Schaeffler at EMO 2013: Components for Economical Operation
Schaeffler offers customized solutions for high-speed rotary table axes
The requirements placed on rotary tables in terms of speed, torque and accuracy are continuously increasing in turning, milling or hard turning applications. Motors for rotary tables must be precisely designed and optimized according to the operating conditions. By using Schaeffler components such as rotary table bearings, direct drives and Schaefflers consultation service, customers can obtain an estimation of the thermal stability of a system before it is realized. The risks that exist particularly with high-speed rotary tables (e.g. thermal overloading) are minimized. It is possible to ensure that all components operate in a stable manner in the limit range by correct selection of the magnet material, motor development, bearing concept and control systems. Heat energy losses are reduced and system accuracy is increased. Optimal design can cut operating costs for axes and reduce the duration of projects.
Selected components for optimized use
With the rotary high performance direct drive series RKI, INA Drives & Mechatronics AG & Co. KG (IDAM) has achieved outstanding and previously unachievable performance characteristics. The drives have torque levels 30% higher than conventional torque motors. The speed and mechanical power have been increased by a factor of five. At the same time, the power loss is reduced by up to 60%. This generates less heat. Energy efficiency is improved and, since less cooling is required, there is a significant reduction in operating costs. Downsizing options may also prove a persuasive solution: Smaller motors can be used while maintaining the same performance and reducing costs for convertors and motors.
The interaction of components, for example, the influence of the convertor on the motor or the influence of speed on the location where heat is developed, are decisive factors for the economical operation of the axis. An ill-considered combination of bearings, motors, control systems and measurement systems for these types of applications is therefore ruled out. An analysis of the entire mechatronic system is essential. The adjustment of the internal design geometry is initially taken into consideration when adapting motors and bearing components. Additional characteristics, such as the robustness of bearing concepts with regard to the introduction of heat and the friction generated at maximum speeds should also be considered. For example, an INA high-speed rotary table bearing ZKLDF is especially suitable for combination with the IDAM RKI drive with regard to the introduction of heat in the inner ring.
Suitable combinations for high-speed applications are the high speed IDAM motor series RKI or the cost-optimized smart power version in conjunction with YTRS or ZKLDF bearing solutions. Experts from IDAM provide professional support with the design, mounting position and simulation right up to initial operation for this large number of possible combinations.
It is important to consider the entire system in order to assess the interaction of the individual solutions and to have a knowledge of specific effects, for example, the heat power loss of a rotary table with milling and/or turning options. This is the only way to make recommendations for fitting bearings, for the associated motor with minimal losses in the rotor and also for a cooling strategy that is matched to the application. This is also a prerequisite for reducing power or heat losses by more than 50% , increasing accuracy and cutting costs.
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Schaeffler at EMO 2013: Components for Economical Operation
