engineering mannesmann Rexroth AC Main Spindle Drives with Controlled Asynchronous Motors and Frameless Spindle Motors Applications Manual DOK-DIAX01-MAIN+2AD+1M-ANW1-EN-P 252103 Indramat
• DOK-DIAX01-MAIN+2AD+1M-ANW1-EN-E1,44 • 07.
Overview of Sections Section About this Documentation ____________________________________________________________________ Table of Contents ____________________________________________________________________ Commissioning 1 __________________________________________________________________ Operating the Controllers 2 ____________________________________________________________________ Controller Functions 3 ____________________________________________________________________ Diagnostics and Fault Cleara
• DOK-DIAX01-MAIN+2AD+1M-ANW1-EN-E1,44 • 07.
About this documentation Titel Type of documentation: Documenttype Internal file reference Reference This documentation is used: AC Main Spindle Drives with Controlled Asynchronous Motors and Frameless Spindle Motors Applications Manual DOK-DIAX01-MAIN+2AD+1M-ANW1-EN-E1,44 • 209-0041-4109-01 This electronic document is based on the hardcopy document with document desig.: 209-0041-4109-01 EN/06.
About this document Documentation summary "AC main spindle drives with controlled ...
About this document AC main spindle drive with 1MB controlled frameless spindle motor AC main spindle drives with changeover gearboxes 1MB AC main spindle drives with 2AD controlled asynchronous motor and changeover 2K planetary gearboxes Selection data - summary of the AC main drive system - power ratings - order guidelines Bausatzspindelmotor Bausatzspindelmotor 1MB 375 1MB 310 1MB 240 1MB 200 1MB 160 Bausatzspindelmotor Bausatzspindelmotor Framless spindle motor 1MB 1MB - Stator - Rotor Frameles
• DOK-DIAX01-MAIN+2AD+1M-ANW1-EN-E1,44 • 07.
Contents Contents 1. Commissioning INDRAMAT AC Main Spindle Drives 13 1.1 Summary of Main Spindle Drive Systems ......................................13 1.2 1.2.1 1.2.2 1.2.3 Safety Guidelines ...........................................................................16 Notes on Protecting Personnel ......................................................16 Guidelines on Protecting Equipment ..............................................17 Guidelines on Protecting the Machine ..........................
Contents 3.4 Speed Command Value Ramps .....................................................45 3.5 Command Value Smoothing ..........................................................48 3.6 3.6.1 3.6.2 3.6.3 Spindle Positioning.........................................................................50 Basic Data for Spindle Positioning ................................................. 52 Spindle Positioning via Motor Feedback ........................................
Contents 5.1 General Parameters (A Parameters) ........................................... 106 5.2 Switchable parameter records (P,Q,R,S parameters) .................. 109 5.3 Motor Parameters (M Parameters) .............................................. 111 5.4 Parameter Protocol and Additions List ......................................... 113 6. Interfaces for the NC Controller and Feedback 6.1 Controller Inputs, Signal and Analogue Outputs, Bb Contact ...... 116 6.
• DOK-DIAX01-MAIN+2AD+1M-ANW1-EN-E1,44 • 07.
1. Commissioning INDRAMAT AC Main Spindle Drives 1. Commissioning INDRAMAT AC Main Spindle Drives 1.
1. Commissioning INDRAMAT AC Main Spindle Drives Complete controller RAC 2.2 Main switch 0 User terminal I AC-MAINSPINDLE DRIVE RAC Plug-in terminals: X15: ON,OFF,CS, Bb X16 X15 X16: thermo-sensor of the motor motor feedback motor blower connection three-phase mains motor connection Programming module AS 5.
1. Commissioning INDRAMAT AC Main Spindle Drives Complete controller RAC 3.1 three-phase mains motor connection control voltage 220V ~ Plug-in terminal: X16 X15: ON,OFF,CS, Bb X16: thermo-sensor of the motor User terminal INDRAMAT AC-MAINSPINDLE DRIVE RAC motor feedback Programming module AS 6.
1. Commissioning INDRAMAT AC Main Spindle Drives 1.2 Safety Guidelines 1.2.1 Notes on Protecting Personnel The following problems can occur when operating a drive or a drive package for the first time: • wiring fault • fault in NC program • for operational reasons, monitors are not working These can cause increased risk of accidents and can lead to • personal injuries, • damage to drives and • machines.
1. Commissioning INDRAMAT AC Main Spindle Drives 1.2.2 Guidelines on Protecting Equipment Risk of damage due to incorrect connection • Allow approximately five minutes for DC bus to discharge. Check that voltage is below 50V before commencing work. If in doubt, use shortcircuit! • The transparent cover or front panel must be screwed on to prevent accidental contact during operation. • Current-operated e.l.c.b systems cannot be used with INDRAMAT equipment.
1. Commissioning INDRAMAT AC Main Spindle Drives 1.
1. Commissioning INDRAMAT AC Main Spindle Drives 1.4 Main Spindle Drives with KDA or TDA 1.4.1 Mains Supply Requirements Each time prior to switching on, check that the mains supply meets the requirements of the supply module being used (see supply module documentation). 1.4.2 Checks with the Equipment Switched Off Checking the drive components The installed drive components must be designed for the existing input voltages.
1. Commissioning INDRAMAT AC Main Spindle Drives Checking the terminals and connectors Check that the conductors are securely attached to the terminals, otherwise there exists the risk of damage. The subminiature connectors must be screwed up! Bus connecting cable The control voltage and monitor connections are made via a bus cable the black core of which must be underneath.
1. Commissioning INDRAMAT AC Main Spindle Drives DC bus dynamic braking To ensure that the main drive can be braked when the mains is disconnected, fit no DC bus short-circuit resistor. Checking motor feedback Set mode switch to right. Pressing the "up" arrow key brings the motor speed N into the display (see Section 2, "Operating the Controllers"). Positive speed must be indicated on the display when the motor shaft is rotated clockwise by hand (motor shaft viewed from front).
1. Commissioning INDRAMAT AC Main Spindle Drives 1.4.5 Initial Start-Up Operating the drive with the command value box Switch on the controller enabling signal on the command value box. Apply a small command value. The speed of the drive must follow the command value input. In the event of a fault, the drive can "chatter" uncontrollably. Disconnect the controller enabling signal immediately. If the motor rotates in an uncoordinated way, check that the phasing of the motor power connections is correct.
