not occur at high temperatures. The coefficient of thermal
iglidur® A290
130
iglidur® UW500
310
80
Tu
permissible loads for plain bearings can be increased by lubrication.
Numerous results from lubricated applications are available from
expansion of iglidur® plain bearings were examined for significant
iglidur® A500
150
iglidur® V400
iglidur ® A500
Material
experiments. Please contact us if necessary. Table 42.2 shows the
temperature ranges and the results are given in the individual materials
iglidur® B
140
iglidur® Z
iglidur ® F
max., short term
correction factors for p x v value using lubrication
tables, at the start of each chapter.
iglidur® C
230
iglidur ® A200
Graph 42.2: Correction factor for p x v-value
Thermal conduc-
Graph 43.1: Comparison of the continuous and short term upper
iglidur® D
200
iglidur ® A290
Table 42.1: Heat conductivity values of shaft or housing materials
tivity [W/m x k]
application temperature limits
iglidur® F
200
250
300
350
iglidur® GLW
Table 42.2: Correction of the tolerated p x v value by lubrication
iglidur ® Z
Ta
Maximum application temperature
9
9
=
8
8
iglidur ® P
88
7
7
150
100
iglidur ® H
77
6
6
4
iglidur ® J
66
5
5
5
iglidur ® Q
55
4
4
Continuous, water
iglidur ® H370
44
3
3
Continuous, oil
Correc. factor
1
Lubrication
1.3
Correc. factor
Dry run
Lubrication
During installation
iglidur ® M250
33
2
2
1times
iglidur ® G
22
1
1
2times
0
50
iglidur ® X
Lifetime calculation, CAD files and much more support
iglidur ® W300
11
00
0
0
3times
Operating time [min.]
4times
2
www.igus.de/en/iglidur
Continuous, grease
Lifetime calculation, CAD files and much more support
Application Temperature [°C]
+49- (0) 22 03-96 49-334
42
Correction factor
®
igus® GmbH
iglidur
Internet: www.igus.de
Phone +49- (0) 22 03-96 49-145
iglidur®
E-mail: info@igus.de
51127 Cologne
Fax
Plain Bearings
+49- (0) 22 03-96 49-334
Wear during abrasive dirt accumulation
Table 45.1: Wear limits of iglidur ® plain bearings
can be maintained at optimal levels even when there is extreme dirt
P
P
0,40
J
J
F
F
2,60
ZZ
2,60
G
G
4,00
H370
H370
2,50
H
H
®
iglidur
Plain Bearings
iglidur® – Plain Bearings – High Performance
Special wear problems frequently occur if abrasive dirt particles get
accumulation.However, it’s not just hard particles that can damage
Z
Z
2,10
M250
M250
3,40
P
P
Fax
iglidur® – Plain Bearings – High Performance
Coefficient of friction
resistance of the materials and the self lubrication process provide for
iglidur® plain bearings are self-lubricating by the addition of solid
the highest service lifetime. Because no oil or grease is on the bearing,
Coefficients of friction and surfaces
bearings and shafts. Soft dirt particles such as, for example, textile
Graph 45.1: Wear with shaft cold rolled steel,
H370
H370
4,00
X
X
H370
H370
iglidur®
Graph 44.1: Frictional values of iglidur® materials under different loads
of friction measurement.
dirt particles can not penetrate as easily into the bearing. The largest
time of machines and systems in these situations. The high wear
FR = µ x F
portion simply falls away from the bearing thus limiting potential damage.
into the bearing. iglidur® plain bearings can clearly improve the operating
Depending on whether an application is starting from a stopped
If however, a hard particle penetrates into the bearing area, then an
lubricants. The solid lubricants lower the coefficient of friction of the
position or the movement is in progress and needs to be maintained
iglidur® plain bearing can absorb this particle. The foreign body becomes
plain bearings and thus increase the wear resistance. The coefficient
a choice is made between static friction coefficient and the dynamic
At study here is the relationship between coefficients of friction and
or paper fibres, are frequently the cause for increased wear. In this
embedded in the wall of the bearing. Up to a certain point, operation
friction coefficient.
surface roughness of shaft materials. It is clearly shown that the amount
instance, the dry running capability and the dust resistance of the
J
J
W300
W300
2,50
JJ
2,40
Material
Wear limit [°C]
iglidur® H
120
iglidur® H2
120
iglidur® H370
150
iglidur® H4
120
iglidur® J200
70
iglidur® L250
120
iglidur® P
100
iglidur® Q
80
iglidur® T220
90
iglidur® UW
70
iglidur® UW500 190
iglidur® V400
130
iglidur® Z
200
of friction is composed of different factors. If the shaft is too rough,
W300
W300
4,00
G
G
1,50
M250
250
Phone +49- (0) 22 03-96 49-145
0,10
0,20
0,30
0,40
0,50
45
mm
+49- (0) 22 03-96 49-334
Material
Wear limit [°C]
iglidur® G
120
iglidur® W300
120
iglidur® X
210
iglidur® M250
80
iglidur® J
70
iglidur® A200
80
iglidur® A290
120
iglidur® A500
190
iglidur® B
70
iglidur® C
70
iglidur® D
70
iglidur® F
130
iglidur® GLW
100
abrasion levels play an important role. Small areas of unevenness that
44
33
22
11
44
33
22
11
44
1,60
W300
W300
www.igus.de/en/iglidur
G
G
0,50
p = 0.75 MPs, v = 0.5 m/s, Ra = 0.20 µm
33
22
11
00
1,50
Graph 45.3: Wear with shaft HR carbon steel,
00
0,30
V2A, p = 0.75 MPa, v = 0.50 m/s, Ra = 0.20 µm
Graph 45.2: Wear with shaft 303 stainless steel,
00
1,30
p = 0.75 MPa, v = 0.50 m/s, Ra = 0.20 µm
Wear and surfaces
Shaft materials
traditional methods of measurement technology. Shafts can be
1,10
help save costs in numerous applications.
