Detroit, MI USA
Contents
1. 1 1 General Information Before you install and start operating this index table please read these safety and operating instructions thoroughly Also read all warning signs on the machine and make sure that they are not damaged and that they cannot be removed Installation start up and care and maintenance may only be undertaken by qualified staff People who are qualified in terms of these safety instructions are people who are familiar with the setup as sembly start up operation and maintenance of index tables and who have appropriate qualifications The safe operation of this machine depends on it being used according to instructions Please keep these safety and ope ration instructions in an accessible place and give them to all people who have access of any kind to the machines Should these instructions and any others contained in this manual not be observed users and plant may be exposed to risks and damage to the equipment or serious injuries or even death could occur AN The index table may only be operated after the entire system in which the index table is integrated as well as the control and safety system com plies with the machine guidelines of the norms appropriate to the country where the table is set up and operated Risk of crushing with rotating parts Keep at a safe distance from moving parts The appropriate accident prevention regulations as well as the otherwise generally acknowledged health and safety regul2. The entire dwell time is lost at the next start up Figure 8 RIGHT Time delayed switch off Ideal breakpoint at the end of the positi on cam No time in the next cycle is lost Figure 9 With continuous reversing operati on always stop with the rising flank of the position sensor since the dwell phase is left again in the opposite direction Figure 10 6 3 Optimizing Index Time Using a Second Cam The Switch Cam can be adjusted by means of two frontal screws on the drive shaft It has a short switching flag and gives the disabling signal for the drive It should be set up in such a way that the position cam still safely activates the sensor with the end of its switching flag See Figure 11 AN The position cam must not be moved Position Cam Delay for stopping the drive Switch Cam Figure 11 6 4 Optimizing Index Time Using Rotary Table Control TIC In a special learning mode the rotary index table control autonomously measures the length of the switching and dwell phase and optimizes the switch off plant independent of the speed of the rotary index table In such a case the second cam is redundant At the same time the TIC control enables different speeds simple change of rotation inching operation and a restart after an emergency stop from intermediate positions in a way that is does not tax the drive An additional motor contactor can be eliminated For more information regarding this control
3. the pointer and the feather key groove point towards each other and the center of the switching flag of the position cam is at the sensor Keep checking that the switching flag comes to a halt within the sensor area and is not left without a starting signal AN If the control of this area is overridden by for example long processing times the drive flange has moved too far and it could lead to a crash AN Faulty motor contactors jammed mechanical or burnt out electronic con tacts prevent the drive motor from being switched off This could lead to severe personal injury or damage to property Initiate an emergency stop immediately Figure 7 6 2 Minimizing Time Losses Depending on the speed of the rotary index table the dwell phase can be a few hundredths to several tenths of a second If the drive is stopped right at the beginning of the dwell phase you will lose in the following cycle the time the drive requires to carry out the rest of the dwell phase Time optimized control of the rotary index table means starting the external machining right at the start of the dwell phase rising flank on the position sensor and allowing the motor to turn for a short time for it to come to a standstill shortly before the end See Figure 9 To do this you need either a second switch cam or rotary index table Con troller TIC 819 WRONG Stop immediately after identifica tion of the rising flank on the posi tion sensor
4. index tables from the RT model range for the following sizes RT 100 RT200 RT160 RT250 RT320 RT400 RT500 and RT630 1 3 Use in Accordance with Regulations The dimensioning of the rotary index tables is effected on the basis of the tables and calculations depicted in the brochure Rotary Index Tables of the RT Model Range and should be undertaken by technical salespeople from MOTION Index Drives Inc AN The rotary index tables described herein are intended for use in normal industrial plant They may not be installed into machines and eguipment whose failure could put human lives directly at risk or cause great losses AN Not be used in an explosive environment Any use of a rotary index tables where safety may be in doubt is not permitted Please contact MOTION Index Drives Inc before using the index table in such an environment 1 4 Set up Rotary index tables must be set up in accordance with the regulations contained in the documentation The installation position is user defined but it has to be disclosed to MOTION Index Drives Inc when ordering the rotary index table Please check the completeness and correctness of the delivery before set a Ring eye bolts ting it up n The following represents a portion of the scope of delivery The rotary index table The documentation The data sheet of the rotary index table The instruction manual for the worm drive option The instruction manual fo