1. Commissioning INDRAMAT AC Main Spindle Drives 1.5 Main Spindle Drives with RAC Controllers 1.5.1 Mains Requirements For RAC 2.2 and RAC 4.1 Before switching on each time, check that the following mains requirements are met: • For 380V type: (type code field „AC supply voltage“=380) 3 x 400V +6% -15% 50 to 60 Hz • For 460V type: (type code field „AC supply voltage“ = 460) 3 x 400V ±15%, 50 Hz or3 x 460V ±10%, 60 Hz • mains-related earth For RAC 3.1 3 x 380V...
1. Commissioning INDRAMAT AC Main Spindle Drives When installing the RAC into the control cabinet, ensure that the housing makes a good electrical connection with the cabinet. Faults could otherwise occur. • Twisting the load conductors: The motor connections from the RAC should either be twisted or a four-core cable (3 x phase, 1 x earth) should be used. • Connections to other KDA modules (RAC 2.
1. Commissioning INDRAMAT AC Main Spindle Drives The motor blower is protected internally when mounted in the RAC 2.2 by means of the Q1 circuit breaker. The Q1 circuit breaker must be set as follows for axial blowers on 2AD motors: RAC 2.2 with 2AD 132/2AD 160 – 0.63 A RAC 2.2 with 2AD 180 – 1.00 A The value actually set depends on the respective supply module of the RAC 2.2.
1. Commissioning INDRAMAT AC Main Spindle Drives 1.5.4 Connecting the Power Infeed Set controller enabling switch on command value box to OFF and set speed command value to 0 volts. The power is applied by shunting the ON and OFF contacts on terminals strip X15. Do this by using a ten-pin terminal block with two switches, i.e., a N/O contact between terminals 1 and 2, and an N/C between 3 and 4. Attach the terminal to X15.
2. Operating the Controllers 2. Operating the Controllers Indramat main spindle drives make a wide range of functions available for numerous applications. The drives can be easily matched to specified applications. The controllers are operated via the control panel, provided that the controllers are supplied with control voltage, i.e., commissioning must have already been carried out to a large extent. 2.1 The Control Panel The control panel is located on the front panel of the controller.
2. Operating the Controllers 2.2 Main Spindle Drive in Operating Mode The main spindle drive is ready for power input or output. Choice of operating mode: The mode selection switch must be set to the right. Control voltage must be present. Message in Display at Power Up: If the unit is only supplied with control voltage, NO POWER is displayed. Both LEDs are off. If the unit is ready for power output, NO RF is displayed. The green LED comes on.
2. Operating the Controllers 2.2.
2. Operating the Controllers Oper. mode switch Analogue output N (X2/21) Display NO POWER N=NCMD NO RF key pad Output status Definition Weighting Motor speed ^ ± MAX RPM ± 10 V = The last or the last set weighting of the N output is maintained. N Motor speed, high-resolution Motor speed ^ ± 50 1/min ± 10 V = over the entire speed range ^ MAX RPM ± 10 V = (value in parameter A01) The last selected weighting of the N output is maintained.
2. Operating the Controllers 2.3 Switching into parameter mode The Main Spindle Drive in Parameter Mode The main spindle drive is not ready for either power input or output. The parameters can be tested, read and changed. They are stored in an EEPROM on the AS programming module. The mode selection switch must be set to the left. Control voltage must be present. If parameter mode is selected when the motor is rotating, the drive brakes to a standstill and remains without torque! Message in display: (P01.
2. Operating the Controllers 2.3.2 Reading the Parameters The parameter values can be called up into the display in the parameter mode. They are subdivided into six parameter records: Parameter Record A (general parameters) Parameter rec. Parameter rec. Parameter rec. Parameter rec.
2. Operating the Controllers Recording the parameter values A parameter form for listing parameters is in section 5. This allows the values as supplied, and those modified by the user, to be recorded. The permissible ranges of parameter values are also shown in the form. Operating mode switch Display pad key output state P 06 . . . . . (any) P 06 . . . . . Definition display of a P parameter ready to leave P parameters 2x Q 06 . . . . . change in Q parameters Q 06 . . . . .
2. Operating the Controllers When a parameter gets a new value it must be transferred into the memory of the programming module by pressing the red key ("accept key"). Oper. mode switch Display pad key Definition Initial state e.g. A 07 . . . . . lockout for accessing parameter values LOCKED code for 2x changing parameter values 2x A 07 . . . . . changing the para. value changing the numbers (continuous function) A 07 . . . . .
2. Operating the Controllers There is a risk of damage from modified motor parameter values. To start up the drive again with the new parameters, the mode switch must be moved to the right. The message "RFAGAIN" appears in the display. The RF control input must be switched from 0 to + 24 volts. Possible fault messages Possible fault message: UNACCEPT Cause: Invalid parameter combination Remedy: Move operating mode switch to left and press the red key. The incorrect parameter is displayed.
2. Operating the Controllers Procedure: • Switch off main drive. Control voltage must not be present. • Unplug programming module AS and replace with PDA 1. • Plug the master programming module into the „MASTER“ connector. • Plug the slave programming module into the „SLAVE“ connector. • Move the operating mode switch to the left. • Switch on the control voltage. The display now shows the checksum of the master module and a rotating pointer, i.e., transfer running (up to 30 seconds).
3. Controller Functions 3. Controller Functions 3.1 Drive "Ready" State The main spindle drive is "ready" when the following conditions are met: • All controller signal voltages must be present. • The control inputs and signal ouputs (terminal strip X2) must be supplied with ±24 V and 0 V. The supply voltage should be provided via the external controller, but the internal +24V can also be used.
3. Controller Functions 3.2 Performance features Speed Command Value The speed command value can be communicated to the control devices from the controller via an analogue voltage or digitally via a bit pattern. Feature: very broad speed range from minimum speed of 0.0005 rpm to maximum speed. In addition, Indramat main spindle drives offer a far more powerful type of command value input via the "SERCOS interface" option (see section 3.2.1). The speed command value is read at 1.2 ms intervals. 3.2.
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3. Controller Functions Input weighting Note: Command value wieghting is CMDVOLT/MAXRPM, if control input EXTPOS is at 0. If control input EXTPOS is at 1, then the weighting is CMDVOLT/PMAXRPM. P-MAXRPM is part of the selected parameter record (P, Q, R or S). The voltage at the analogue output N can be output with parameter FUNCT2 with reference to P-MAXRPM. Input switching Changing to the second differential input is effected with the EXTPOS control unit.