Shaft surfaces are important for the wear of bearing systems. Similar
The shaft is, next to the plain bearing itself, the most important parameter
distinguished and classified according to their hardness and according
is the small wear results of the systems with hard-chromed shafts.
1,40
iglidur® plain bearings go into action. In the past, they were able to
the adhesion, which results from an increased coefficient of friction.
to the considerations for coefficients of friction, a shaft can be too
Due to the fact that the wear of machine parts is a function of so many
in a bea ring system. It is in direct contact with the bearing, and like
page 45
easily vary by a factor of 10 between materials pairings that run well
When the shafts are less hard, the shaft is smoothed during the break-
This very hard, but also smooth shaft acts beneficially on the wear
0,40
can interlock with each other must be worn off the surface. When the
Stick-slip can be the result of a large difference between static and
rough in regard to the bearing wear, but it can also be too smooth. A
different influences, it is difficult to make general statements about the
the bearing, it is affected by relative motion. Fundamentally, the shaft
together. Shaft materials
iglidur ® J
iglidur ® M250
iglidur ® Z
to the surface roughness. The effect of the surface is described on
in phase. Abrasive points are worn off and the surface is rebuilt. For
page 44. The hardness of the shaft also plays an important role.
the preceding pages: Coefficients of friction and wear resistance
plain bearings, certain materials are optimized for low loads, while
some materials, this effect has positive influences, and the wear
Different loads greatly influence the bearing wear. Among the iglidur
Wear and load
iglidur ® H
iglidur ® P
iglidur ® F
others are better suited for high or extremely high loads. With a
iglidur ® A200
iglidur ® A290
hardened, ground shaft, iglidur® J can be characterized as the most
resistance of the polymer bearing increases. In the following graphs,
iglidur ® D
wear resistant bearing material for low loads. iglidur® Q on the other
iglidur ® H2
iglidur ® GLW
the most common shaft materials are listed and the iglidur® materials
that are best suited are compared. For easier understanding, the
Within wide temperature ranges, the wear resistance of the iglidur®
behaviour in many bearing pairs. The wear of many iglidur ® plain
Graph 44.1
hand, is optimized for extreme loads.
iglidur ® L250
iglidur ® A500
iglidur ® H4
plain bearings shows little change. In the maximum temperature range,
bearings is lower on this shaft than on any other shaft material tested.
scaling of the wear axis is the same in all graphs. Especially impressive
iglidur ® J200
however, the temperature increases and the wear of the plain bearing
However, it should be pointed out that because of the typically small
Wear and temperature
iglidur ® C
increases. Table 45.1 on the following page compares the “wear limits”.
surface roughness, the danger of stick-slip on hard chromed shafts
iglidur ® V400
iglidur ® B
One particular exception is represented by iglidur® X The wear resistance
is especially high. Such an overwhelmingly positive influence is not
iglidur ® UW
iglidur ® T200
of iglidur® X increases greatly as temperature increases and reaches
as readily available in the other shaft materials.
Lifetime calculation, CAD files and much more support
the optimum wear resistance at a temperature of 160°C. Then
www.igus.de/en/iglidur
resistance decreases again, gradually.
iglidur ® UW500
Lifetime calculation, CAD files and much more support
0,80
surfaces are too smooth, however, higher adhesion results, i.e. the
dynamic friction and of a higher adhesive tendency of mating surfaces.
shaft that is too rough acts like a file and during movement separates
surfaces adhere to each other. Higher forces are necessary to overcome
Stick-slip also occurs due to intermittent running behaviour and can
however, higher wear can also occur. An extreme increase in friction
result in loud squeaking. Stick slip thus represents a cause for
results due to adhesion. The forces that act on the surfaces of the
High Load
iglidur ® G
0,08
0,08
iglidur ® W300
0,08
iglidur ® X
iglidur ® M250
0,1
iglidur ® J
0,07
iglidur ® Q
0,05
iglidur ® H370
0,07
iglidur ® H
0,07
iglidur ® Z
0,06
iglidur ® P
0,06
0,1
iglidur ® F
iglidur ® A200
0,1
iglidur ® A290 0,13
iglidur ® H2
0,07
iglidur ® D
0,08
0,08
iglidur ® GLW
0,10
iglidur ® A500
0,08
iglidur ® L250
0,08
iglidur ® V400
0,08
iglidur ® H4
0,09
iglidur ® J200
0,10
iglidur ® C
0,06
iglidur ® B
0,09
iglidur ® T220
0,09
iglidur ® UW
iglidur ® UW500 0,12
these noises do not occur or can be eliminated with rough shafts.
