2SP1202-1.B..-2... - Siemens

simodrive

ECS Motor Spindle

2SP1

Configuration Manual 03/2007 Edition

03/2007 Edition

SIMODRIVE

ECS Motor Spindle

2SP1

Configuration Manual

Safety Information 1

FAQ 2

Function of the Spindle 3

Mechanical Data 4

Electrical Data 5

Supplying the Various Media 6

Sensors 7

Control 8

Order Number 9

Data Sheets 10

References A

Abbreviations and

Terminology B

Index C

Designation of the documentation

Printing history

Brief details of this edition and previous editions are listed below.

The status of each edition is shown by the code in the ”Remarks” column.

Status code in the ”Remarks” column:

ANew documentation.....

BUnrevised reprint with new Order No......

CRevised edition with new status.....

Edition Order No. Remark

02.03 6SN1 197-0AD04-0BP0 A

10.04 6SN1 197-0AD04-0BP1 C

11.05 6SN1 197-0AD04-0BP2 C

03.07 6SN1 197-0AD04-0BP3 C

Trademarks

SIMATICr, SIMATIC HMIr, SIMATIC NETr,SIROTECr, SINUMERIKr, SIMODRIVErand

MOTION-CONNECTrare registered trademarks of Siemens AG. Other names in this publication might

be trademarks whose use by a third party for his own purposes may violate the rights of the registered

holder.

Additional information is available in the Internet at:

http://www.siemens.com/motioncontrol

This publication was produced with Interleaf V 7

The controller may support functions that are not described in this

documentation. However, no claim can be made regarding the

availability of these functions when the equipment is first supplied or

in the event of servicing.

We have checked that the contents of this document correspond to

the hardware and software described. Since deviations cannot be

precluded entirely, we cannot guarantee complete conformance. The

information given in this publication is reviewed at regular intervals

and any corrections that might be necessary are made in the

subsequent printings. Suggestions for improvement are also

welcome.

Subject to change without prior notice.

Siemens Aktiengesellschaft

Order No. 6SN1 197--0AD04--0BP3

Printed in the Federal Re

ublic of German

3ls

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Foreword

Information on the documentation

You will find an overview of the publications, which is updated on a monthly basis,

in the available languages on the Internet under: http://www.siemens.com/motion-

control.

Follow the menu items ”Support” →”Technical Documentation” →”Overview of

Documents”.

The Internet version of DOConCD (DOConWEB) is available at:

http://www.siemens.com/motioncontrol under menu option ”Support”.

Target group

Planners and project engineers

Benefits

The Configuration Manual supports you when selecting motors, calculating the

drive components, selecting the required accessories as well as when selecting

line and motor--side power options.

Standard scope

The scope of the functionality described in this document can differ from the scope

of the functionality of the drive system that is actually supplied. Other functions not

described in this documentation might be able to be executed in the drive system.

However, no claim can be made regarding the availability of these functions when

the equipment is first supplied or in the event of servicing. The OEM documents

any supplements or changes that he makes.

For reasons of transparency, this documentation does not contain all detailed infor-

mation about all types of the product and cannot cover every conceivable case of

installation, operation, or maintenance.

Foreword

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Technical Support

Europe/Africa Asia/Australia America

Phone +49 (0) 180 5050-222 +86 1064 719 990 +1 423 262 2522

Fax +49 (0) 180 5050-223 +86 1064 747 474 +1 423 262 2289

Internet http://www.siemens.com/automation/support-request

E--mail mailto:adsupport@siemens.com

Note

Country telephone numbers for technical support are provided under the following

Internet address: http://www.siemens.com/automation/service&support

Questions about the manual

If you have any questions (suggestions, corrections) regarding this documentation,

please fax or e-mail us at:

Fax +49 9131 98 63315

E-Mail mailto:docu.motioncontrol@siemens.com

A fax form is available at the end of this document.

EC Declaration of Conformity

The EC Declaration of Conformity for the EMC Directive can be found/obtained in

the Internet: http://www.ad.siemens.de/csinfo

under the Product/Order No. 15257461 or at the relevant branch office of the A&D

MC Division of Siemens AG.

Definition of qualified personnel

For the purpose of this documentation and warning information on the product

itself, qualified personnel are those personnel who are familiar with the installation,

mounting, start--up and operation of the equipment and the hazards involved.

They must have the following qualifications:

STrained and authorized to energize/de--energize, circuits and equipment in

accordance with established safety procedures.

STrained in the proper care and use of protective equipment in accordance with

established safety procedures.

SFirst aid training.

Foreword

vii

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Explanation of symbols

The following danger and warning concept is used in this document:

!Danger

This symbol is always used if death, severe personal injury or substantial material

damage will result if proper precautions are not taken.

!Warning

This symbol is always used if death, severe personal injury or substantial material

damage can result if proper precautions are not taken.

!Caution

This symbol is always used if minor personal injury or material damage can result

if proper precautions are not taken.

Caution

The warning note (without a warning triangle) means that material damage can

occur if proper precautions are not taken.

Notice

This warning note indicates that an undesirable result or an undesirable status can

occur if the appropriate information is not observed.

Note

In this document, it can be advantageous to observe the information provided in a

Note.

Foreword

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Danger and warning information

!Danger

SStart--up/commissioning is absolutely prohibited until it has been completely

ensured that the machine, in which the components described here are to be

installed, is in full compliance with the specifications of Directive 98/37/EC.

SOnly appropriately qualified personnel may commission the SIMODRIVE units

and the motor spindles.

SThis personnel must take into account the technical customer documentation

belonging to the product and be knowledgeable and observe the specified

information and instructions on the hazards and warnings.

SOperational electrical units and motor spindles have parts, components and

electric circuits that are at hazardous voltage levels.

SWhen the machine or system is operated, hazardous axis movements can

occur.

SAll of the work carried--out on the electrical machine or system must be

carried--out with it in a no--voltage condition.

SSIMODRIVE drive units are designed for operation on low--ohmic, grounded

line supplies (TN line supplies).

SSIMODRIVE units with motor spindles may only be connected to the line

supply through residual--current operated circuit--breakers, if corresponding to

EN 50178, Chapter 5.2.11.2, it has been proven that the SIMODRIVE drive unit

is compatible with the residual--current operated circuit--breaker.

!Warning

SPerfect and safe operation of these units and motors assumes professional

transport, storage, mounting and installation as well as careful operator control

and servicing.

SThe information provided in Catalogs and quotations additionally applies to

special versions of units and motors.

SIn addition to the danger and warning information/instructions in the technical

customer documentation supplied, the applicable domestic, local and

plant--specific regulations and requirements must be carefully taken into

account.

!Caution

SIt is not permissible that temperature--sensitive parts -- e.g. cables or electronic

components -- are in contact or mounted to the motor spindle.

SWhen handling cables, please observe the following:

-- They may not be damaged,

-- they may not be stressed,

-- they cannot come into contact with rotating parts.

Foreword

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Caution

SSIMODRIVE units with motor spindles are subject to a voltage test

corresponding to EN50178 as part of the routine test. While the electrical

equipment of industrial machines is being subject to a voltage test in

compliance with EN 60204-1, Section 19.4, all of the SIMODRIVE equipment

connections must be disconnected/withdrawn in order to avoid damaging the

SIMODRIVE equipment.

SIt is not permissible to directly connect the motor spindles to the three--phase

line supply as this will destroy the motor spindles.

Notes

SSIMODRIVE equipment with motor spindles fulfill, in the operational state and

in dry operating areas, the Low--Voltage Directive 73/23/EEC.

SSIMODRIVE equipment with motor spindles fulfill, in the configurations which

are specified in the associated EC Declaration of the Conformity, the EMC

Directive 89/336/EEC.