3. Controller Functions 3.2.2 Digital Speed Command Value (option) The "digital speed command value" enables a task to be matched to the specific plant requirements. The speed command value can be transferred directly from the PLC controller, binary or floating-point coded, depending on the required speed resolution. The parallel signals are interrogated by the control unit every 1.2 ms.
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3. Controller Functions Floating-Point Coding X2 control inputs X4 inputs for digital command value: exponent mantissa ^ 0 1/min "0" = ^ assume 1= current bit pattern 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 BewertungFließkomma Bit 1 1 ^ Bit 2 2 1= ^ Bit 3 4 1= ^ Bit 4 8 1= ^ Bit 5 1 = 1/min 1= ^ " Bit 6 2 1= ^ " Bit 7 4 1= ^ " Bit 8 8 1= ^ 16 " Bit 9 1= ^ 32 " Bit 10 1= ^ 64 " Bit 11 1= ^ 128 " Bit 12 1= ^ 256 " Bit 13 1= ^ 512 " Bit 14 1= Bit 15 rotational dir.
3. Controller Functions 3.3 Main Spindle Speed Signals The main spindle speed determines the time point of the feed enabling signal, gear change and clamping of the holding brake. Function conversion The requirements are met if signal output „Nact = Ncomml“, „N < Nmin“ and the selectable torque disconnect is below Nmin . The signal operating thresholds can be set as required.
3. Controller Functions Motor standstill Furthermore, when the drive is stopped with the controller enable signal switched off (RF contol input=0), the controller can check standstill via the signal output "N=CMD" (speed command value must be 0!). Torque disconnect Torque disconnection is compatible via function parameters if the motor speed is less than the value in parameter MINRPM.
3. Controller Functions Parameter S R Q P01 Designation Function Value range or value RAMP 1 ramp 1 switched off 0 gradient of ramp 1 1.....999 (rad / s2) (1 / min) S R Q P02 RPM 1 end speed of ramp 1 1.....24000 S R Q P03 RAMP 2 ramp 2 switched off 0 gradient of ramp 2 1.....999 (rad / s2) (1 / min) S R Q P04 RPM 2 end speed of ramp 2 1.....24000 S R Q P05 RAMP 3 ramp 3 switched off 0 gradient of ramp 3 1.....
3. Controller Functions ∆ t/s 3 Example 1: ∆ N = 5000 1/min in ∆ t = 2s ⇒ RAMP = 250 2 rad s2 Example 2: ∆ N = 9000 1/min in ∆ t = 1s ⇒ RAMP = 940 500 ( RAMP axis) 100 rad s2 1000 RAMP / 1 rad s2 ∆ N/rpm origin 1000 ☞ 5000 Parameter protocol! 10000 Umrechnung von Drehzahl Figure 28: Converting speed ∆N and slope times ∆t in RAMP (rad/s2) Instructions for using the conversion graph Slope values must be entered in rad/s2 (see Figure 28 for conversions).
3. Controller Functions Function sequence graph Drehzahlrampen Sprung ^ U analogue = A01 ( CMD VOLT ) speed command value, e.g., analogue ( MAX RPM ) A01 motor speed S R Q P05 S R Q P04 ( RPM2 ) S R Q P02 ( RPM1 ) ( RAMP2 ) S R Q P03 S R Q P01 ( RAMP3 ) ( RAMP1 ) time t Figure 29: Speed ramps for step change in speed command value 3.
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3. Controller Functions 3.6 Spindle Positioning Three standard spindle positions can be set for the drive via the controller for simple and rapid tool change on milling centers. If more than three positions are required, for example, • for aligning the tool to the workpiece contour on milling machines, • indexing the workpiece on lathes, or, • positioning workpieces for balance holes on balancing machines, then 3600 optional selectable spindle positions are available.
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3. Controller Functions 3.6.1 Basic Data for Spindle Positioning Function conversion: a) Standard version - three spindle positions • Inhibit the speed command value at the control unit by removing the RUN control signal from the PLC. • Binary selection of one of the three spindle positions via control signals POS1 and POS2 from the PLC.
3. Controller Functions Parameter Designation Function Value range or value A07 OFFSET angular offset of the zero pulse and the spindle reference point 0.....360.0 (°) A08 POS 1 spindle position 1 0.....360.0 (°) A09 POS 2 spindle position 2 0.....360.0 (°) A10 POS 3 spindle position 3 0.....360.
3. Controller Functions 3600 spindle positions Precondition is that the interface for digital position input must be fitted to control unit (type code field "additional interface" = D). inputs for digital position value: X6 with KDA /TDA; X13 with RAC BCD- coded position default ^ 1 = bit pattern connection X2 control inputs 1 1 1 1 * 0.1° 2 2 * 0.1° ^ N command 0= 3 4 * 0.1° value locked 0 4 8 * 0.
3. Controller Functions Parameter Designation Function Value range or value A07 OFFSET angular offset of the zero pulse and spindle reference point 0.....360.0 S R Q P17 POS GAIN gain factor in position control loop 16.6 =^ Kv = 1 0.....99.9 (1/s) S R Q P18 POS RPM positioning speed (limited to 30*POSGAIN) 0.....9999 (1/min) S R Q P21 P-WINDOW tolerance window within which the message "INPOS" is issued S R Q P12 GEAR IN gear ratio i= S R Q P13 N1 N2 (°) N1 1.....999 N2 1.....
3. Controller Functions 3.6.2 Spindle Positioning via Motor Feedback Parameter S R Q P16 ☞ Designation Function Value range or value PQ-FUNCT rotational direction of motor and spindle - same <0> - opposite <2> Parameter protocol ! Para-Spindel-zusatz Figure 40: Additional parameters to 3.6.
3. Controller Functions 3.6.3 Spindle Positioning via Motor Feedback with Spindle Reference Switch Parameter S R Q P16 Designation Function PQ-FUNCT Value range or value - same <0> - opposite <2> rotational direction of motor and spindle spindle reference switch signal to X2/37 < 64 > Note: invalid value < 65 > ! P-MAXRPM Here: spindle speed for searching S R Q P15 1.....