sliding face can be so large that regular material blow-outs occur. It
Low Load
0,16
0,24
0,28
0,4
0,19
0,15
0,16
0,20
0,16
0,20
0,36
0,40
0,38
0,27
0,30
0,22
0,38
0,21
0,20
0,22
0,16
0,23
0,30
0,33
0,33
0,28
Thus for applications that have a great potential for stick slip – slow
is significant to note that wear by erosion is non linear. Moreover, it is
small particles from the bearing surface. For shafts that are too smooth,
movements, large resonance of the housings – attention must be paid
malfunction of plain bearings. Over and over again, it is observed that
Graph 44.2: Coefficients of friction of the iglidur® plain bearings for
to the optimal roughness of the shafts.
wear behaviour. Therefore, in numerous experiments, the wear is of
random and can not be accurately predicted in advance.
primary importance as a measurement parameter. In testing, it has
is also worn, however, modern bearing systems are designed so that
Wear resistance
the recommended surface roughness and low load, p = 0.75 MPa
iglidur ® G
become clear what variances are possible between different material
the wear of the shafts is so small that it can not be detected with
iglidur ® W300
iglidur ® Q
pairings. For given loads and surface speeds, the wear resistance can
iglidur ® X
iglidur ® H370
Coefficient of friction
0,00
44
Wear [µm/km)]
Wear [µm/km)]
Wear [µm/km)]
®
igus® GmbH
iglidur
Internet: www.igus.de
Phone +49- (0) 22 03-96 49-145
iglidur®
E-mail: info@igus.de
51127 Cologne
Fax
Plain Bearings
46
+49- (0) 22 03-96 49-334
0,40
H370
H370
0,80
P
0,60
H370
H370
1,70
Q
Q
2,00
Z
Z
1,10
F
F
1,10
A200
2,80
H
H
1,80
H370
H370
1,80
FF
A200
A200
A200
A200
2,10
A200
1,50
A200
0,80
F
1,50
D
D
1,70
For example, with shafts made of 303 Stainless with low loads, good
A comparison of the resistance to radioactive radiation is shown in
Radioactive radiation
iglidur® A200, M250
iglidur® X, Z, UW500
Material
1 x 105 Gy
Radiation resistance
Table 47.2: Comparison of the radiation resistance of iglidur® plain bearings
iglidur® – Plain Bearings – High Performance
to very good values can be obtained with the right bearing material.
materials.
table 47.2. By a wide margin iglidur® X and Z are the most resistant
1 x 104 Gy
However, it must also be stated that no other shaft material produces
2 x 102 Gy
3 x 102 Gy
UV Resistance
2 x 105 Gy
5 x 102 Gy
materials is especially important. Other soft shaft materials obtain a
Plain bearings can be exposed to constant weathering when they are
iglidur® H, H2, H370
3 x 104 Gy
iglidur® P
slightly different view with different bearing materials. With machining
used outside. The UV resistance is an important measurement and
iglidur® A500
2 x 104 Gy
iglidur® A290, G, J, W300, F, Q, D,
steel, the wear values of the seven best iglidur® bearing materials are
indicates whether a material is attacked by UV radiation. The effects
iglidur® L250
J200, B, T220,UW
in a narrow range between 0.6 and 1.8. For many other shafts, the
can extend from slight changes in colour to brittleness of the material.
iglidur® H4
2 x 102 Gy
influence of the shaft materials is much larger, resulting in a difference,
The results show that iglidur® plain bearings are suitable for outside
iglidur® V400, C
use. Only for a few iglidur® materials are any changes expected.
A comparison of the materials to each other is shown in table 47.3.
the shaft that you have chosen for your application is missing in this
p = 0.75 MPa and v = 0.5 m/s You can call us for the data for other
loads and speeds: All of the results shown were made with the loads
Only a small amount of outgassing takes place. In most iglidur® plain
iglidur® plain bearings can be used in a vacuum to a limited extent.
Vacuum
iglidur® X
iglidur® W300
iglidur® G
Material
dependent on the temperature, the length of exposure, and the type
properties. The behaviour of plastics toward a certain chemical is
during their use. This contact can lead to changes of the structural
iglidur® plain bearings can come into contact with many chemicals
iglidur® C
iglidur® B
iglidur® A500
iglidur® A290
iglidur® A200
iglidur® J
iglidur® L250
iglidur® P
iglidur® Q
iglidur® T220
iglidur® UW
iglidur® UW500
iglidur® V400
iglidur® Z
iglidur® plain bearing in UV test
Points UV resistance
Table 47.3: UV resistance of iglidur® plain bearings
p x v combinations.
and amount of the mechanical loading. If iglidur® plain bearings are
iglidur® D
iglidur® M250
resistant against a chemical, they can be used in these media.
iglidur® F
iglidur® H
Sometimes, the surrounding media can even take on the role of a
iglidur® H2
table 47.1 should quickly assist you: If it is not completely clear in a
design application which of the different chemicals can occur or in
which concentration, plain bearings made out of iglidur® X should be
used. This has the best resistance and is only attacked by a few
page 115
concentrated acids. You’ll find a detailed list of chemical resistances
in the rear of the catalog. Chemical resistance
Use in the food industry
For the special requirements made of machines and systems for
producing food and pharmaceuticals, the iglidur® product line offers
two specially developed bearing materials. The material of the bearings
made of iglidur® A200 has approval of the FDA. iglidur® A290 responds
to the norms of the BgVV (German Federal Institute for Consumer
Health Protection and Veterinary Medicine). However, there are also
a number of other iglidur® materials that can be used without hesitation,
since their material contents are physiologically harmless. This applies
and iglidur® X. For all other iglidur® plain bearings, direct contact with
especially for iglidur® M250, iglidur® H, iglidur® Q and iglidur® W300
food should be avoided.