Foreword

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Notes on ESDS

!Caution

ElectroStatic Discharge Sensitive Devices (ESDS) are individual components,

integrated circuits, or modules that can be damaged by electrostatic fields or

discharges.

Handling regulations for ESDS:

SWhen handling components, make sure that personnel, workplaces, and

packaging are well earthed.

SElectronic components may only be touched by people in ESDS areas with

conductive flooring if

-- These persons are grounded with an ESDS wrist band

-- They are wearing ESDS shoes or ESDS shoe grounding strips.

SElectronic boards should only be touched if absolutely necessary.

SElectronic boards must not come into contact with plastics or items of clothing

containing synthetic fibers.

SElectronic modules must only be placed on conductive surfaces (table with

ESDS surface, conductive ESDS foam, ESDS packaging, ESDS transport

container).

SElectronic boards may not be brought close to data terminals,

monitors or television sets. Minimum clearance to the screen > 10 cm.

SMeasurements must only be taken on boards when:

-- the measuring unit is grounded (e.g. via a protective conductor) or

-- when floating measuring equipment is used, the probe is briefly discharged

before making measurements (e.g. a bare--metal control housing is

touched).

Products from third--party manufacturers

The products from third--party manufacturers described in this document are prod-

ucts which we know to be essentially suitable. It goes without saying that equiva-

lent products from other manufacturers may be used. Our recommendation should

only be considered as such and not as a specification. We cannot accept any liabil-

ity for the quality and properties/features of third--party products.

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Table of Contents

1 Safety Information 1-15.....................................................

1.1 Protection against potentially hazardous motion 1-15....................

1.2 Speed limits 1-18...................................................

1.3 Responsibility for providing information to the company

operating the machine 1-22..........................................

2FAQ 2-23..................................................................

2.1 What has to be observed after the equipment has been supplied? 2-23....

2.2 How is a the shipment checked? 2-24.................................

2.3 How is the spindle unpacked? 2-25....................................

2.4 How is the spindle laid--down vertically? 2-26...........................

2.5 How is the spindle installed/mounted? 2-27.............................

2.6 Which media should be connected after mounting/installation? 2-27.......

2.7 Which electrical connections must be made after mounting/installation? 2-28

2.8 What has to be checked before the spindle is commissioned? 2-28........

2.9 What has to be observed when starting to work with the spindle? 2-29.....

3 Function of the Spindle 3-31................................................

3.1 Overview of the functionality 3-32.....................................

3.2 Drive motor 3-34....................................................

3.3 Cooling concept 3-35................................................

3.4 Supply 3-36........................................................

4 Mechanical Data 4-39.......................................................

4.1 Observing the shutdown speed 4-39...................................

4.2 Installation conditions 4-39...........................................

4.2.1 Mechanical requirements placed on the spindle support 4-43.............

4.2.2 Support at the non--drive end 4-47....................................

4.3 Spindle bearings 4-49...............................................

4.3.1 Features and operating conditions 4-49................................

4.3.2 Warming--up phase of the motor spindle 4-50...........................

4.3.3 Load capability of the spindle bearings 4-51............................

4.3.4 Lifetime of the spindle bearings 4-52..................................

4.3.5 Maximum angular acceleration when the spindle is accelerating 4-54......

4.3.6 Stiffness 4-54......................................................

4.3.7 Axial shaft growth 4-54..............................................

4.4 Tools and tool holders 4-56...........................................

4.4.1 Tools 4-56.........................................................

4.4.2 Tool holders 4-59...................................................

4.5 Clamping system and tool change 4-63................................

4.5.1 Clamping system 4-63...............................................

4.5.2 Tool change 4-64...................................................

Table of Contents

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

4.5.3 Tool changing for standard clamping systems 4-65......................

4.5.4 Changing tools for the HSK A63 Type C tool holder 4-67.................

4.6 Operating modes 4-70...............................................

5 Electrical Data 5-71.........................................................

5.1 Definitions 5-71.....................................................

5.2 Motor 5-72.........................................................

5.2.1 Advantages of a direct drive 5-72.....................................

5.2.2 Synchronous and induction motor versions 5-73........................

5.2.3 General motor characteristics 5-74....................................

5.2.4 Suitable drive converter/system environment 5-76.......................

5.2.5 Overvoltage protection (only for synchronous motors) 5-77...............

5.2.6 Star-delta mode (only for induction motors) 5-77........................

5.2.7 System overview and engineering information/instructions 5-80...........

5.3 Connecting cables/connector assignments 5-84.........................

5.3.1 Power connection 5-84..............................................

5.3.2 Direction of rotation 5-85.............................................

6 Supplying the Various Media 6-87...........................................

6.1 Overview, supplying the various media 6-87............................

6.2 Cooling medium 6-88................................................

6.2.1 Cooling water connections 6-89.......................................

6.2.2 Conditioning the cooling water 6-89...................................

6.2.3 Cooling systems 6-91...............................................

6.3 Compressed air 6-94................................................

6.3.1 Using compressed air 6-94...........................................

6.3.2 Compressed air connections 6-96.....................................

6.3.3 Conditioning the compressed air 6-97..................................

6.3.4 Hydraulic fluid flow data and controlling the hydraulic fluid flow

requirement 6-98...................................................

6.3.5 Standalone units to generate compressed air 6-99......................

6.4 Hydraulic (option, only for 2SP120) 6-100...............................

6.4.1 Using hydraulics 6-100...............................................

6.4.2 Hydraulic connections 6-101...........................................

6.4.3 Hydraulic fluid flow data and controlling the hydraulic fluid flow

requirement 6-101...................................................

6.5 Internal tool cooling using the cooling--lubricating medium (option) 6-102....

6.5.1 Operating conditions 6-104............................................

6.6 External tool cooling with cooling--lubricating medium

(option, only for 2SP120j) 6-106........................................

6.6.1 Operating conditions 6-108............................................

6.7 Media connections and coding 6-109...................................

6.7.1 Media connections for 2SP120j 6-109..................................

6.7.2 Media connections for 2SP125j 6-115..................................

Table of Contents

xiii

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

7 Sensors 7-119...............................................................

7.1 Encoder/angular encoder 7-119........................................

7.1.1 Electrical signals 7-119...............................................

7.1.2 Connecting the signal lines 7-123......................................

7.2 Clamping state sensors 7-125.........................................

7.2.1 Analog and digital sensors of the 2SP120 spindle 7-125...................

7.2.2 Digital sensors of 2SP125 spindles 7-128...............................

7.3 Thermal sensors/motor protection 7-129................................

8 Control 8-133...............................................................

8.1 Conditions that enable the spindle to rotate 8-133........................

8.2 Clamping state sensors 8-134.........................................

8.2.1 Clamping state sensors 2SP120VV 8-134...............................

8.2.2 Clamping state sensors 2SP125VV 8-140...............................

8.3 Tool change 8-143...................................................

8.3.1 Automatic tool change for 2SP120VV 8-143.............................

8.3.2 Tool change sequence with standard clamping system and

tool change gripper 8-146.............................................

8.3.3 Tool change sequence with holding clamping system and

tool change gripper 8-147.............................................

8.3.4 Manual tool change for 2SP125VV 8-148...............................

8.3.5 Automatic tool change for 2SP125VV 8-151.............................

9 Order Designation 9-155.....................................................

10 Data Sheets 10-159...........................................................

10.1 Technical characteristic data 10-159.....................................

10.2 P/n and M/n diagrams 10-164..........................................

10.2.1 2SP120V synchronous motor 10-164....................................

10.2.2 2SP125V synchronous motor 10-168....................................

10.2.3 2SP125V induction motor 10-172.......................................

10.3 Dimension drawings 10-176............................................

A References A-183.............................................................

B Abbreviations and Terminology B-187.........................................

C Index C-189..................................................................