3. Controller Functions + 24V ext 0V spindle reference switch X2 control inputs 37 2 18 17 1 19 α cams for spindle reference switch spindle EXT POS 0 V int + 24 V int 0 V ext + 24 V ext controller α min = P-MAXRPM * 550*10-6s * 6° * min s Referenzschalter Figure 43: Reference switch connections and dwell angle Note: The reference switch can, e.g., be an inductive proximity switch such as one of the Balluf BES 516 series. A shielded cable must be used to connect the spindle reference switch.
3. Controller Functions RUN X2/25 POS 1 X2/26 POS 2 X2/27 α EXT POS X2/37 N spindle speed (P-MAXRPM) P15 spindle position P21 spindle accelerates to speed command value (POSRPM) P18 (P-WINDOW) 360° A08 (POS 1) 270° A10 (POS 3) A09 (POS 2) A07 (OFFSET) 180° 90° 0° positioning direction A06 ( FUNCT 2 ) = < 16 > as per rotational dir. qualifying sign N command value INPOS X2/7 e.g., Display: INPOS INPOS INPOS N = CMD e.g.
3. Controller Functions 3.6.4 Spindle Positioning via Spindle Feedback A precondition is that the control unit is fitted with the interface for the second encoder input (type code field "second encoder input" = P). The incremental encoder fitted to the spindle must be compatible with ROD 420/426 (5V supply voltage).
3. Controller Functions RUN X2/25 POS 1 X2/26 POS 2 X2/27 S = Scommand S = Scommand S spindle speed S X2/21 (POSRPM) P18 spindle position P21 spindle accelerates to speed command value (P-WINDOW) 360° A08 (POS 1) 270° A10 (POS 3) A09 (POS 2) A07 (OFFSET) 180° 90° 0° positoning direction A06 ( FUNCT 2 ) = < 16 > as per rotational direction qualifying sign N command value INPOS X2/7 e.g., Display: INPOS INPOS INPOS N = CMD e.g.
3. Controller Functions 3.7 Speed Controller Functions When changing the speed or changing the operating mode of the drive from the main spindle to the C-axis servo function, different mechanical systems make different demands on the speed controller. Torque build-up Four diferent parameter records, which can be called up via control inputs, are available. Specified speed control parameters are in each of these parameter records for the appropriate mechanical coupling or operating mode.
3. Controller Functions Parameter Designation Function Value range or value S R Q P07 P-GAIN 1 P-gain of the speed controller below switching speed 0.....20.00 S R Q P08 I-GAIN 1 I-gain of the speed controller below switching speed 0.....20.00 S R Q P09 GAIN RPM switching speed from P-I-Gain1 to P-I-Gain2 0.....9999 S R Q P10 P-GAIN 2 P-gain of the speed controller above switching speed 0.....9.99 S R Q P11 I-GAIN 2 I-gain of the speed controller above switching speed 0.....9.
3. Controller Functions Further information about the speed controller and tachometer filter. Follow-up time TN of the speed controller: P-GAIN data: TN ≈ 7ms * P-GAIN I-GAIN approx. 80 1/min ^ = maximum torque command value P-GAIN time constant TGN of tacho filter: T - FILTER TGN /ms 0 ≈0 1 ≈ 1.1 2 ≈ 1.7 3 ≈ 2.7 Tachofilter Figure 49: Data of the speed controller and tachometer filter Note: The values given are guide values only. They vary by about 10% depending on the drive. 3.
3. Controller Functions power spindle and rotor position 1MB frameless spindle motor spindle position power rotor position 2AD main spindle motor C-Achse-Indramat Figure 51: C-axis with Indramat main spindle drives C-axis functions In comparison to pure main spindle speed control, the drive requires the following for C-axis applications. • higher rotational stiffness, • finer resolution of command value input voltage and • a second command value input, depending on the type of controller.
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3. Controller Functions 3.9 Power and Torque Limits Torque and power limiting protects the workpiece, tool and machine from damage in some cases. Indramat main spindle drives provide a choice between: • limiting peak torque without limiting peak power of the drive or • limiting peak torque and peak power of the drive at the same time.
3. Controller Functions Limiting with parameter or analogue voltage In the simplest case, the amount of limiting is stored as a per cent in the switchable parameter records. One value is possible per parameter record. If several limiting values are required within the parameter records, then the limiting value can also be input as a voltage of the analogue input. In both cases, limiting is activated via the MD-RED control input. To avoid speed dips, the drive monitors the utilization.
3. Controller Functions 3.10 Drive Utilitzation Output There is a risk of damage to tools, workpieces or the machine if cutting power is fully utilized. To prevent damage, the main spindle drive controller has three simple ways for displaying and signalling the utilization: • analogue output for visual display on a measuring instrument (analogue output M, see 3.1.0.1) • 90% LOAD signal output (see 3.9) • LOAD LIMIT signal output with adjustable signal threshold (see 3.10.2) 3.10.
3. Controller Functions B) Torque utilization related to the machining • The voltage value relates to the value in parameter LOAD LIM (PQRS 19). • LOAD LIM (PQRS 19) must be arranged via function parameter FUNCT2 (A06) = < 1 > as a % value. • The value in parameter PQ-FUNCT (PQRS 16) must contain < 16 >! The analogue output M now indicates how near the drive approaches a set percentage torque utilization threshold. Four machining-dependent thresholds can be set by the fourfold LOAD LIM parameters.
3. Controller Functions D) Torque value • The voltage value relates to the value in parameter LOAD LIM (PQRS 19). • The value in function parameter FUNCT2 (A06) must contain < 512 >! • Parameter PQ-FUNCT (PQRS 16) has no significance in this case! The analogue output M now indicates how near the load approaches a machining-dependent torque limit. Four machining-dependent torque thresholds can be set by the fourfold LOAD LIM parmeters.
3. Controller Functions Parameter S R Q P16 S R Q P19 A06 ☞ Designation Function Value range or value PQ-FUNCT M output indicates load in per cent +10V = 100% <0> M output indicates voltage +10V as relates to value in LOAD LIM, (kW or %) as specified in A06 < 16 > LOAD LIM torque or power output threshold, depends on A06 0....
3. Controller Functions 3.10.2 Signal output with adjustable threshold for drive utilization (LOAD LIMIT) The signal threshold for drive utilization is fully adjustable. It is included in each of the switchable parameter records PQRS and can be arranged as torque utilization or power signal threshold. If the drive utilization reaches the signal threshold of the active parameter record, then the LOAD LIMIT signal output is active.