0
0
+
0
0
0
0
+
0
0
0
0
+
+
+
+
0
0
0
0
0
0
+
+
+
iglidur® J200
can even be hydrochloric acid. All iglidur® plain bearings can be used
Table 47.1: Chemical resistance of iglidur® plain bearings
iglidur® H370
Alcohol
in greatly diluted acids and diluted alkalines. Differences can result at
Diluted
iglidur® H4
Diluted
0
0
+
0
0
0
0
+
0
0
0
0
0
+
+
+
+
0
0
0
0
0
0
+
+
+
higher concentrations or higher temperatures. For all iglidur® plain
same way. Therefore plain bearings may also be used lubricated.
Material
Alkalines
+
+
+
0
+
0
+
+
+
+
0
+
+
+
+
+
+
+
0
0
0
+
+
+
+
Solvents
However, in dirty environments, a traditional lubricant can decrease
Acids
+
0
+
0
0
+
+
+
0
0
0
+
+
+
the wear resistance when compared to running dry. The overview in
iglidur® G
iglidur® W300
iglidur® X
iglidur® M250
iglidur® J
iglidur® A200
iglidur® A290
iglidur® A500
iglidur® B
iglidur® C
iglidur® D
iglidur® F
iglidur® GLW
iglidur® H
iglidur® H2
iglidur® H370
iglidur® H4
iglidur® J200
iglidur® L250
iglidur® P
iglidur® Q
iglidur® T220
iglidur® UW
iglidur® UW500
iglidur® V400
iglidur® Z
bearings, their resistance against traditional lubricants applies in the
lubricant. With the most resistant iglidur® material iglidur® X the medium
Chemical resistance
bearings, the outgassing does not change the material properties.
existing data. All of the results given were obtained under the same
overview, please call us. The test results give only a sample of the
up to 10 times, between the best and the worst of the bearings tested.If
such as 303 Stainless Steel, therefore, the selection of suitable bearing
a larger difference in wear among the bearing materials. For materials
iglidur® – Plain Bearings – High Performance
Graph 46.1: Wear with a hard chromed shaft,
1,80
Q
Q
3,20
Z
J
J
J
J
2,80
Q
www.igus.de/en/iglidur
®
iglidur
Plain Bearings
p = 0.75 MPs, v = 0.5 m/s, Ra = 0.20 µm
3,00
0,20
J
J
0,80
J
1,50
M250
M250
1,30
M250
M250
0,30
JJ
Lifetime calculation, CAD files and much more support
Fax
44
0,20
M250
M250
2,00
M250
1,50
1,40
M250
M250
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iglidur®
33
22
11
00
W300
W300
0,30
p = 0.75 MPa, v = 0.5 m/s, Ra = 0.20 µm
Graph 46.2: Wear with a silver steel shaft,
4
3
2
1
0
W300
2,00
1,30
W300
W300
0,30
p = 0.75 MPa, v = 0.5 m/s, Ra = 0.20 µm
Graph 46.3: Wear with an aluminum shaft,
44
33
22
11
00
G
G
1,20
W300
W300
0,60
p = 0.75 MPa, v = 0.5 m/s, Ra = 0.20 µm
Graph 46.4: Wear with a machining steel shaft,
44
33
22
11
00
G
G
W300
W300
0,10
p = 0.75 MPa, v = 0.5 m/s, Ra = 0.20 µm
Graph 46.5: Wear with a shaft made of X90,
44
33
22
1
1
00
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mm
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Wear [µm/km)]
Wear [µm/km]
Wear [µm/km]
Wear [µm/km]
Wear [µm/km]
®
igus® GmbH
iglidur
Internet: www.igus.de
Phone +49- (0) 22 03-96 49-145
iglidur®
E-mail: info@igus.de
51127 Cologne
Fax
Plain Bearings
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48
bearings, there are both insulating as well as electrically conductive
In the product line of the maintenance free, self lubricating iglidur plain
Electrical properties
is necessary, table 699.1 shows the machining standard values.
cases. If for some reason, a subsequent machining of the plain bearing
product line makes it possible to use a standard dimension in most
iglidur® plain bearings are delivered ready to install. The extensive
Machining
Tool relief angle
Feed [mm]
Tool material
Process
5 - 15
0.1 - 0.5
SS
Turning
Table 49.1: Guidelines for machining
10 - 12
0.1 - 0.5
SS
Boring
SS
Milling
iglidur® – Plain Bearings – High Performance
Surface resistance [Ω]
materials. The most important electrical properties are given in detail
iglidur® – Plain Bearings – High Performance
1.5 x 10 1
in the individual material descriptions. Table 48.1 compares the most
Tolerances and measurement system
recommended tolerance. The before pressfit oversized dimension can
diameter adjusts only after pressfit in the proper housing bore with a
iglidur® plain bearings are produced oversized as standard. The inner
> 1000
®
iglidur
Plain Bearings
Table 48.1: Electrical properties of conductive iglidur® plain bearings
Material
8.8 x 10 1
The installation dimensions and tolerances of the iglidur® plain bearings
be up to 2% of the inner diameter. In this manner, the secure pressfitting
Fax
> 0.5
iglidur® F
2.8 x 10 3
are a function of the material and wall thicknesses. For each material,
of the bearing is achieved. Axial or radial shifts in the housing are also
3-5
iglidur® H
the moisture absorption and the thermal expansion are imperative.