Table of Contents

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Space for your notes

1-15

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Safety Information

The specific issues relating to the functional safety of the motor spindle are ex-

plained in this Chapter. These functional safety issues involve defining and moni-

toring the spindle and tool--related speed limit values.

Table 1-1 Safety measures required

Measures to protect against

Electric shock Potentially hazardous motion

The spindle has the appropriate design.

This means that there are no different mea-

sures required than are otherwise applied

for motors.

Measures are not specifically described

here.

With reference to safe stopping, there are

no different measures required than are

otherwise applied for motors.

Specific for motor spindles:

Functional safety by defining and monitor-

ing the spindle and tool--related speed

limits.

1.1 Protection against potentially hazardous motion

In the following text, at several locations, reference will be made to the

SINUMERIK Safety IntegratedRsafety package. The requirements relating to ma-

chine safety and the possibilities of using Safety IntegratedRfor machine tools is

described in the associated Safety Integrated -- Application Manual, especially in

Chapters 1 and 5.

The 2SP1 motor spindle fulfills all of the relevant EU Directives. It is also possible,

beyond this, to use the Safety IntegratedRoption. These are certified according to

the EC--type examination test carried--out by a German regulatory body.

Depending on the operating mode (e.g. setting--up, production) of the machine,

motor spindles, just like feed drives, represent a specific, potential hazard. This

must be taken into account when designing and engineering the machine.

Safety Information

1.1 Protection against potentially hazardous motion

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Precautions

The protective goals of the EC Machinery Directive must be fulfilled by applying

suitable protective measures. It is important that the machine is correctly used.

In order to implement these protective goals, in addition to being knowledgeable

about the applicable standards and Directives, it is also necessary to carefully

observe the information and instructions in this Configuration Manual (refer to

Table 1-2).

Table 1-2 Target group--specific documentation on the 2SP1 motor spindle

Target group Task of the target group Relevant

documentation

Machine OEMs/

designers

-- Carry--out a risk analysis

-- Draw--up a safety concept

-- Provide the necessary safety

equipment at the machine

-- Instruct the operating company

about the ”correct use” of the

machine and spindle

Configuration Manual

and

Operating Instructions

Company operating the

machine

-- Inform/train employees about

the ”correct use” of the spindle

and the application of the safety

functions and how they work

-- Reference to residual risks

Operating Instructions

When applied to the motor spindle, the potentially hazardous motion is when the

maximum permissible speed for the spindle and/or tool is exceeded (refer to Figs.

1-1 and 1-2).

Speed monitoring

Table 1-3 Possible strategies to monitor the speed

Degree of reliability of the speed

monitoring which is strived for

Features and requirements of the

technology used

Standard Can be implemented (without additional

technology) using the existing operating and

machine technology

Safe Must be implemented in a safety--related fash-

ion (e.g. through two channels).

Must correspond to the required control cate-

gory (according to EN 954-1).

Must be authorized/certified for specific ma-

chines.

Safety Information

1.1 Protection against potentially hazardous motion

1-17

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

When using a machine tool spindle, the machinery construction OEM is always

responsible in taking the appropriate measures to detect and to avoid speeds that

are not permitted and their associated effects -- and to instruct the company using

the machine about these measures.

When an inadmissible speed occurs, then the spindle must be stopped. In this

case, the limit value is interpreted as that value where the maximum permissible

speed is exceeded. This limit value depends on the following factors:

SOperating state (setting--up or automatic mode)

STool which is currently being used (refer to Fig. 1-1)

SMaximum permissible spindle speed (refer to Fig. 1-2)

Table 1-4 Measures to prevent the maximum speed being exceeded and its effects

Level of the measures Example of safety measures

Preventing the speed

being exceeded

-- Monitoring the spindle speed

-- Activating tool--specific limit values

-- Monitoring operational and cutting parameters

-- Monitoring the tool condition

Controlling the effect

when the speed is ex-

ceeded

-- Providing machine panels which can withstand the

maximum impact of pieces which are thrown off at the

maximum energy which can be assumed

-- Ensure that these machine panels can only be opened

at a defined low spindle speed

-- Automatic stopping when faults/errors occur

Future--oriented strategies which are applied to limit risks, distinguish themselves

by the fact that they are measures which are practical and safe and which are de-

signed to avoid faults and errors. This means that the machinery construction com-

pany has a certain degree of flexibility in appropriately reducing the costs involved

to control faults and errors.

Safety Integrated as a measure to avoid faults

Safety Integrated is an efficient measure which is optionally available at the fault

prevention level. It can be used to monitor the drive functions.

The basic Safety IntegratedRprinciple is based on a two--channel monitoring func-

tion. This means that the requirements from the EC Machinery Directive can be

simply and cost--effectively fulfilled.

Example for Safety IntegratedR:

The maximum energy of broken tool pieces, flung--out, can be safely limited using

Safety Integrated by activating the tool--specific limit value. This means that the

costs and resources which would otherwise be incurred for providing the appropri-

ate machine panels with the corresponding strength, can be significantly reduced.

Safety Information

1.2 Speed limits

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Table 1-5 Excessive speed -- fault prevention using Safety Integrated®

Type of error Avoided by ...

Excessive spindle speed -- ”Safely reduced speed”

-- Safe spindle stopping when faults occur

Excessive tool speed (for tools

whose maximum speed lies be-

low the maximum spindle

speed)

-- ”Safely reduced speed” as a function of the tool

being used

-- The tool is detected in a safety--related fashion

by ”safely reading” the tool coding, or

-- The tool is detected in a safety--related fashion

by reading the tool coding and making a compa-

rison with the program parameters

-- Safety--related stopping of the spindle

1.2 Speed limits

The spindle is designed for a maximum operating speed. This is specified as

”maximum speed” in Chapter 10. The operating company can use this speed in

operation.

Maximum operating speed

The maximum operating speed is the highest speed that the spindle can be oper-

ated at. This speed can be saved in the control and part programs.

Shutdown speed

The speed limit, where the system is shutdown if this value is exceeded, is desig-

nated in this document as ”Shutdown speed”.

The machinery construction manufacturer (OEM) defines this taking into account

the secondary conditions and limitations which apply to the spindle and tool. The

shutdown speed should be defined so that shutdown does not occur during normal

operation and, on the other hand, the spindle system and tool are not overloaded

due to speed peaks which are permitted. The spindle must be shutdown if erro-

neous functions occur and the speed is exceeded. Standard technology or also

safety--related technology can be used to monitor the speed (refer to Table 1-3).

Safety Information

1.2 Speed limits

1-19

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Adapting the shutdown speed to various tools

If the maximum speed, which is permitted for the tool currently being used, lies

below the maximum operating speed of the spindle, then the speed monitoring and

the shutdown speed must be adapted to the particular tool.

!Warning

The shutdown speed may only be set a maximum of 15% above the maximum

operating speed of the spindle.

The shutdown speed may not be set higher than the permitted maximum speed of

the tool. The maximum operating speed, programmed for the tool, must be limited

to a value, which lies a minimum of 5% below the shutdown speed (refer to Fig.

1-1).

[RPM]

Maximum programmable

spindle speed

Spindle shutdown speed

Maximum programmable

speed of tool 2

Tool 2Tool 1 Tool 3

Tool 2

Tool 1

Tool 3

max. +15%

Shutdown speed of tool 2(= max. permissible speed of tool 2)

min. --5%

Maximum programmable

speed of tool 1 min. --5%

Shutdown speed of tool 1

(= max. permissible speed of tool 1)

Fig. 1-1 Adapting the shutdown speed to various tools

Safety Information

1.2 Speed limits

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Table 1-6 Translation for Fig. 1-1

English German

RPM Umdrehungen pro Minute

Maximum programmable spindle speed Maximal programmierbare Drehzahl der

Spindel

Maximum programmable speed of tool ... Maximal programmierbare Drehzahl des

Werkzeugs ...