5. please read the instruction manual for TAKTOMAT Rotary Index Table controller TIC Figure 12 6 5 Schematic for Three Phase Model 10111 from overvoltage by using diodes Start in Automatic mode gt Position Reached Start in Manual mode gt Ready to Start Direction gt p Programmable Cam Sensor T gt Position Error Stop gt Speed ae IE 24V OV L Warning All outputs connected to Pi inductive loads must be protected Cycle Time Error flashing Braking Voltage Error always 1 Reset Error Monitor Braking Voltage VBR Wires to motor max 20m long Operating Mode VV Voet Measurement Cycle a Monitor Braking Voltage VBR gt External Brake Relay lt Power Supply 3x400V 50Hz Aa E STOP Frequency Inverter Customer Side Low Frequency Filter I Warning If using brakes with a supply voltage of 230VAC or 400VAC N If a standard 230 400VAC three phase electric motor is interfaced to a jumper is NOT allowed between MC and S2 In this case S2 must be our single phase Rotary Index Table controller TIC a Y connection must connected directly to 24V DC Braking voltage monitoring is then no longer be used Please refer here to the description on the motor terminal block possible Hence we strongly recommend a 24V DC brake when using this Rotary Index Table 7 Installation and Start Up Installation and start up may only be undertaken by e
6. you to conti nuously vary the step time Please ensure that the 3 phase motors used have been optimized for 50Hz and that they clearly loose torque below 30Hz and above 60Hz 6 7 6 Control In order to control the rotary index table the drive cam is fitted with a po sition cam The length of the switching flag corresponds to the length of the dwell phase in the drive cam Length of the 0 increase minus 2 5 safety area on both sides The drive flange is in a securely locked position when the sensor is some where in the area of this switching flag In order to synchronize the rotary index table the brake and motor voltage have to be applied The drive turns and the switching flag of the position cam leaves the sensor area If the sensor is activated again the drive flange depending on the step angle of the rotary index table will move to the next dwell position and the motor and brake have to be switched off Brake voltage off brake active 6 1 Adjustment of the Positioning Cam The position cam is secured in place by means of two frontal screws on the drive shaft It is correctly set up when the feather key groove and the pointer points to the zero reference mark on the decal and the middle of the switching flag is positioned to the sensor See Figure 7 AN The grey area of the decal is only symbolic and does not indicate the length of the dwell phase Correctly set up position cam The zero reference mark on the decal
7. Motion INDEX DRIVES INC Detroit MI USA Phone 1 313 366 1677 Fax 1 313 366 8960 info motionindexdrives com www motionindexdrives com h ma ADO et die agentur HD Operating Manual Rotary Index lables RT INDEX DRIVES INC Contents 1 Safety Instructions 1 1 General Information 1 2 Validity of This Documentation 1 3 Use in Accordance with Regulations 1 4 Set up 1 5 Transportation and Storage 1 6 Type Plate 1 7 Electrical Connection 2 Assembly and Mode of Operation 3 Modes of Operation 3 1 Normal Operation 3 1 1 Intermittent Operation 3 1 2 Continuous Operation 3 1 3 Continuous Reversing Oscillating Operation 3 2 Inching Jog Speed Operation 3 3 Emergency Stop 4 Cycle Times 5 Speeds 6 Control 6 1 Adjustment of the Positioning Cam 6 2 Minimizing Downtime 6 3 Optimizing Cycle Time Using a Second Cam 6 4 Optimizing Cycle Time Using Rotary Table Control TIC 6 5 Circuit Diagram TIC Three Phase 7 Installation and Start up 7 1 Installation 7 2 Start up 8 Maintenance and Repair 8 1 Maintenance 8 2 Inspection 8 3 Repair 9 Spare Parts and Wear Parts 10 Malfunctions 11 Disposal Symbols are as follows x Note Attention GEM Attention Warning Danger ti Danger Do not touch of Electrocution on PSP Fw WwW Ww OM ODM OO OO 10 10 11 12 12 12 Danger Advice must be followed YT Oil Lubrication 1 Safety instructions