prevented. The bore in the housing should be finished in the
50 - 100
iglidur® H370
Plain bearings with low moisture absorption can be designed when
recommended tolerance for all bearings and be as smooth, flat, and
0 - 10
Tool rake angle
there is a minimal amount of tolerance. For wall thickness, the rule is:
chamfered when possible. The installation is done using an flat press.
Adhesion
200 - 500
Cutting speed [m/min]
the iglidur® M250 which is very suitable for secondary machining. In
The subsequent machining of the running surfaces is to be avoided
plain bearings not mentioned here are electrically insulating. Please
if possible. Higher wear rate is most often the result. An exception is
observe that for some materials the properties can be changed by
machining can be counteracted by lubrication during installation.
other iglidur ® plain bearings, disadvantages of a sliding surface
important electrical properties of iglidur® plain bearings. The iglidur®
the material’s absorption of moisture. In experiments, it should be
The thicker the bearings are, the larger the tolerances must be. Thus,
The use of centering or calibrating pins can cause damage to the
Installation
different tolerance classes exist for iglidur® plain bearings: Within these
bearing and create a larger amount of clearance.
conditions are changing.
tested whether the desired properties are also stable when the
6.9 x 10 2
1
2
3
temperature range and in humidity conditions up to 70% according
tolerances, iglidur® plain bearings can operate in the permissible
Adhering of the bearing is normally not necessary. If the pressfit of the
to the installation recommendations. Should higher air moisture levels
be present, or the bearing is operated underwater, our application
bearing could be lost because of high temperatures, the use of a plain
advice is available to help you use your bearings correctly.
however, the securing of the bearing by adhesives is planned, individual
Section view: pressfit of the bearing
iglidur®
49
mm
+49- (0) 22 03-96 49-334
iglidur® X
Ø
Positions of the measurement planes
tests are necessary in each case. The transfer of successful results
bearing having a higher temperature resistance is recommended. If
iglidur® plain bearings are pressfit bearings for bores machined to
to other application cases is not possible.
Testing methods
our recommendations. This pressfitting of the bearing fixes the
Troubleshooting
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The installation
Lifetime calculation, CAD files and much more support
bearing in the housing, and the inner diameter of the plain bearing
is also formed upon pressfit. The bearing test is performed when
the bearing is installed in a bore with the minimum specified
dimension; both using an indicating caliper and a Go-No-Go
gauge.
must pass easily through the bearing
the "Go-Side" of the Go-No-Go gauge, pressed into the bore,
pressfit must lie within the prescribed tolerance on the measurement
With the 3 point probe, the inner diameter of the bearing after
In spite of careful manufacturing and assembly of the bearings,
plane.
Measurement of the inner
differences and questions regarding the recommended installation
diameter of a pressfit plain bearing
dimensions and tolerances can result. For this reason, we have compiled
a list of the most frequent reasons for differences. In many cases, with
www.igus.de/en/iglidur
within the same parameters shown.
The measurement is not performed
The shaft is not within recommended tolerances.
that was expanded by the bearing installation
The housing is made out of a soft material
recommended housing bore specifications
The bore does not meet the
the inside diameter of the bearing during pressfit
A centering pin was used which expanded
bearing material is removed upon pressfitting.
The bore is not chamfered properly – the
this troubleshooter, the reasons for the differences can be found quickly.
.
Lifetime calculation, CAD files and much more support
Phone +49- (0) 22 03-96 49-145
®
igus® GmbH
iglidur
Internet: www.igus.de
51127 Cologne
Fax
Product Range
3 Styles
> 904 Dimensions
Ø 1–150 mm
+130º
–40º
Max. running speed
Rotating
4
1.5
1
5
2.5
2
Continuous Short term
Oscillating
[m/s]
Linear
Price index
iglidur® G – the Allround Performer
iglidur® G bearings cover an extremely wide range of differing requirements – they are truly
and medium temperatures.