Tool 1, Tool 2, Tool 3 Werkzeug 1, Werkzeug 2, Werkzeug 3

Spindle shutdown speed Abschaltdrehzahl der Spindel

Shutdown speed of the tool Abschaltdrehzahl des Werkzeugs

Max. permissible speed of tool ... Maximal erlaubte Drehzahl für das Werk-

zeug...

Caution

If various shutdown speeds are programmed for various tools, then this must be

adapted to the tool using the Tool Manager. The machinery construction

manufacturer (OEM) is responsible in clearly indicating to the operating company

that it is necessary to adapt the shutdown speed to the actual tool being used.

Critical speed

The critical speed is the speed where resonance vibration is excited in the com-

plete mechanical structure.

Safety Information

1.2 Speed limits

1-21

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Control--related speed peaks

The spindle speed is obtained as the result of a control (closed--loop) process. De-

pending on the particular controller setting and the load condition, it oscillates

around the programmed setpoint. When the spindle is operated, it is therefore nor-

mal that the spindle shaft assumes speeds which briefly lie above the programmed

operating speed. However, even if mechanical critical speeds are even briefly ex-

ceeded, this can result in excessive material stressing and in turn damage. This

means that tools and spindle systems must be able to withstand normal speed

peaks as a result of control operations.

t[ms]

[RPM]

Programmed

speed

Shutdown speed

Fig. 1-2 Control--related speed peaks

Table 1-7 Translation for Fig. 1-2

English German

RPM Umdrehungen pro Minute

Programmed speed maximale Betriebsdrehzahl

Shutdown speed Abschaltdrehzahl

In order to ensure the appropriate degree of safety at all permitted operational

speeds, the speed peaks must be taken into account when designing the machine

(e.g. the natural resonance of the spindle support) and when selecting the tools.

This is the reason that the subjects relating to natural resonance and centrifugal

force strength, discussed in Chapter 4, do not refer to the speed programmed for

normal operation, but always refer to the shutdown speed which is higher.

Safety Information

1.3 Responsibility for providing information to the company operating the machine

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

1.3 Responsibility for providing information to the company

operating the machine

Some of the information provided in this Configuration Manual must also be com-

municated to the machinery construction company (OEM).

It is the clear responsibility of the machinery construction company (or the com-

pany which markets the machine) to communicate the appropriate information and

instructions to the company actually operating the machinery. Refer to Table 1-8 for

a summary.

Table 1-8 Overview: Important information for the company operating the machine

Subject Chapter

Instructing the company, operating the machine, about measures to detect and to avoid

inadmissible speeds and their effects

1.1

Adapting the shutdown speed to the tool 1.2

In order to achieve the normal bearing lifetime, it is absolutely necessary that the air seal-

ing system is correctly operated

4.3.1

The necessity to check the bearing load 4.3.3

Reference to possible damage when overloading the bearings 4.3.3

Information regarding the highest programmable angular acceleration = 4.3.5

Note that it is strictly forbidden to adjust the position of the clamping state sensors 4.5

Information on the the prerequisites which the tool must fulfill when used on an 2SP1

motor spindle

4.4.1

Reference to the potential hazards and potential damage when using tools which are not

suitable

4.4.1

15000 RPM

0.5 s

2-23

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

FAQ

2.1 What has to be observed after the equipment has been

supplied?

!Caution

Do not allow the crate with the spindle to fall.

Do not push--over the crate with spindle.

Always lay down the crate with spindle horizontally.

Only raise the crate using suitable equipment (fork--lift truck with the appropriate

fork or crane).

The spindle may only be transported in the original crate.

While transporting the crate ensure that it is always in the horizontal position.

After the spindle has been supplied in the sealed packaging (wooden crate/foil),

store it in a dry room with temperature control (10 to 35_C).

The spindle must be kept sealed in the packing until it is mounted/installed in the

machine.

A maximum of 3 crates may be stacked on top of one another.

Fig. 2-1 Transport crate in which the spindle is shipped

FAQ

2.2 How is a the shipment checked?

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

2.2 How is a the shipment checked?

1. Place the crate with spindle in a horizontal position.

2. Remove the packaging straps using the appropriate shears.

3. Remove the crate cover (tools are not required).

4. Carefully open the foil.

5. Check that the contents are complete.

6. Check for damage during transport.

7. Re--package the spindle in the foil.

8. Close the crate using the cover and store (refer to Chapter 2.1).

Fig. 2-2 To check the shipment open the foil

FAQ

2.3 How is the spindle unpacked?

2-25

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

2.3 How is the spindle unpacked?

1. Screw the ring bolts (1) -- supplied with the spindle -- into the threads provided.

2. Attach the hoisting equipment to the ring bolts.

3. Lift the spindle from the crate in a horizontal position and place down on

wooden blocks.

Fig. 2-3 Attaching the ring bolts (1)

Fig. 2-4 Locating the spindle on the wooden V--shaped blocks in a horizontal position

!Caution

Do not lift the spindle at the shaft (this will damage the bearings).

FAQ

2.4 How is the spindle laid--down vertically?

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

2.4 How is the spindle laid--down vertically?

1. Screw--in the 2 ring bolts into the bearing cover.

2. Cover the spindle head with a protective jacket (for the spindle jacket design,

refer to Fig. 2-6.

3. Attach the hoisting equipment to the ring bolts attached to the bearing flange

and carefully lift, refer to Fig. 2-5, Drawing A.

4. Carefully bring the spindle unit into the vertical position above the protective

jacket, refer to Fig. 2-5, Drawing B. Secure the spindle so that it cannot slide.

When bringing the spindle into the vertical position no force may be introduced

into the shaft.

5. Set--down the spindle unit with protective jacket in the vertical position, refer to

Fig. 2-5, Drawing C.

ABC

Fig. 2-5 Bringing the spindle into the vertical position

Fig. 2-6 Protective jacket

FAQ

2.5 How is the spindle installed/mounted?

2-27

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

2.5 How is the spindle installed/mounted?

1. Preparing the mounting location

-- The mounting location must be dry and dust--free

-- All of the required tools must be available

-- Only use suitable tools

2. Screw the ring bolts into the threads provided

3. Clean the spindle stock and apply a thin film of oil to the jointing surfaces

4. Horizontally/vertically install the spindle using the assembly equipment

Caution

Use guide rods to secure and support.

When mounting horizontally, also observe the alignment of the sealing air relief at

the bottom.

Neither stress nor crush the power cable.

Do not apply excessive force when jointing (this could damage the bearings).

Tighten the flange retaining bolts with a tightening torque of 125 Nm.

2.6 Which media should be connected after mounting/installation?

SThe inlet/outlet hoses for the motor cooling should attached. The correct as-

signment/inlet/outlet should be carefully observed. The supply pressures and

flow rates must be checked against the specifications.

SThe hose for the sealing air should be connected. Ensure that the supply pres-

sure is correct.

SThe hoses for ”release tool” and ”clamp tool” (hydraulic or pneumatic) should be

connected. The supply pressures and flow rates must be checked against the

specifications.

Notice

It is not permissible to close--off the ”clamp tool” bore. The transport plug must be

removed.

SThe hose for the tool purge air should be connected. Ensure that the supply

pressure is sufficient correspond to the specifications.

SThe hose for the optional internal tool cooling should be connected. Carefully

observe the max. pressure specifications, excessive pressure will result in damage.

FAQ

2.7 Which electrical connections must be made after mounting/installation?

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

SThe hose for the optional external tool cooling should be connected. Carefully

observe the max. pressure specifications, excessive pressure will result in

damage.

SFor a detailed description, refer to section 6.

2.7 Which electrical connections must be made after mounting/

installation?

SElectrical connections may not be made with the system under voltage

(i.e. live).