3. Controller Functions 3.11 Temperature Pre-Warning Due to the overload capacity of the main drives, load cycles can be used which need more than the continuous power from the drive for short periods. Choice of correct drive size ensures that the temperature of motor and controller is always in the permissible temperature range. If, though, the cooling system of motor or controller is not operating correctly (dirt, etc.), there is a risk of damage to the drive from overheating.
3. Controller Functions 3.12 Maximum Spindle Speed In machine tools, various tools or chucking devices with different permissible maximum speeds, can be used on the main spindle. INDRAMAT main spindle drives enable the spindle speed to be monitored and limited to seven different, freely-selectable maximum speeds.
3. Controller Functions Acknowledging maximum speeds The spindle speed is limited to the amount (±) of the selected maximum speed, and, on reaching the limit speed, is also acknowledged via the LIMIT signal output. Condition for "Nactual = Ncommand" The controller calculates the limit speed of the motor associated with the limit speed of the spindle with the reduction ratio (GEAR IN/GEAR OUT).
3. Controller Functions 3.14 Switchable Parameter Records The switchcable parameter records enable the drive to automatically and rapidly match the various tasks of a flexible machine tool while the drive is in operating mode by • matching to different speeds, • providing functions for various operating processes, • operating with position control loop parameters for spindle positioning, • and with automatic speed change in a two-speed gearbox. Indramat main spindle drives have six parameter records.
3. Controller Functions Parameter name Parameter record P Parameter record Q Parameter record R Parameter record S RAMP 1 RPM 1 RAMP 2 P01 P02 P03 Q01 Q02 Q03 R01 R02 R03 S01 S02 S03 RPM 2 RAMP 3 MD-RED P04 P05 P06 Q04 .. .. R04 .. .. S04 .. .. P-GAIN 1 I-GAIN 1 GAIN-RPM P07 P08 P08 P-GAIN 2 I-GAIN 2 GEAR IN P10 P11 P12 .. .. .. .. .. .. .. .. .. .. .. .. GEAR OUT G-CHANGE P-MAX RPM P13 P14 P15 .. .. .. .. .. .. .. .. .. P16 P17 P18 .. .. .. .. .. ..
3. Controller Functions 3.15 Gear Change Various gear reduction stages are used, according to the spindle speed, to obtain a wide speed range with constant power at the spindle. This requires automatic gear changes in modern machine tools. For two reduction stages, the controller handles the automatic changeover; for more than two stages, the changeover is supported by the controller by speed oscillation (hunting). 3.15.1 Automatic Gear Change via the Controller Prerequsites: • two auxiliary d.c.
3. Controller Functions Parameter S R Q P14 Designation Function G-CHANGE allocation of Value range or value - none <0> - stage 1 <1> - stage 2 <2> parameter record to a gear stage A20 OSCI RPM ☞ oscillation speed for gear changeover Parameter protocol! 1 to 200 (1/min) Para-Getriebeumschalt Figure 74: Parameter for gear change via the controller Note: Gear stages 1 and 2 must each be assigned at least once to a parameter record by parameter values 1 and 2 in the G-CHANGE parameters.
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3. Controller Functions X2 12 SPEED CHANGE 2 maximum load 50 mA K1 11 SPEED CHANGE 1 K2 K2 K1 0 Vext 36 SPEED 2 35 SPEED 1 control unit + 24 Vext 24 V DC 0V do not tap off 24 V DC for gear change motor from the control unit load: Imax = 7A (starting torque) Icont = 2A K2 K1 7 3 2 1 5 4 31 6 S2 S1 M 53 S1 acknowledges gear stage I S2 acknowledges gear stage II Optional blocking brake 24V DC - 2A ZF-indexing mech.
3. Controller Functions 3.15.2 Gear Change via an External Controller Gear stage dependent drive optimization The controller supports the gear change by the NC by: • signalling the gear change "ready" stage (N < Nmin) • and oscillating the speed of the motor shaft. The four parameter records enable the drive to be optimized according to the reduction stage.
3. Controller Functions N < MIN X2/6 OSCILATE X2/29 N = Ncommand N = Ncommand motor speed analog output N A20 A04 X2/21 ( OSCI RPM ) motor accelerates to speed command value ( MIN RPM ) 180 ms 220 ms duration during which the external control switches gears Fkt-ext-Steuer Figure 79: Sequence of operations - gear change via external controller with constant speed command value Sequence of operations The controller initiates the gear change by taking the OSCILLATE control input to 1.
3. Controller Functions 3.16 Two-Motor Changeover It is conceivable in some installations that two drive tasks have to be performed at two different sites. If the two tasks never occur at the same time, then they can be performed with two motors connected to one control unit. The motors are selected by the controller.
3. Controller Functions Parameter S R Q P14 Designation Function value range or value G-CHANGE assignment to - motor 1 <1> - motor 2 <2> motor A06 FUNCT 2 additional encoder input is used as input <4> for the motor feedback of motor 2 ☞ Parameter protocol! Para-2-Motorenumschalt Figure 82: Parameters for two-motor changeover Note: The values 1 or 2 must always be assigned to the G-CHANGE parameters in the four switchable parameter records.
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3. Controller Functions 3.17 Master-Slave Operation Two drives can be combined as master/slave to increase drive power. Here, the master receives the speed command value from the NC; the slave, the torque command value from the master. Master-slave operation is used in a stiff mechanical connection for transmitting power to a common drive shaft. If the mechanical link between the slave and master drive is broken, the speed of the slave drive goes to maximum speed.
3. Controller Functions Parameter Designation Function Value range or value A05 FUNCT 1 Analogue output N continuously outputs < 64 > the torque command value, cannot be changed! ☞ Parameter protocol ! Para-Master Figure 87: Parameters for master drive Slave drive data The slave drive must be fitted with an analogue command value interface (type code field "speed command value" = A).
3. Controller Functions Switching torque-speed control If a main spindle drive is programmed for torque input, the message SLAVE appears in the display. Matching slave to master The drive can be switched from torque to speed input with the PQ FUNCT whilst the machine tool is operating. The correct polarity (direction of rotation) must be observed when applying the torque command value to the slave. Connecting 0 VM of the master and E2 of the slave gives the same direction of rotation.