8. Only an overhaul by MOTION Index Drives Inc en Replacing the cam followers The Rotary Index Table must be checked for play If there is any play in sures the agreed features Any unauthorized opening of the casing will one or more stations the cam rollers have to be replaced void the warranty 13 16 17 02 ZA AEK KT OA ANTEE 7 Turn input shaft 02 to the middle of the dwell In the standard version the grooves of the feather keys point upwards Loosen long screws 25 from the four point contact bearing of the casing Every second screw In an upward direction pull out the drive flange 13 with the ring eye screws Check cam followers Loosen the locking screws 16 17 on the cam roller that has to be replaced Remove cam roller 15 Replace the damaged and the two neighboring cam followers Re assemble in reverse order Ay All cam followers may have to be replaced Check whether the mounting holes for the cam followers in the drive flange are still round and true to size Alternatively completely replace the drive flange 9 Spare Parts and Wear Parts Wear parts are marked x Please order replacement parts set The quantity or amount n of the cam followers and lubricants depend on the model and design of the Rotary Index Table MOTION Index Drives Inc rotary index tables are practically mainte nance free The cam followers do not cause any wear and tear on the har dened cam tracks all roller
9. Operation Normal operation is regarded as the movement of the output flange in a direction from one dwell position to the next The rotational direction of the output flange is determined by the rotational direction of the drive With a three phase motor this can easily be reversed by swapping two phases of the supply voltage 3 1 1 Intermittent Operation The drive shaft stops in the dwell phase The step time is fixed The dwell period is variable This mode of operation is used in plants with much longer processing times than rotating times and is the most common mode of operation 3 1 2 Continuous Operation The rotary table runs continuously without the motor stopping Step and dwell times are fixed and run through continuously The drive motor has only one rotational direction This mode of operation is frequently used in high production plants which require short processing times The rotary index table is synchronized to the rest of the plant mechanically by means of a free drive shaft The re lationship between dwell and step time can be adjusted within certain li mits by MOTION Index Drives Inc when producing the cam 3 1 3 Continuous Reversing Oscillating Operation The drive of the index table is always reversed in the dwell phase With this kind of mode of operation the drive flange shuttles backwards and forwards between two positions With rotation angles of less than 90 on the drive flange the cam can be construc
10. ations must be complied with Improper alterations and the use of replacement parts and additional devices not recommended by the manufacturer may result in injuries to staff or damage to property Before working on the rotary index table and related tooling switch the drive off electrically and make sure it cannot restart by itself 213 Tips This instruction manual was issued in January 2007 The information contained in this document is the property of MOTION Index Drives Inc and may not be copied reproduced or given to third parties without ex press written permission No liability is assumed with regard to the use of the information contained herein Furthermore the information contained in this manual can be changed without any prior notice since MOTION In dex Drives Inc is continually developing its high quality products and ad apting them in accordance with new findings All due care was used when creating this manual MOTION Index Drives Inc assumes no responsibility for any mistakes or omissions neither does the company assume any lia bility with regard to damage that may arise from the use of the informati on contained in this publication CE certification is in line with the following standards EEC machine guideline 98 37 EG EEC low voltage guideline 93 68 EWG EEC guideline over the electromagnetic compatibility 89 336 EWG 1 2 Validity of this Documentation This instruction manual is valid for rotary
11. bearings are oversized and run through an oil bath For reasons of safety only replacement parts which are of the same quality as the original parts may be used When ordering please give the following data j Model and order number see type plate Name see table below Quantity 13 12 10 14 14 08 07 06 05 02 F 19 i 20 NaN m 21 SANS 22 PA YY f MES EIEN Ty o9 15 Spare Parts and Wear Parts Number 01 02 05 x 06 x 07 x 08 x 1 1 Quantity Name Casing Input Shaft Shaft Seal Groove Nut Tapered Roller Bearing Groove Nut Barrel Cam Central Column O Ring Output Flange Drive Flange 10 Malfunctions Malfunctions Motor does not run Motor turns but Rotary Index Table does not and the output flange has no play Motor turns but Rotary Index Table does Help No supply voltage check voltage Faulty motor contactor replace Number 14 x 15 x 18 x 19 x 20 x 21 x 22 x 23 x 26 14116 Quantity Bezeichnung 1 Shaft Seal Cam Follower Four Point Contact Bearing Adjustment Ring for Four Point Contact Bearing O Ring O Ring Center Ring for Four Point Contact Bearing Shaft Seal Housing Cover Depending on Number of Indexes Motor contactor switch activated possibly allow motor to cool off and engage switch Brake not open improperly connected or worn out not and the drive flange has play Moto