SThe power cables should be connected corresponding to the UVW coding (refer

to the electrical data).

SThe signal cable for rotary encoder and motor temperature should be con-

nected. The coding to align the connector should be carefully observed (refer to

sensors). Joint connections must be easy to rotate.

SThe signal cables to monitor the clamping status should be connected (carefully

observe the assignment of the sensors). The coding to align the connector

should be carefully observed (refer to sensors). Joint connections must be easy

to rotate.

2.8 What has to be checked before the spindle is commissioned?

SCheck that the shaft can be easily manually rotated. For synchronous spindles,

the slot notching (permanent magnet rotor) must be able to be felt.

SThe setting dimension of the tool interface should checked. Dimensions and

settings should be taken from the Operating Instructions.

SThe tool draw--in force should be checked using the draw--in force measuring

instrument (e.g. OTT Power Check). Pull--in forces, refer to the Operating In-

structions.

SThe switching logic for ”clamp tool” and ”release tool” should be checked (refer

to the control). Checking the state ”clamped without tool”: Function check with

the tool removed. Check the function of the other clamping states using the

pull--in force measuring unit (”0” setting value for OTT power check). Check the

”draw bar in the release position” by manually releasing and check the function

at the sensor and the PLC.

SIt should be checked as to whether the sealing air discharge is available at the

sealing gap at the spindle nose.

SUsing compressed air it should be checked that the rotary seal does not leak

before the cooling--lubricating medium is connected/switched--on (check for air

leakage at the tool interface; no air should leak at the leakage opening of the

rotary gland). The check must be made in the ”tool released” state.

FAQ

2.9 What has to be observed when starting to work with the spindle?

2-29

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

2.9 What has to be observed when starting to work with the

spindle?

Startofwork

Check the tool interface to ensure that it is clean and if required, clean.

Switch--in the supply media (air, water).

When commissioning for the first time and when starting the machine from cold,

the running--in and warm operating regulations must be carefully observed, refer to

Chapter 4.3.2 or the Operating Instructions.

Notice

The spindle should already be in the warm operating state if the upper speed

range is approached.

Running--in the spindle after longer non--operational periods

See Chapter 4.3.2 or the Operating Instructions.

FAQ

2.9 What has to be observed when starting to work with the spindle?

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Space for your notes

3-31

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Function of the Spindle

Applications

The 2SP1 motor spindle is a high--speed directly--driven tool spindle for milling and

drilling operations.

2SP1202

2SP1204

2SP1253

2SP1255

2SP1202

Fig. 3-1 2SP1 motor spindles

Features

The 2SP1 motor spindle is integrated into the SIMODRIVE drive system just like

the feed and main spindle motors.

The drive motor and the tool holder of the spindle form a mechanical unit which

has a common bearing system. This eliminates all of the generally used mechani-

cal transmission elements, such as belts or toothed couplings. With the directly--

driven 2SP1 motor spindle, the user has many advantages over conventional

spindles with mechanical transmission elements. Further, directly--driven 2SP1

motor spindles are very compact. The advantages include:

SHigh speeds because there are no mechanical transmission elements

SSmooth running properties as a result of the stable balancing arrangement

SGood speed stability, good closed--loop speed control

SHigh accuracy of the closed--loop position control

SLower weight, more compact dimensions

SLower mechanical design costs, as all of the functions are integrated

SEssentially compatible to the electrical drive system as the spindle, drive

converter and NC are engineered and supplied from a single source

Function of the Spindle

3.1 Overview of the functionality

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

3.1 Overview of the functionality

The 2SP1 motor spindle is ready to be built--in -- and the functions that are re-

quired to operate a milling spindle and for drilling are already completely integrated

in the system. This guarantees perfect interaction of the individual function ele-

ments and minimizes the mechanical design costs for the machinery construction

company (OEM).

Table 3-1 Brief overview standard functions

Function 2SP1202

2SP1204

2SP1253

2SP1255

Tool holder HSK A63 SK 40 for tools with non--symmetrical

T sliding blocks [T--slot stones]

Tool clamping device Released using a pneumatic cylinder,

clamped using a spring assembly

Released using a pneumatic cylinder,

clamped using a spring assembly

Tool cleaning Compressed air Compressed air

Working position Horizontal, vertical Horizontal, vertical

Housing Cartridge with flange mounting Cartridge with flange mounting

Bearing lubrication Maintenance--free, permanently lubri-

cated

Maintenance--free, permanently lubri-

cated

Seal, bearing front Sealing air Sealing air

Hollow--shaft encoders Incremental, sin/cos 1Vpp (256

pulses/rev) with zero mark

Incremental, sin/cos 1Vpp (256

pulses/rev) with zero mark

Thermal motor protection KTY84--130

PTC for full thermal protection

NTC PT3-51F, NTC K227 for third--

party drive converters

KTY84--130

Sensor, clamping status

(analog)

-- Tool clamped

-- Draw bar in the release position

-- Clamped without tool

-- -- --

Sensor system, clamped

status (digital)

-- Position of the tool release unit -- Tool clamped 1)

-- Draw bar in the release position

-- Clamped without tool

Cooling Water--cooling Water--cooling

Connections for the

media

-- for cooling

-- for sealing air

-- for air purge

-- to release the tool

-- to clamp the tool

-- for cooling

-- for sealing air

-- for air purge

-- to release the tool

-- to clamp the tool

Electrical connections -- Power cable

-- Signal connectors for the encoder

system and clamping state sen-

sors

-- Power cable

-- Signal connectors for the encoder

system and clamping state sen-

sors

1) All sensors for detection are required for an automatic tool change

Function of the Spindle

3.1 Overview of the functionality

3-33

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Table 3-2 Brief overview of the possible options

Function 2SP1202

2SP1204

2SP1253

2SP1255

Tool cooling -- Inner tool cooling

-- Ring for external tool cooling

-- Inner tool cooling

Max. speed 18,000 RPM 15,000 RPM (with HSK A63)

Thermal bearing monitor-

ing

PT100 -- -- --

Tool clamping device -- Released using a hydraulic cylinder

-- Clamped using a spring assembly

-- -- --

Tool interface -- -- -- BT 40, CAT 40, HSK A63

Function of the Spindle

3.2 Drive motor

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

3.2 Drive motor

An integrated built--in motor drives the 2SP1 motor spindle. This built--in motor has

a high torque and its rotor is directly mounted onto the tool spindle. The electric

power is only fed to the stationary, outer section of the motor. The inner rotating

part of the motor does not require any electric power.

These motor spindles are available in various speed classes. They are designed

for dynamic load operations and can quickly follow changing torque requirements.

Synchronous/induction motors

Depending on the frame size, the following motor versions are available.

SMotor spindle as synchronous motor

SMotor spindle as induction motor (option)

-- The induction (asynchronous) motor version is prepared so that the torque

can be adapted to the machining situation, for both the star and delta con-

nection types. The operator can select the connection type as required (refer

to Chapter 4.2).

Designs

The motor spindle is available in 2 types of construction in order to graduated the

power demand:

SShort design

SLong design

Function of the Spindle

3.3 Cooling concept

3-35

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

3.3 Cooling concept

2SP1 motor spindles have integrated ducts to liquid--cool the stationary stator of

the drive motor. The stator, which draws the electric drive power, represents the

main source of power loss of the spindle unit. This is the reason that the cooling

duct system is closely and thermally coupled to the drive motor stator. However,

even sources of power loss (thermal energy) which are located further away are

sufficiently cooled as a result of the integrated cooling ducts.

The spindle unit should be supplied with the cooling medium through a feed and

return line. The cooling medium absorbs the power loss of the spindle which

means that the cooling medium temperature appropriately increases. The cooling

medium is cooled down to the original inlet temperature using an external cooling

or heat--exchanger system mounted outside the spindle. This is the responsibility

of the machinery construction company. A pump must be used to provide the nec-

essary cooling medium pressure in the inlet line. This external pump is also the

responsibility of the machinery construction company.