3. Controller Functions + 24V ext Emergency-Stop of control unit (min. 0.
3. Controller Functions 3.18 EMERGENCY-STOP circuit (RAC) The EMERGENCY-STOP circuit is built into the RAC control unit. It requires no additional circuitry for the power-down logic. In addition, energy released during braking is fed back into the mains. For the E-stop circuit, there are two distinct methods for stopping the drive and switching off the power. Internal command value disconnect The speed command value is set to zero internally after the E-stop control inputs goes from 1 to 0.
3. Controller Functions Parameter Designation Function Value range or value A06 FUNCT 2 Ramp active with E-Stop also < 32 > ☞ Parameter protocol ! Para-NOT-AUS Figure 94: Parameters to activate speed comand value ramps with E-Stop due to mains failure 3.19 Performance during mains failure (RAC) To prevent the main spindle from coasting during a mains failure, the RAC control unit can also brake the asynchronous drive.
3. Controller Functions Parameter Designation Function M15 MOT-FUNCT no braking with power failurel Value range or value <0> braking with power failure by < 16 > " DC bus dynamic braking " ☞ Parameter protocol! Para-Gleich-Brems Figure 95: Parameter for d.c. braking Note: Braking is not possible with the set ramp or via the NC controller during d.c. braking! Parameter Designation Function additional bleeder monitor Value range or value - not working <0> - active < 256 > (RAC 2.
3. Controller Functions Bleeder monitor features of the RAC 2.2 Activated bleeder monitoring prevents a device with overheated bleeder from being switched on again. The display then shows „BLEEDER“. Activated bleeder monitoring also signals „BLEEDER“, if the RAC 2.2 has been inadvertently installed with a bleeder! Bleeder monitor features of the RAC 3.1 Bleeder montioring is always operative when a bleeder is fitted.
3. Controller Functions 3.21 Starting lockout in KDA/TDA For safety reasons, the main spindle should be stopped when settingup machine tools. INDRAMAT main spindle drives are thus fitted with a starting lockout. • The modular system's main drive remains selectively and reliably shut down. • Disconnection is safe, even if the electronics malfunction, since the opto-couplers are switched off and the power bridge is inhibited.
3. Controller Functions 3.22 Serial Interface (option) – in preparation 3.23. SERCOS interface (option) - in preparation 3.24 Incremental Encoder Output (option) – see Section 9 • DOK-DIAX01-MAIN+2AD+1M-ANW1-EN-E1,44 • 07.
4. Diagnostics and Fault Clearance 4. Diagnostics and Fault Clearance The control unit shows main spindle drive operating states and faults in the display. Requirements are that the drive is in operating mode (mode switch to the right). 4.1 Operating Status Diagnostics The green „READY“ LED comes on. The operating states appear in the display. DISABLED (KDA only) The drive is free of torque, the power output stage is inhibited. The AS (X2/3) control input is at 1. Note: see Section 3.
4. Diagnostics and Fault Clearance Note: The message appears in the acceleration and braking mode if the speed command value is changed abruptly. It can also appear when the drive is purely P-controlled under load! Note: see Section 3.3 N
4. Diagnostics and Fault Clearance 4.2 Fault Diagnostics The red „FAULT“ LED comes on. The fault messages appear in the display. The fault messages must be cancelled with the red accept key after the fault has been remedied (reset). ADW2 Cause: Plug connector X7 on the CDR board in the control unit has been fitted with an ADW2 analogue speed command value interface. Remedy: Switch off the control unit. Replace ADW2 with ADW3.
4. Diagnostics and Fault Clearance EEPROM Cause: No EEPROM (IC3) in the programming module, or the existing EEPROM is faulty. Remedy: Switch control unit off. Insert EEPROM inito programming module, or replace faulty EEPROM. Contact Indramat customer service! FEEDBACK Cause: • Wrong value in FEEDBACK (M03) parameter. This type of motor feedback requires a different parameter value. • Faulty or wrong feedback cable. Remedy: • Set parameter value in M03 which suits the type of motor feedback.
4. Diagnostics and Fault Clearance KK WARN Cause: The heatsink of the control unit has reached the cut-off temperature. The TEMP WARN signal output (X2/9) has switched from 1 to 0. Remedy: With KK WARN, the drive must be perceptibly unloaded because a further rise in temperature at the heatsink means the drive switches off after 30 seconds! Note: see Section 3.11 MOT TEMP Cause: The temperature of the motor windings has reached 155oC. The TEMPWARN signal was ignored. The control unit has switched off.
4. Diagnostics and Fault Clearance NO TEMP Cause: • Broken connection between motor temperature sensor and control unit, or faulty temperature sensor (signal appears approximately ten minuates after fault occurs). Remedy: • Check temperature sensor connections. • If sensor is faulty, contact Indramat customer service! Note: see Section 3.11 NO 8 MHz or NO 12 MHz Cause: Software in programming module does not match control unit. Remedy: Use a programming module which matches the control unit.
4. Diagnostics and Fault Clearance PARA LOST Cause: Programming module has no parameter values. The values were either not loaded or erased. Remedy: Slide mode switch to left and press red button. This loads the general base parameters for running the drive. The load operation is completed when the message "BASISPAR" appears in the display. Pressing the red button again puts the drive into parameter mode. The base parameters are not the optimum ones for the drive and should be replaced (AS ../..).
4. Diagnostics and Fault Clearance RSKCURNT (RAC 3 only) Cause: Overcurrent during regenerative feedback. Remedy: Check if infeed voltage is below minimum. S-CIRCUIT Cause: Short-circuit in motor cable. Remedy: Switch off control unit. Check motor cable (control cabinet cable gland?) and replace, if necessary. Check motor. SPINDLE Cause: No speed information from spindle position encoder. Remedy: • Check coupling between spindle and drive.
5. Overview of Parameters 5. Overview of Parameters 5.1 General Parameters (A Parameters) The general parameters are always active when the drive is in operation. Changes can only be made to parameter alues in the parameter mode. When the parameter mode is selected, the drive brakes to the set ramps and is then free of torque. See sec. Value range or value Parameter Designation Function A01 MAX RPM maximum motor speed 3.2 1.....24000 A02 CMD VOLT analogue voltage for MAX RPM 3.2 6.....