When not to use iglidur® G
“allround”. Application is recommended for medium to high loads, medium sliding velocities
When to use iglidur® G
iglidur® M250
When mechanical reaming of the wall surface is
necessary
Multi purpose
Vibration dampening
Dirt resistant
Maintenance free, dry running
use
For oscillating
iglidur® W300
When the highest wear resistance is necessary
Cost
Resistance to dust and
Over 900 sizes available from stock
For low to
Economical all round performance
For above average loads
to run on different shaft materials
iglidur® G
% weight
4.0
0.7
0.42
DIN 53457
DIN 53495
Testing method
High wear resistance
dirt
effective
bearing
and rotational movements
When the bearing needs
Conveyor chains: Through edge
average running speeds
loading, short term surface pres-
Unit
% weight
MPa x m/s
7,800
DIN 53452
sures of over 50 MPa can occur
General properties
1.46
Material table
g/cm3
Max. moisture absorption at 23°C / 50% r.F.
dark grey
Density
Max. moisture absorption
0.08 - 0.15
Colour
Coefficient of sliding friction, dynamic against steel µ
Mechanical properties
MPa
210
(Ra = 1 µm, 50 HRC)
The pneumatic rotational drive
Modulus of elasticity
78
p x v Value, max. (dry)
unit in steam lines at steam
MPa
Physical and thermal properties
DIN 53505
MPa
80
Tensile strength at 20°C
MPa
130
Compressive strength
Max. static surface pressure (20°C)
°C
-40
220
temperatures up to 135°C
Max. long term application temperature
°C
°C
81
Max. short term application temperature
Shore D hardness
Min. application temperature
DIN 53752
DIN IEC 93
ASTM C 177
DIN 53482
9
> 1013
0.24
> 1011
[K-1 x 10-5]
Ω cm
[W/m x K]
Electrical properties
Ω
Thermal conductivity
Tests under high radial forces,
Surface resistance
Specific volume resistance
Coefficient of thermal expansion (at 23°C)
distances of 3,ooo km are cover-
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ed with negligible wear values
Lifetime calculation, CAD files and much more support
10
06
08
0
50
100
120
23°C
75
140
160
100
60°C
0,5
0,4
0,3
0,2
0,10
0,15
Surface speed [m/s]
0,1
0,05
0,35
10
Load [MPa]
0
20
30
0,20
40
0,25
50
Coefficient of friction of
iglidur® G as a function of the load
0,30
0,25
0,20
0,15
0,10
0,05
0,00
0,5
0,4
0,3
0,2
0,1
0,0
0,5
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Shaft roughness Ra [µm]
0,0
1,0
1,5
70
0,30
Coefficient of friction as function of the
shaft surface (shaft – cold rolled steel)
60
2,0
80
0,35
Coefficient of friction of iglidur® G as a
function of the running speed, p = 0.75 MPa
iglidur® G – Information and Technical Data
100
1,0
Permissible p x v - values for running
dry against a steel shaft, at 20°C
10
1,0
0,1
0,1
Surface speed [m/s]
0,01
04
Temperature in °C
02
Recommended max. permissible static
surface pressure as a function of temperature
90
100
80
70
60
50
40
30
20
10
0
10
Load [MPa]
25
iglidur® G deformation
under load and temperature
9
8
7
6
5
4
3
1
2
0
0
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G
51
mm
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iglidur® G
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Coefficient of friction µ
Coefficient of friction µ
Coefficient of friction µ
G
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50
igus® GmbH
Load [MPa]
Load [MPa]
Deformation in %
iglidur® G
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Fax
12
10
8
6
4
2
0
0
1
CR Steel
Temperature in °C
303
10
20
30
2
3
3,5
4,4
4
Hard chromed
HR Carbon steel
50
60
6,4
70
CR Steel (pivoting)
5
80
Effect of moisture absorption
on iglidur® G plain bearings
0,6
0,5
0,4
0,3
f = 0,5
f = 0,3
d1 = 12–30
d1 = 6–12
d1 = 1–6
G S M-01 03 - 02
Structure – Part No.
d1
d2
iglidur® G – Sleeve Bearing – Type S
f = 0,8
d1 > 30
b1
f = 1,2
GSM-0911-06
GSM-0810-22
GSM-0810-20
GSM-0810-16
GSM-0810-15
GSM-0810-13
GSM-0810-12
GSM-0810-10
GSM-0810-08
GSM-0810-07
GSM-0810-06
GSM-0809-12
GSM-0809-08
GSM-0809-05
GSM-0709-12
GSM-0709-10
GSM-0709-09
GSM-0708-19
GSM-0708-10
GSM-0608-13
GSM-0608-11
GSM-0608-10
GSM-0608-09
GSM-0608-08
GSM-0608-06
GSM-0608-055
GSM-0608-05
GSM-0608-04
GSM-0607-17.5
GSM-0607-06
10.0
10.0
9.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
7.0
7.0
7.0
7.0
7.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
12.0
11.0
11.0
11.0
10.0
10.0
10.0
10.0
10.0
10.0
10.0
10.0
10.0
10.0
9.0
9.0
9.0
9.0
9.0
9.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
7.0
7.0
4.0
25.0
10.0
6.0
22.0
20.0
16.0
15.0
13.0
12.0
10.0
8.0
7.0
6.0
12.0
8.0
5.0
12.0
10.0
9.0
19.0
10.0
13.8
11.8
10.0
9.5
8.0
6.0
5.5
5.0
4.0
17.5
6.0
GSM-1618-25
GSM-1618-20
GSM-1618-15
GSM-1618-13.5
GSM-1618-12
GSM-1618-10
GSM-1517-25
GSM-1517-20
GSM-1517-15
GSM-1517-12
GSM-1517-10
GSM-1517-04
GSM-1516-15
GSM-1416-25
GSM-1416-20
GSM-1416-15
GSM-1416-10
GSM-1416-08
GSM-1416-03
GSM-1315-25
GSM-1315-20
GSM-1315-15
GSM-1315-10
GSM-1315-075
GSM-1215-22
GSM-1215-06
GSM-1214-25
GSM-1214-20
GSM-1214-15
GSM-1214-14
GSM-1214-12
GSM-1214-10
GSM-1214-08
16.0
16.0
16.0
16.0
16.0
16.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
14.0
14.0
14.0
14.0
14.0
14.0
13.0
13.0
13.0
13.0
13.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
18.0
18.0
18.0
18.0
18.0
18.0
17.0
17.0
17.0
17.0
17.0
17.0
16.0
16.0
16.0
16.0
16.0
16.0
16.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
14.0
14.0
14.0
14.0
14.0
14.0
14.0
25.0
20.0
15.0
13.5
12.0
10.0
25.0
20.0
15.0
12.0
10.0
4.0
15.0
25.0
20.0
15.0
10.0
8.0
3.0
25.0
20.0
15.0
10.0
7.5
22.0
6.0
25.0
20.0
15.0
14.0
12.0
10.0
8.0
d1-Tol.*
Dimen.