Refer to Chapter 6.2 for detailed basic data required to dimension and design the

cooling medium supply.

Function of the Spindle

3.4 Supply

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

3.4 Supply

Compressed air Medium

filter

Sealing air

Air filterAir filter

Valve Valve

Valve

Cooling-

lubrica-

ting

medium

VPM

Power

Sensor(s)

Encoder

Heat--exchanger unit

CNC Converter PLC I/O modules

Medium for

tool ejection,

tool clamping

Air

purge

Leakage

Compressed medium inlet

Compressed medium outlet

Fig. 3-2 Supplying the spindle

Function of the Spindle

3.4 Supply

3-37

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Table 3-3 Translation for Fig. 3-2

English German

Motor spindle Motorspindel

Compressed air Druckluft

Compressed medium inlet Druckmedium Zulauf

Compressed medium outlet Druckmedium Rücklauf

Valve Ventil

Air purge Kegelreinigungsluft

Air filter Luftfilter

Medium filter Mediumfilter

Sealing air Sperrluft

Medium for tool ejection, tool clamping Medium für Werkzeug lösen, Werkzeug

spannen

Cooling-lubricating medium Kühlschmiermittel

Leakage Leckage

Heat-exchanger unit Wärmetauschersystem

Encoder Geber

Sensor(s) Sensor(en)

Electric power Elektrische Leistung

Converter Umrichter

PLC I/O unit PLC Ein-/Ausgabeeinheit

2SP1 motor spindles have integrated function elements to operate and control the

various operations and sequences. The following media must be provided for the

spindle, either through suitable cables or hoses:

SElectric power for the drive motor (the consumption depends on the power

drawn)

SCooling liquid (continuous flow; load depends on the power level)

SCompressed air or hydraulic oil to actuate the tool clamping system -- de-

pending on the release unit type, either pneumatically or hydraulically operated

(media only flows when releasing and clamping the tool)

SAir purge to clean the tool cone (this air is only used when releasing and eject-

ing the tool)

SSealing air to protect the bearings from dirt accumulating (this air is continually

used)

SOptional cooling--lubricating medium supply for internal tool cooling (the

flow depends on the actual process)

SOptional cooling--lubricating medium supply for external tool cooling (the

flow depends on the actual process)

S24 V electrical supply for the sensors to monitor the tool clamping state

(power is continually drawn)

SPower supply for the rotary encoder (for SIEMENS drive converters, this is

integrated in the encoder interface)

Function of the Spindle

3.4 Supply

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

The requirements regarding the conditioning of the various media, and which are

required to design and dimension the various units and equipment, are described

in detail in Chapter 6 and Chapter 10.

4-39

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Mechanical Data

The 2SP1 motor spindles allow operating companies to fully utilize the benefits of

high--speed machining. At high speeds, the components involved in the machining

operation are subject to significant levels of stress. This means that the machine

must be mechanically designed to withstand the high speeds and the user must

harmonize and align the tools and the process conditions to the load capability of

the spindle.

4.1 Observing the shutdown speed

Even if the critical speed is briefly exceeded, the following can occur:

SVibration of the spindle carrier (support structure),

Sthe centrifugal strength of the tools can be exceeded,

and excessive mechanical stress can cause damage.

!Caution

The shutdown speed should be used as basis for load assumptions and

strength requirements. It is not permissible to use the speed which can be

programmed for operation (refer to Chapter 1.2).

4.2 Installation conditions

The spindle is integrated into the machine assembly as a complete unit. The static

and especially the dynamic properties are obtained from the interaction between

the spindle itself and the spindle carrier of the machine.

Mechanical Data

4.2 Installation conditions

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Degree of protection

IP64 IP53

Drive end Non--drive end

Fig. 4-1 Degree of protection of the 2SP120 spindle

IP64 IP53

Drive end Non--drive end

Fig. 4-2 Degree of protection of the 2SP125 spindle

Table 4-1 Translation for Fig. 4-2

English German

Drive end A-Seite

Non-drive end B-Seite

Caution

The degree of protection refers to the ingress of water (DIN ISO EN 60034,

Part 10). Cooling--lubricating mediums that contain oil, can creep and/or are

aggressive, and can penetrate more than water.

Table 4-2 Degree of protection in front of and behind the mounting flange

In front of the mounting flange

(drive end)

Behind the mounting flange

(non-drive end)

Degree of

protection

IP64 IP53

Description On the drive end, the spindle has a lab-

yrinth seal and a connection for the

sealing air. This therefore protects the

spindle against the ingress of water

spray and dirt. It is not permissible that

cooling water acts directly on the laby-

rinth seal. The specifications for the

sealing air must be carefully observed,

refer to Chapter 6.3.1.

The spindle support design must guarantee

suitable protection behind the mounting flange

against the effects from the machining area.

Mechanical Data

4.2 Installation conditions

4-41

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Installing the spindle

The spindle must be installed in the machine so that liquids and dust--type dirt from

the machining area cannot be permanently deposited on the spindle.

Caution

It is not permissible that spray water or other liquids are directly pointed at the

sealing gap (labyrinth seal) or openings in the spindle (refer to Fig. 4-3).

It is not permissible that foreign bodies are drawn through the spindle. This is the

reason that it is not permissible to have a pressure difference between the drive

and drive--out sides.

Fig. 4-3 The jet of cooling--lubricating medium may not be directly aimed at the labyrinth

seal

Notice

Horizontal mounting:

When the spindle is mounted horizontally, the relief (compensating) holes for the

sealing air, located at the spindle nose, must face downwards.

Orientation help: The position of the ring bolt thread, located at the retaining

flange, when viewing the nose of the spindle from the front, must be inclined at a

certain angle to the right (refer to Figs. 4-4 and 4-5).

Mechanical Data

4.2 Installation conditions

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

M8 thread for ring bolt

Spindle below with horizontal mounting

Compensating

holes for sealing air

Fig. 4-4 Mounting position of the 2SP120Vspindle

M10 thread for ring bolt

Spindle below with horizontal mounting

Compensating

holes for sealing air

Fig. 4-5 Mounting position of the 2SP125Vspindle

Table 4-3 Translation for Figs. 4-4, 4-5

English German

M8/M10 thread for ring bolt Gewinde M8/M10 für Ringschraube

Spindle below with horizontal mounting Spindel unten bei horizontalem Einbau

Compensating holes for sealing air Entlastungsbohrungen für Sperrluft

The spindle must be mounted so that the motor spindle is not subject to any com-

pulsive forces. If the housing is subject to tension, this can result in a slight de-

formation and increased stressing on the roller bearings. This will have a negative

impact on the smooth running characteristics, operating temperature and therefore

the lifetime.

Axial tapped holes (on the rear bearing cover) and radial tapped holes (on the

flange and at the rear bearing cover) are provided on the spindle for lifting lugs.

These are used when the spindle is mounted.

Mechanical Data

4.2 Installation conditions

4-43

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

4.2.1 Mechanical requirements placed on the spindle support

Load situation of the spindle support

The spindle is subject to an alternating force caused by the residual imbalance of

the shaft and the tool. The residual imbalance transfers tilting and lateral forces to

the spindle mounting flange so that principally, the following associated vibration

types

STilting vibration (tilting from the non--drive end to the drive end)

SLateral vibration (lateral movement of the spindle)

canbeexcited(refertoFig.4-6).

The forces excited by the residual imbalance increase with speed.

Drive end

Non--drive end

Lateral

vibration

Deformation and displacement of spindle support

make tilting and lateral vibration possible.