5. Overview of Parameters Function Relevant summand Function See section torque limit if control input MD-RED is on 1 <1> <0> Torque and power limit if control output MD-RED is on 1 3.9 analogue speed command value below value in parameter MIN RPM (A03) is invalid (drift prevention) <2> <0> analogue speed command value is always 1 3.3 torque off if speed less than value in parameter MIN RPM (A03) <4> <0> no speed-dependent torque switch off 3.
5. Overview of Parameters Function Relevant summand Function See section <1> <0> value in parameter LOAD LIM( PQRS 19 ) means power in kW <2> <0> Type code field " speed command value" = D binary coded speed command value 3.2.2 Type code field "2nd enc. input " = P 2nd encoder input is used as motor feedback of motor 2 <4> <0> Type code field " 2nd enc. input " = P 2nd encoder input is input for spindle feedback 3.
5. Overview of Parameters 5.2 Switchable parameter records (P,Q,R,S parameters) These records can be selected when the drive is running. Use control inputs PAR1 and 2. Change parameter values only in parameter mode. When the parameter mode is selected, the drive brakes to set ramp and is then torque free. Refer to section 3.14 for explanations of the switchable parameter records.
5. Overview of parameters Function Relevant summand Function See section If control input EXT POS = 1: analogue N command value via E3/E4 ( X4 ) <1> <0> If control input EXT POS = 1: analogue N command value via E1/E2 ( X4 ) 3.2 Rotational direction of motor shaft and spindle or spindle feedback is counterclokwise <2> <0> Rotational direction of motor shaft and spndle or spindle feedback is the same 3.
5. Overview of Parameters 5.3 Motor Parameters (M Parameters) The motor parameter values are set at the factory and guarantee the characteristics that are specified for the drive (motor controller programming module). The M parameter values may only be changed by trained personnel. The drive could otherwise be damaged. An exception is the MOTFUNCT parameter in drives with RAC. Parameter Designation Function M01 POLES pole number of the motor 2,4,6,8 M02 FEEDBACK feedback type 1.....
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5. Overview of Parameters Remedy: • Set a parameter value in M02 that corresponds to the feedback type of the motor. • Repair or replace feedback cable. Note: In 2AD motors, the feedback type can be read directly from the type designation of the motor (see type code field "motor feedback"). Values for the FEEDBACK parameter In the case of 1MB motors (spindle motors), the feedback type cannot be obtained from the type designation as the motor feedback is fitted separately on the spindle.
5. Overview of Parameters PARAMETER PROTOCOL Motor: Software: Controller: Checksum: Prog. module: Date: A Parameters Design. Parameter number current value value at delivery value range Design. MAX RPM A01 1.....24000 CMD VOLT A02 6.....10 MIN RPM A03 MAX DEF Parameter number current value value at delivery value range ( 1/min ) LIMIT 2 A13 1.....24000 ( 1/min ) (V) LIMIT 3 A14 1.....24000 ( 1/min ) 1.....999 ( 1/min ) LIMIT 4 A15 1.....24000 ( 1/min ) A04 1.....
5. Overview of Parameters ADDITIONS LIST for the FUNCT Parameters for the Parameter Protocol Motor: Software: Controller: Checksum: Prog.
6. Interfaces for the NC controller and feedback control inputs selected spindle position 6. Interfaces for the NC Controller and Feedback 6.1 Controller Inputs, Signal and Analogue Outputs, Bb Contact X2 Control inputs POS 1 POS 2 parameter 0 0 no position 1 0 position 1 A08 0 1 position 2 A09 1 1 position 3 A10 ^ E-stop switched off (RAC) 0= ^ controller lockout 0= ^ command value inhibit for pos.
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6. Interfaces for the NC controller and feedback 6.2 Analogue Speed Command Value •10V (option) 20 K 2 ( E2 ) 20 K voltage level of analogue inputs - 20 K P1 20 K 20 K 1 (E1) + 15V parameter dependent + + 15VM 20 K 5 (E3) 20 K + 20 K - 4 P2 20 K 6 (E4) 20 K - 15V + 15VM 9 ( 10 mA ) + 15V M 8 ( 10 mA ) - 15V M 7 controller Schnittstelle-analog Figure 108: Interface for analogue speed command value Analogue inputs E1/E2 are configured as differential inputs.
6. Interfaces for the NC controller and feedback 6.3 Digital Speed Command Value (option) X4 voltage level + 36V + 24V + 18V + 5V 0V 0 (low) 1 (high) ^ right rotation 1 ^= left rotation, 0 = 1 ^= acceptance of current N comm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Bit 1 Bit 2 4k7 Bit 3 to data bus of controller Bit 4 Bit 5 Bit 6 Bit 7 12 V 2k Bit 8 Bit 9 Bit 10 Bit 11 10 k Bit 12 Bit 13 Bit 14 valid for all rotational direction 16 inputs DATA VALID - 15V int ( max.
6. Interfaces for the NC controller and feedback 6.
6. Interfaces for the NC controller and feedback 6.5 Digital Position Command Value (option) X6 with KDA/TDA; X13 with RAC voltage level + 36V + 24V + 18V + 5V 0V 0 (low) 1 (high) 0 ^= shortest path to position 1 ^= pos. direction of current Ncomm 1 ^= current command value assumed 1 1 * 0.1° 2 2 * 0.1° 4k7 to the data bus 3 4 * 0.1° of the controller 4 8 * 0.
6. Interfaces for the NC controller and feedback 6.6 Incremental Encoder Output (option) voltage level outputs + 5V + 1.8V + 0.5V 0 (low) 1 (high) X6 with KDA/TDA X13 with RAC 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 to the control unit voltage source voltage level for +5 V source U + 5.25V B 0 from the data bus 0 A (max 40 mA ) A (max 40 mA ) B 0V also applies to B,B and O,O +5 V ( max 200 mA ) X17 + 5V + 4.75V to the additional outputs 1 2 24 V; 0.
6. Interfaces for the NC controller and feedback 6.7 Serial Interface (option) X6 withKDA/TDA; X13 with RAC voltage level of transmission line TXD, RTS + 15V + 9V + 3V 0V - 3V - 9V - 15V 0 ( low ) 1 ( high ) voltage level of receiver line RXD, CTS + 9V + 2V 0V + 1V - 9V 0 ( low ) 1 ( high ) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 GND TXD ( max. 6mA ) RXD ( 8mA ) RTS ( max.