5.0
b1 h13
Chamfer in relation to the d1
d2
6.0
Type
d1
12.0
7.0
Dimensions according to ISO
Part No.
10.0
12.0
8.0
Material
b1 h13
GSM-1012-05
10.0
12.0
3547-1 and special dimensions
d2
2.0
GSM-1012-06
10.0
*after Pressfit in Ø H7
d1
3.0
3.0
GSM-1012-07
0,2
Part No.
1.5
3.5
5.0
d1-Tol.*
GSM-0103-02
2.0
4.5
9.0
0,1
GSM-0203-03
2.5
12.0
10.0
0,0
GSM-02504-05
10.0
12.0
12.0
4,0
GSM-1012-08
10.0
12.0
14.0
3,5
3.0
GSM-1012-09
10.0
12.0
3,0
4.5
5.0
GSM-1012-10
10.0
2,0
3.0
4.5
6.0
GSM-1012-12
15.0
1,5
GSM-0304-03
3.0
4.5
4.0
12.0
1,0
GSM-0304-05
3.0
5.5
10.0
0,5
GSM-0304-06
4.0
GSM-1012-14
0,0
GSM-0405-04
6.0
Moisture absorption [weight %]
Electrical properties of iglidur® G
5.5
20.0
4.0
12.0
GSM-0405-06
12.0
iglidur® G
13.0
17.0
10.0
12.0
12.0
10.0
GSM-1012-20
GSM-1012-15
GSM-1213-12
8.0
5.0
6.0
8.0
4.0
15.0
4.5
6.0
13.0
GSM-0406-08
6.0
12.0
14.0
> 1013 Ω cm
5.0
GSM-1213-15
12.0
Specific volume resistance
5.0
5.0
GSM-1214-04
12.0
GSM-0506-05
7.0
8.0
10.0
GSM-0506-07
5.0
7.0
GSM-1012-17
GSM-0507-05
5.0
14.0
GSM-1011-10
10.0
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GSM-1011-25
Lifetime calculation, CAD files and much more support
GSM-1012-04
6.0
GSM-0507-08
12.0
5.5
Resistance
GSM-1214-06
7.0
Resistant
10.0
4.0
Medium
Resistant
7.0
GSM-0407-055
Alcohols
Not resistant
5.0
> 1011 Ω
Important tolerances for iglidur® G
plain bearings after pressfit
iglidur®G
+0.020 + 0.068
Shaft h9
+0.025 + 0.083
Diameter
0 - 0.030
+0.032 + 0.102
E10 [mm]
0 - 0.036
+0.040 + 0.124
[mm]
> 3 to 6
0 - 0.043
+0.050 + 0.150
d1 [mm]
> 6 to 10
0 - 0.052
+0.060 + 0.180
+0.014 + 0.054
> 10 to 18
0 - 0.062
+0.072 + 0.212
0 - 0.025
> 18 to 30
0 - 0.074
up to 3
> 30 to 50
0 - 0.087
+0.085 + 0.245
> 80 to 120
0 - 0.100
> 50 to 80
> 120
Chlorinated hydrocarbons
Resistant
Chemical resistance of iglidur® G
Esters
Conditionally resistant
Conditionally resistant
Greases, Oils
Weak acids
Not resistant
Resistant
Strong acids
Conditionally resistant
Ketone
Weak alkalines
Conditionally resistant
Fuels
Strong alkalines
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GSM-0507-10
Surface resistance
2,5
iglidur® G – Information and Technical Data
40
Wear for pivoting and rotating applications with
shaft material cold rolled steel 1018, as a
function of the load
200
180
160
140
120
100
80
60
40
20
0
0
Load [MPa]
CR Steel (rotating)
Reduction of the inner diameter [%]
Wear rotating with different shaft materials,
load p = 0.75 MPa, v = 0.5 m/s
3,2
H. A. Aluminum
7
2,6
HSS
6
2,5
Drill rod
5
1,6
Hard chromed
4
1,2
CRS
3
2
1
0
303
Wear with different shaft materials in rotational
operation, as a function of the load
Shaft materials
Free cutting
Lifetime calculation, CAD files and much more support
G
53
mm
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HRCS
G
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52
igus® GmbH
iglidur® G
+49- (0) 22 03-96 49-334
Fax
Wear [µm/km]
Wear [µm/km]
Wear [µm/km]
iglidur® G
+49- (0) 22 03-96 49-334
Internet: www.igus.de
51127 Cologne
Fax
GSM-1820-45
GSM-1820-25
GSM-1820-20
GSM-1820-15
GSM-1820-12
GSM-1820-10
Part No.