12. ce work may only be undertaken by experienced specialists A Before working on the rotary index table and related tooling switch the drive off electrically and make sure it cannot restart by itself Lubrication Quantity Installation position 6 Indexer Type Filling amount RT100 0 31 RT160 0 6l R1250 1 R1320 Al RT400 9 5l RT500 18 51 RT630 30 8 1 Maintenance The rotary index tables and worm gears on the drive are lubed for life as our standard for normal environment and conditions of use Every month please lubricate using the bearing ring grease fittings on models RT400 RT500 and RT630 The bearing ring on smaller indexers are maintenance free A Do not mix mineral lubricants with synthetic lubricants 8 2 Inspection The intervals specified must be adjusted to suit the conditions ZN Switch the drive off electrically and make sure it cannot restart by itself Every six months visually inspect for damage Remove any deposit of dust especially on the ventilation grille of the motor and examine the electrical cables for damage Every 12 months check the Rotary Index Table for play in the dwell positions Lubricants used 12113 Oil gears Grease bearings Mobilgear XP460 Mobilux EP2 While handling these lubricants you consider please the safety data sheets of the manufacturer Figure 11 8 3 Overhauling If the Rotary Index Table or drive is damaged please contact MOTION In dex Drives Inc first
13. mo tor overload switches or other suitable protective devices 2 Assembly and Mode of Operation The rotary index table transforms a constant input drive motion into an intermittent output drive motion The intermittent drive motion oc curs by means of an inductively hardened and fine milled barrel cam The use of mathematical laws of motion guarantees a soft shock proof and jerk free movement that has been optimally designed for its intended purpose The designed assembly allows for accurate and se cure mounting to the output flange which is also free of play No additional adjustment of the output flange is necessary This can lead to mechanical over tightening and thus the rotary index table being destroyed in the long term The power is provided either by means of a three phase brake motor via worm drive or by means of a chain wheel or belt wheel on the drive shaft of the rotary index table This is firmly connected to the barrel cam without any further internal gear sets and it turns the cam followers and subsequently the output flange The output flange is mounted within a wire bearing assembly stiff and free of play Wi thin steel rings not in the casting The shaft seals appropriate for each size seal the rotary table off inside and out Dwell Phase Indexing Phase 415 Cam Follower Carrier Barrel Cam _ do _ ss _ BEET Figure 4 BET Figure 5 3 Modes of Operation 3 1 Normal
14. or a minute of operating time Regardless of the interval time specified by the use Fixed Stages There are 4 6 or 8 pole motors and worm gears with various reduction gear ratios available The combination of the two gives us a sensitive gradation of the step times of inertia The correlation is clearly laid out in the load tables of the Rotary Index Table RT Model Range catalog 1 8 9 10 11 12 13 1 52 1 87 2 13 23 2 9 3 32 4 27 5 4 8 6 11 7 14 9 23 7 32 57 1 43 1 75 2 222 2 72 3 11 4 da 14 8 20 2 25 7 41 06 99 029 1 98 1 8 2 2 45 2 8 3 6 11 4 18 24 8 32 9 50 69 122 LES 1 98 1 8 2 2 45 2 6 3 6 16 26 39 44 71 97 173 1729 1 98 1 8 2 2 45 2 0 3 6 21 34 46 08 93 127 226 1 29 1 98 1 8 2 2 45 2 8 3 6 31 5 50 68 87 138 183 297 IZS 1 98 1 8 2 2 45 2 6 42 67 92 115 171 225 1 29 1 98 1 8 2 2 45 2 8 az 83 113 145 210 2 6 0 64 079 0 9 1 1 23 1 4 19 29 38 46 70 91 0 64 0 79 0 9 1 1 23 1 4 24 36 47 08 88 115 0 64 0 79 0 9 1 1 23 1 4 29 43 D 70 105 138 0 64 0 79 0 9 1 1 23 1 4 32 48 62 79 119 155 0 43 0 53 0 6 0 67 0 82 0 93 17 29 38 47 63 83 If you can select a longer step time than that specified in the step time table then you will extend the service life of the rotary index table dramatically Doubling of the step time extends the service life by a factor of 200 to 500 The speed can be altered either in fixed stages or continuously Infinitely Variable Frequency Inverter or rotary index table control TIC allows
15. r runs with a loud humming noise 11 Disposal af Lubricants oils grease pollute the environment Please dispose of them according to your local environmental regulations enough Faulty worm gear contact MOTION Index Drives Inc Torque limiting clutch has tripped remove outside blockage Cam rollers broken off due to overload contact MOTION Index Drives Inc Motor runs on only 2 phases check fuse or motor contactor Measure current in all 3 phases voltage measurement is not