6. Interfaces for the NC controller and feedback 6.8 Motor Feedback Connection X3 voltage level of motor feedback source + 5.25V + 5V + 4.
6. Interfaces for the NC controller and feedback 6.9 Additional Encoder Input (option) Differential voltage level between, e.g., A and A, B and B, 0 and 0 + 1V 0V 0 ( low ) 1 ( high ) - 1V Signal from incremental encoder, max. input voltage at 0V: ± 15V voltage source of attached spindle feedback + 5.25V + 5V + 4.
7. Index 7. Index Symbole < > 137 ±24 V 37 ∆N in rpm 47 ∆t in seconds 47 „E-Stop“ control input 37 „MASTER“ 36 „MAX DEV“ 44 „N * NCMD“ 44 „NO TEMP“ 25 „SLAVE“ 36 „TEMP WARN“ 25 0 136 0 V 37 0.001/i angular degrees 59 0.1/i angular degrees 59 1 136 1MB 136 1MB frameless spindle motor 64 2AD 136 2X SIM 105 3.
7. Index Anschlußplan für Getriebeumschaltung 82 für Master-Slave-Antrieb mit KDA/TDA für Master-Slave-Antrieb mit RAC 91 für Zwei-Motoren-Umschaltung 87 91 Antriebsauslastung Analoger Ausgang für 69 AS programming module 31, 35 AS.. 136 Assignment of gear stage 79 Automatic speed change 77 Auxiliary d.c.
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7. Index NO 24V 103 NO 8 MHz or NO 12 MHz 103 NO 8V 103 NO INPUT 40, 43, 102 NO MAINS(RAC 3 only) 102 NO POWER 24, 28, 98 NO RAC 2.2 (RAC 2.1 only) 102 NO RF 26, 98 NO RUN 52, 98 NO TEMP 103 Noise immunity reasons 38 NOPOWER 28 Nsoll.
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8. Abbreviations, Agreements, Type Codes 8. Abbreviations, Agreements, Type Codes RAC Main spindle drive controllers with 2AD and 1MB asynchronous motors with regenerative capabilities (see type codes for RAC) KDA Modular main spindle drive controller for 2AD and 1MB asynchronous motors in cold-running technology (see type codes for KDA) TDA Modular main spindle drive controller for 2AD and 1MB asynchronous motors (see type codes for TDA) AS..
8. Abbreviations, Agreements, Type Codes ADW Interface for analogue speed command value PDS Interface for digital speed command value PDA Parameter duplicating adapter < > Summand, a part of the total value for the function parameters • DOK-DIAX01-MAIN+2AD+1M-ANW1-EN-E1,44 • 07.
8. Abbreviations, Agreements, Type Codes Type code fields: Example: 1. Device abbreviation: KDA 3.2 - 150 - 3 - A00 - W1 KDA 2. Series: 3 3. Version: 2 4. Rated current: 50 A 100 A 150 A 050 100 150 5. DC supply voltage: DC 300V: 3 6. Speed command value: analogue (+/- 10 V) digital (16 bit parallel) SERCOS interface A D L 7. Second encoder input: without second encoder input O Second encoder input for spindle feedback or add.
8. Abbreviations, Agreements, Type Codes Type code fields: Example: 1. Device abbreviation: TDA 1.1 - 100 - 3 - A00 TDA 2. Series: 1 3. Version: 1 4. Rated current: 50 A 100 A 050 100 5. DC supply voltage: DC 300V: 3 6. Speed command value: analogue (+/- 10 V) digital (16 bit parallel) SERCOS interface A D L 7. Second encoder input: without second encoder input O Second encoder input for spindle feedback or add.
8. Abbreviations, Agreements, Type Codes Type code fields: Example: 1. Device abbreviation: RAC 2.2 - 200 - 460 - A00 - W1 RAC 2. Series: 2 3. Version: 2 4. Rated current: 150 A 200 A 250 A 150 200 250 5. AC supply voltage: 3 x AC 400V/50…60 Hz 3 x AC 400V/50 Hz, 3 x AC 460V/60 Hz 380 460 6. Speed command value: analogue (+/- 10 V) digital (16 bit parallel) SERCOS interface A D L 7. Second encoder input: without second encoder input O Second encoder input for spindle feedback or add.
8. Abbreviations, Agreements, Type Codes Type code fields: Example: 1. Device abbreviation: RAC 2. Series: 3 3. Version: 1 4. Rated current: 100 A 150 A 100 150 5. AC supply voltage for power electronics: 3 x 380V…460V; 50…60 Hz 460 6. Speed command value: analogue (+/- 10 V) digital (16 bit parallel) SERCOS interface A D L 7. Second encoder input: without Second encoder input O Second encoder input for spindle feedback or add.
8. Abbreviations, Agreements, Type Codes Type code fields: Example: 1. Device abbreviation: RAC 4.1 - 400 - 460 - A00 - W1 RAC 2. Series: 4 3. Version: 1 4. Rated current: 300 A 400 A 300 400 5. AC supply voltage: 3 x AC 400V/50Hz, 3 x AC 460V/60Hz 460 6. Speed command value: analogue (+/- 10 V) digital (16 bit parallel) SERCOS interface A D L 7. Second encoder input: without Second encoder input O Second encoder input for spindle feedback or add.
8. Abbreviations, Agreements, Type Codes Type code fields: Example: 1. Device abbreviation: AS 53 / 004 - 001 AS 2. Differentiation by controller KDA 3.2 RAC 2.2 RAC 3.1 TDA 1.1 RAC 4.1 3. Software i.d. Standard main spindle drive controller (all combinations not listed below) Servo drive (always with incremental enc.output) Main spindle drive with incremental enc. output Main spindle drive with SERCOS interface Main spindle drive with add. functions 3 5 6 7 8 (((- L I -) I -) -) 1 2 3 4 5 4.
9. Supplementary documentation 9. Supplementary documentation AC main spindle drive with controlled asynchronous motor AC main spindle drive with controlled asynchronous motor Selection data doc. no.: 9.567.013.
AC main spindle drive with controlled asynch. motor 2AD and changeover 2K planetary gearboxes 1MB AC main spindle drive with controlled frameless spindle motor 1MB Selection data doc. no. 9.567.012.4-00 AC main spindle drive with 2AD controlled asynchronous motor and 2K changeover planetary gearbox Selection data doc. no. 9.567.022.
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