19.0
19.0
18.0
18.0
18.0
18.0
18.0
18.0
d1
21.0
22.0
22.0
22.0
20.0
20.0
20.0
20.0
20.0
20.0
d2
10.5
3.0
20.0
35.0
28.0
6.0
45.0
25.0
20.0
15.0
12.0
10.0
b1 h13
GSM-4044-16
GSM-4044-10
GSM-3539-50
GSM-3539-40
GSM-3539-30
GSM-3539-25
GSM-3539-20
GSM-3539-14
GSM-3236-40
GSM-3236-30
GSM-3236-20
GSM-3034-40
GSM-3034-35
GSM-3034-30
Part No.
40.0
40.0
40.0
40.0
35.0
35.0
35.0
35.0
35.0
35.0
32.0
32.0
32.0
30.0
30.0
30.0
d1
44.0
44.0
44.0
44.0
44.0
44.0
39.0
39.0
39.0
39.0
39.0
39.0
36.0
36.0
36.0
34.0
34.0
34.0
d2
50.0
40.0
30.0
20.0
16.0
10.0
50.0
40.0
30.0
25.0
20.0
14.0
40.0
30.0
20.0
40.0
25.0
30.0
b1 h13
*after Pressfit in Ø H7
3547-1 and special dimensions
Dimensions according to ISO
Chamfer in relation to the d1
f = 1,2
f = 0,8
f = 0,5
f = 0,3
d1 > 30
d1 = 12–30
d1 = 6–12
d1 = 1–6
G F M-03 04 - 02
Structure – Part No.
Material
Type
Dimen.
d1
d2
iglidur® G – Flange Bearing – Type F
GSM-1922-06
19.0
22.0
15.0
GSM-4044-20
40.0
40.0
iglidur® G – Sleeve Bearing – Type S
GSM-1922-28
20.0
22.0
20.0
GSM-4044-30
40.0
22.0
d1-Tol.*
GSM-1922-35
20.0
22.0
22.0
GSM-4044-40
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www.igus.de/en/g
30.0
Lifetime calculation, CAD files and much more support
GSM-3034-24
www.igus.de/en/g
GSM-3034-25
Lifetime calculation, CAD files and much more support
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+49- (0) 22 03-96 49-334
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54
igus® GmbH
iglidur® G
Phone +49- (0) 22 03-96 49-145
iglidur® G
+49- (0) 22 03-96 49-334
Internet: www.igus.de
STATOIL HYDRAWAY HMA 68
Hydraulikkolje
ANVENDELSEOMRÅDER
EGENSKAPER
Moderne, kompakte hydrauliske systemer stiller høye krav til
hydraulikkoljer for å sikre problemfri drift i mange år.
HydraWay HMA 68 anbefales til all innendørs hydraulikk samt
til visse typer utendørs hydraulikk. Oljen kan dessuten med
fordel benyttes i tåke- og sirkulasjonssystemer.
HydraWay HMA 68 er en sinkfri hydraulikkoljeserie som er
utviklet for å overstige de kravene som stilles til dagens og
morgendagens hydraulikkoljer. HydraWay HMA 68 er basert
på lyse, hardt solventraffinerte parafinbasisoljer med
funksjonsforbedrende additiver. Oljen motvirker effektivt
slitasje og har meget gode luft- og vannutskillende
egenskaper. Fraværet av sink gir redusert risiko for
allergireaksjoner og reduserer miljøbelastningen.
FORDELER
HydraWay HMA 68 sikrer problemfri drift p.g.a. sine ekstremt
gode slitasjebeskyttende egenskaper og den gode evnen til å
skille ut luft og vann. Oljen er sinkfri, noe som reduserer
miljøbelastningen.
TYPISKE DATA
EGENSKAPER
METODE
ENHET
ISO VG
Densitet ved 15 °C
Viskositet ved 40 °C
Viskositet ved 100 °C
Viskositetsindeks
Flytepunkt
Flammepunkt COC
Filtrerbarhet 1.2
TOST
FZG A/8 - 3/90
ASTM D 4052
ASTM D 445
ASTM D 445
ASTM D 2270
ASTM D 97
ASTM D 92
"CETOP"
ASTM D 943
CEC-L-07-A-75
kg/m³
mm²/s
mm²/s
°C
°C
ml/cm²
h
FLS
68
879
68
8.7
100
-27
244
104
>2000
>12
SPESIFIKASJONER
Klassifiseres som ISO-L-HM i henhold til SS 155454 og
ISO 6743-4, IP 281/80,
DIN 51524-HL / DIN 51524-HLP
Med forbehold om endringer i produktspesifikasjonen
Statoil Norge AS, Postboks 1176 Sentrum, 0107 Oslo.
Tel. 22 96 20 00, fax 22 96 27 33. email. lubsupno@statoil.com
2006-06-22
Statoil Norge AS, Postboks 1176 Sentrum, 0107 Oslo.
Tel. 22 96 20 00, fax 22 96 27 33. email. lubsupno@statoil.com