16. r the motor option The instruction manual for rotary index table control TIC Only if the control is part of the scope of delivery Please verify that the type of rotary index table is correct by checking the type plate see Figure 2 1 5 Transportation and Storage In general rotary index tables should be stored and set up in a clean dry environment When transporting only use means of transport and hois ting gear that has been permitted for the weight of the rotary index table in question In order to raise the rotary index table please use two ring eye bolts for size RT320 but three ring bolts for size RT400 and higher which you screw into the screw thread of the output flange See Figure 1 Figure 1 1 6 Type Plate The following information can be gathered from the type plate P Mot Manufacturer 777 Model Size ___ Detroit h Serial Number eae a l Shop Order Number sy 1 7 Electrical Connection EI Only applies if the drive is part of the scope of delivery gt Figure 2 AN Any work on the electrical installation may only be undertaken by trained and qualified staff Please observe all technical and country speci fic regulations and norms during installation Our rotary index tables are driven by three phase brake motors as stan dard Connect the motor and brake only to the power supply as specified on the type plate The motors must be protected from overload by means of
17. ted in such a way that continuous reversing operation is possible without the direction of the drive being reversed 3 2 Inching Operation With inching operation the drive flange moves in small steps between two dwell positions The barrel cam cannot gently accelerate and decele rate the built up load This puts the hardware under stress since any ac celeration that occurs during the inching operation exceeds that of normal operation many times over Without any suitable rotary index table con trols that allow gentle acceleration and braking of the load outside the dwell phase in a way that is also kind to the drive inching operation is not permitted Please use our rotary index table control TIC 3 3 Emergency Stop Emergency stop is comparable with the stopping in inching operation Here too the stopping and re starting of the built up load occurs outside the dwell phase Frequent emergency stop situations should be avoided or should take place by using the rotary index table control TIC in such a way that there is no danger to the mechanism 4 Cycle Times A complete cycle of the rotary index table is defined as the indexing of the drive flange from one dwell position to the next The cycle time con sists of the step time and dwell time together The step time corresponds to the step angle of the cam and the dwell time corresponds to the angle without the cam gradient see figure 6 Example RT160 8 270 This is a rotary inde
18. x table size 160 with 8 index points 8x45 drive flan ge rotation a switch angle of the cam of 270 and a dwell angle of 90 With an input revolution speed of 60 rom and continuous input revolution speed the rotary index table will execute 60 cycles per minute The step time of the drive flange is 0 75s The dwell time is 0 25s 0 cam gradient 5 Speeds The maximum speed of the drive flange or the shortest step time of the rotary index table depends on the resulting built up load mass moment Example Load Table RT100 speed step 1 2 3 4 5 6 n J 0 38 0 57 0 76 1 07 t 0 22 0 56 1 1 2 4 J 0 25 0 36 0 54 0 71 1 i t 0 13 0 38 0 97 1 9 4 1 J 02 0 32 0 48 0 64 0 9 t 0 18 0 47 1 25 2 4 5 3 J 0 22 0 32 0 48 0 64 0 9 i t 0 26 0 66 iP di 7 J 0 22 0 32 0 48 0 64 0 9 i t 0 32 0 9 2 25 4 3 g d J 0 19 022 032 0 48 0 64 di j t 0 39 0 48 1 3 3 3 6 4 13 8 J 0 19 022 0 32 0 48 0 64 09 i t 0 52 0 64 1 72 44 8 5 18 5 J 0 19 0 22 0 32 0 48 0 64 0 9 i t 0 65 0 82 2 16 5 5 10 6 23 J 0 16 0 24 0 32 0 45 i t 0 95 2 4 4 6 9 J 0 16 0 24 0 32 0 45 _ t 1 28 3 2 6 11 8 J 0 16 0 24 0 32 0 45 a t 1 6 4 1 7 14 J 0 16 0 24 0 32 0 45 t 1 7 4 5 8 6 16 m J 0 16 0 21 0 3 t 2 46 4 32 8 6 The shortest possible step time with any existing mass moment of inertia guarantees a service life of at least 30 000 hours of pure fixed cycle ope ration This means that for a rotary index table with a 0 5s step time one would calculate 120 cycles f
19. xperienced specialists ZN Read the instruction manual Also take note of the data in the other ac AN Before working on the rotary index table and related tooling switch the companying documents drive off electrically and make sure it cannot restart by itself ZN Any work on the electrical system may only be performed by specialists Please comply with all technical and country specific regulations and standards when carrying out installation work 7 1 Installation Ensure that the mounting surface is flat Clean mounting surface and apply an oil film Mount the rotary index table onto mounting surface in installation position Tighten fastening screws evenly Mount alignment pins Compare supply voltage with data on the rating plate Connect motor and brake separately and with separately installed lines Keep EMC in mind Connect see circuit diagram in terminal box Adjust motor overload switch to the motors rated current For data see motor s rating plate Not necessary with TIC Connect ground conductor to the motor s grounding screw 7 2 Start Up Do not reach into the danger area Check that the switch cam Is in the correct position See Figure 7 Remove all possible obstacles from the swivel range Visually inspect the direction of rotation and reverse the polarity of the motor if necessary Visually inspect the entire process 8 Maintenance Maintenance includes inspection servicing and overhauling Maintenan
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