Fig. 4-6 Types of vibration which can be excited due to imbalance

Table 4-4 Translation for Fig. 4-6

English German

Non-drive end B-Seite

Drive end A-Seite

Tilting vibration Kippschwingung

Lateral vibration Seitwärtsschwingung

Deformation and displacement of spindle

support make tilting and lateral vibration

possible.

Verformung und unterschiedliche Plazier-

ung des Spindelträgers ermöglichen Kipp-

und Seitwärtsschwingungen.

Mechanical Data

4.2 Installation conditions

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

The alternating stressing frequency precisely corresponds to the rotating frequency

of the spindle.

f = 1min/60s ⋅N with f: exciting frequency in [Hz]

N: speed in RPM

Vibrational characteristics: Mechanical design requirements placed on the spindle support

The spindle support must have a stiff design so that no natural resonance points of

the appropriate vibration types can be generated over the complete speed range

up to the shutdown speed. The lowest resonant frequency must lie above

the rotating frequency of the shutdown speed which can be excited by an

imbalance condition. In this frequency range, the spindle support must be able to

absorb the tilting and lateral forces caused by the residual imbalance, without

being deformed.

The spindle is mounted to the machine assembly at the drive end (front end) using

the mounting flange. This must be taken into account in the mechanical design of

the spindle support, especially when it comes to suppressing the tilting vibration of

the rear (non--drive end) end of the spindle, which is relatively far away from the

mounting flange.

Mechanical Data

4.2 Installation conditions

4-45

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Information regarding the design of the spindle support

The following points should be carefully observed when designing the spindle sup-

port to accept the motor spindle:

SMaterial strength

The fit area around the mounting flange is extremely important due to the high

force density to counteract the tilting vibration. The material thickness and

strength must be adequately dimensioned.

SLateral stability of the flange plane

The plane of the mounting flange must be embedded so stiffly in the machine

that in the frequency range up to the shutdown speed, no vibrational types are

possible with lateral movement of the mounting flange. Designs, where the

plane of the mounting flange is located far beyond the plane of the guide ele-

ment of the spindle slide, are especially critical when it comes to a shift in the

flange plane due to torsional rotation and deformation of the spindle support.

SCarefully observe the fit and tolerance

The spindle mounting flange must be attached to the spindle support so that it

is geometrically precise and is as dynamically stiff as possible. The mechanical

design and the tolerances, which are documented in the drawings to accept the

mounting flange, must be carefully maintained. For drawings and dimension

dimension drawings, refer to Chapter 10. For the recommended tolerance for

the spindle support, refer to Fig. 4-7.

SSupporting the spindle support using the guide elements

The guide elements (linear guides) which support the spindle support with re-

spect to the machine bed, should provide an appropriately wide basis to with-

stand tilting vibration (refer to Fig. 4-8).

SShort length between the spindle mounting flange and where the spindle

support is retained

If the spindle mounting flange extends in front of where the spindle support is

retained, then this can undesirably reduce the resonant frequency of the tilting

vibration (refer to Fig. 4-8). This means that the length which extends between

the spindle mounting flange and the point where the spindle support is retained

at the machine bed should be kept as short as possible. This is also the reason

that the spindle support should not have a high mass close to the flange plane

which does not directly serve to make the support assembly stiff.

Mechanical Data

4.2 Installation conditions

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Fig. 4-7 Mounting the spindle in the spindle support

attachment

Spindle support

Spindle

support

Avoid mass

accumulation of

spindle support

in this zone

Avoid long unsupported distances

Spindle mounting flange

Fig. 4-8 Example: Tilting vibration for an extended spindle mounting flange

Mechanical Data

4.2 Installation conditions

4-47

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Table 4-5 Translation for Fig. 4-8

English German

Avoid long unsupported distances Größere frei tragende Längen vermeiden

Spindle support Spindelträger

Tilting vibration Kippschwingung

Spindle mounting flange Spindelbefestigungsflansch

Spindle support attachment Befestigung des Spindelträgers

Avoid mass accumulation of spindle support

in this area

Masseansammlung in diesem Bereich des

Spindelträgers vermeiden

SStiffening long unsupported lengths

Longer unsupported lengths should be avoided. If the spindle mounting flange

is extended, then appropriate ribs and transverse reinforcing elements should

be used. These reinforcing measures should be designed so that they counter-

act tilting vibrations (refer to Fig. 4-6).

SNo additional components mounted directly on the spindle

In order that the natural frequency of the tilting vibration is not undesirably

reduced, it is not permissible to mount or anchor any components directly on

the spindle. For example, connecting strain relief elements for drag cables.

Numerical techniques, such as the FEM--based modal analysis have proven them-

selves to be helpful when evaluating a mechanical design regarding its vibrational

characteristics. For additional support, please contact your local Siemens office.

4.2.2 Support at the non--drive end

2SP1 motor spindles are available in several power classes. For the high--speed

versions with high torques, an additional direct mechanical support is required

between the non--drive end of the spindle and the spindle support.

For a list of the spindle types where the non--drive end support is specified, refer to

Chapter 10, Table 10-4 and 10-5.

Function of the support

The direct support between the non--drive end of the spindle and the spindle

support has the function to stabilize the spindle against tilting vibrations so that

the lowest resonance frequency lies above the rotational frequency of the

shutdown speed.

Mechanical Data

4.2 Installation conditions

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Properties and characteristics of the support

This is the reason that the support design must be as stiff as possible to counter

the lateral vibration shown in Fig. 4-8. Further, this support must have a low mass

close to the non--drive end. This is because an increase in the effective spindle

mass at the non--drive end increases the moment of inertia of the tilting vibration

and in so doing undesirably lowers the resonant frequency. Also in this case,

FEM--supported modal analysis can be effectively used when evaluating the

mechanical design.

Mechanical Data

4.3 Spindle bearings

4-49

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

4.3 Spindle bearings

High precision spindle bearings are used for the 2SP1 motor spindle shaft.

They offer excellent precision and are designed to withstand loads at high speeds.

Hybrid bearings are used for spindle versions which rotate at even higher speeds.

Special significance was placed on the ruggedness of the bearings. They have

proven themselves over many years in applications ranging from job shops up to

three--shift series production.

4.3.1 Features and operating conditions

The high precision spindle bearings absorb the radial and axis forces from the ma-

chining process without any play. Thermal stressing of the spindle shaft does not

influence the mechanical tension. The bearings have excellent balance quality and

extremely low roughness.

Radial eccentricity (run--out) at the tool holder, refer to Chapter 10.

The spindle’s own sealing air system

The bearings are equipped with an integrated seal. The seal to the machining

space at the spindle drive end is backed--up by the spindle’s own sealing air

system, refer to Chapter 6.

Notice

In order to achieve the specified bearing lifetime, the sealing air system must be

correctly used. The machinery construction company is responsible in explaining

this to the company operating the spindle.

Bearing lubrication

2SP1 motor spindles have permanently lubricated bearings. This is the reason that

they are maintenance--free. A re--lubrication device is not required.

Notice

The permanent grease lubrication may not be negatively influenced or polluted by

other materials and substances.

Mechanical Data

4.3 Spindle bearings

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

4.3.2 Warming--up phase of the motor spindle

Warming--up phase of the motor spindle (temperature distribution)

An uneven temperature distribution can have a negative impact on the bearing lifetime.

When commissioning for the first time and when starting the machine from cold,

the running--in and warming--up specifications (refer to the the Operating Instruc-

tions) must be carefully observed.

Notice

The spindle should already be in the warm operating state if the upper speed

range is approached.

Table 4-6 Warming--up phase of the motor spindle

Speed Operating time

25% of the maximum speed 2min

50 % of the maximum speed 2min

75 % of the maximum speed 2min

Ready to operate

The machinery construction company can include a motor spindle warm--up cycle

in the control software.

Longer periods of time where the spindle is not operational

Notice

A spindle must be run--in if it has not been used for more than one week.

Table 4-7 Running--in the spindle after longer non--operational periods

Speed Operating time

25% of the maximum speed 5min

50 % of the maximum speed 5min

75 % of the maximum speed 5min

Ready to operate

Longer storage times

Notice

If the motor spindle has been stored for longer periods of time, the procedure for

storing spindles, described in the Operating Instructions, must be carefully

observed.

Mechanical Data

4.3 Spindle bearings

4-51

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

4.3.3 Load capability of the spindle bearings

Bearing overload

Notice

High--speed bearings are sensitive to overload conditions.

This is the reason that in operation and at standstill, overload conditions

must be avoided.

Table 4-8 Possible damage due to bearing overload and how it is avoided

Overload situation Damage Possibilities of avoiding the overload

situation

Applying force when

assembling and

disassembling

Immediate bearing

damage

Machinery construction company and operating

company:

-- When assembling the spindle, it is not per-

missible that forces are transferred to the

spindle shaft and therefore to the bearings.

The Operating Instructions must be carefully

observed.

Machinery construction company:

-- Design the space in which the spindle is to

be mounted so that it can be easily acces-

sed

-- Provide equipment for assembly and disas-

sembly

-- Provide the operating company with the ap-

propriate mounting/installation equipment

and resources

The effect of force due to

a collision

The bearings are

immediately damaged

the bearing lifetime is sig-

nificantly reduced

Operating company:

-- Check new workpiece programs using a

slow path velocity

-- Visualize the programmed tool paths on the

control side

Overload when a tool

breaks

The bearing lifetime is

reduced

Operating company:

-- When a tool breaks, the spindle should be

quickly brought to a standstill

The machinery construction company (OEM) is responsible in informing the oper-

ating company about the possible damage if the spindle is overloaded.

Mechanical Data

4.3 Spindle bearings

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

4.3.4 Lifetime of the spindle bearings

Grease lifetime

In many applications, the grease lifetime is, with respect to the fatigue lifetime, the

decisive factor which has to be taken into account therefore determining the

spindle bearing lifetime The grease lifetime decreases with increasing speed (refer

to Fig. 4-9).

2000

4000

6000

8000

10000

2000

4000

6000

8000

10000

12000

14000

16000

n[RPM]

Grease lifetime [h]

18000

20000

12000

14000

16000

18000

20000

2SP1253--VHV0--0VV2

2SP1255--VHV0--0VV2

2SP1253--VHV0--1VV2

2SP1255--VHV0--1VV2

2SP1202--1HAVV-- 1 D F 2

2SP1204--1HAVV-- 1 D F 2

2SP1202--1HBVV-- 2 D F 2

2SP1204--1HBVV-- 2 D F 2

Fig. 4-9 Grease lifetime

A prerequisite for reaching the specified grease lifetime is that the permitted bear-

ing temperatures are maintained.

The following must therefore be observed:

SThe spindle cooling must be operated in compliance with the specifications

SIt is not permissible that the bearing load is exceeded

SThe maximum permissible ambient temperature in the operating state may not

be exceeded

Mechanical Data

4.3 Spindle bearings

4-53

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Table 4-9 Determining the probable grease lifetime

Sequence Description, formulas

1. The spindle operation is sub--

divided into constant speed

phases

toperate

[min]

[RPM] Repeat cycle t cycle

t2tktK

....

n2nK

....

2. The relative duration of the

speed phases is determined

(relative proportion of the time

in the cycle)

trel k =tk

tcycle

3. The individual grease lifetime

Tuse k of the individual phases

is determined

n[RPM]

[h]

n1nknKn2

Tlife 2

Tlife k

Principle grease lifetime as a

function of the speed

Grease

lifetime

Principle grease lifetime as

a function of the speed

4. The individual lifetimes are

added in a weighted fashion to

obtain the complete grease life-

time

Tuse total=1

trel 1

Tlife 1

trel 2

Tlife 2

trel k

Tlife k

trel k

Tlife k

... ++

... +

Table 4-10 Translation for Fig. 4-9

English German

RPM Umdrehungen pro Minute

Repeat cycle Wiederholungszyklus

tcycle Zykluszeit

toperate Betriebsdauer

trel relative Zeitdauer einer Drehzahlphase

Grease lifetime Fettgebrauchsdauer

Tlife total Gebrauchsdauer gesamt

Tlife Gebrauchsdauer einer Phase

Mechanical Data

4.3 Spindle bearings

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

4.3.5 Maximum angular acceleration when the spindle is accelerating

For extreme rates of angular acceleration and extremely short accelerating times,

the rollers of the spindle bearings can slide rather than rotate. This has a negative

impact on the bearing lifetime and must be avoided. When programming the

spindle acceleration (and braking) it is imperative that a maximum angular accel-

eration corresponding to 15000 RPM in 0.5 s is not exceeded.

≤15000 RPM

0.5 s with: N

.Programmed angular acceleration

The machinery construction company is responsible in clearly informing the oper-

ating company that higher levels of angular acceleration may not be programmed.

4.3.6 Stiffness

The mechanical stiffness at the tool holder with respect to radial and axial forces is

documented in the data sheets, Chapter 10. The natural bending of the tool addi-

tionally shifts the cutting edge if radial forces are present. For narrow profile tools,

the natural bending of the tool is significantly greater than the shift of the tool

holder.

4.3.7 Axial shaft growth

The spindle shaft is subject to a geometrical shift in the axial direction. This shift is

known as shaft growth.

The shaft growth comprises the following elements:

SThermally--related shaft growth

SSpeed--related shaft growth

The shaft growth is independent of the tool being used.

Thermal shaft growth

In the thermal stabilization phase, while the spindle warms up, the spindle shaft

temperature increases up to its steady--state condition. This means that during this

thermal stabilization phase, the tool holder shifts forwards (due to thermal expan-

sion). After the warm--up phase has been completed, the spindle shaft essentially

has a constant operating temperature so that the tool holder no longer moves as a

result of thermal expansion.

Mechanical Data

4.3 Spindle bearings

4-55

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Speed--related shaft growth

Due to the geometrical arrangement of the roller bearing assemblies, the rolling

bearing contact point shifts in the bearing ring as a function of the speed. This

causes the tool holder to shift forwards. This shift is a function of the speed and

increases with increasing speed. This shift reverses as the speed decreases.

When required, this shaft growth can be equalized by correcting the Z axis. We

recommend that the thermally--related shaft growth and the speed--related shaft

growth are determined by machining sample workpieces. The appropriate correc-

tion tables can then be drawn--up for the Z axis position.

Mechanical Data

4.4 Tools and tool holders

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

4.4 Tools and tool holders

4.4.1 Tools

The interaction between the motor spindle and the tools which are used has a

decisive influence on the productivity and quality of the machining operation. When

selecting the appropriate tools, the safety information and instructions relating to

high speeds must be carefully observed.

As a result of the high speed, 2SP1 motors spindles allow excellent surface quali-

ties and high productivity to be achieved. However, when incorrectly used, the high

speeds can also represent potential risks and significant wear. It is especially im-

portant that the tools are carefully selected.

Only use tools which are in a perfect condition

The following behavior/characteristics in operation are only achieved when tools,

which must be in a perfect condition, are correctly used:

SPerfect machining results

SLow vibration levels

SLow wear of the spindle bearings

SLow noise emission

SSafety of operating personnel and the machine

This is the reason that it must always be ensured that only tools in a perfect condi-

tion are in the tool magazine -- and that these tools were checked to ensure that

they are suitable for operation with the particular spindle. The machinery construc-

tion company is responsible in clearly informing the operating company the poten-

tial danger and damage if unsuitable tools were to be used.

Prerequisites for tools

The tools must fulfill the following prerequisites:

1. The tool must be released/certified for high speeds and centrifugal forces.

2. It is not permissible that the tool reduces the natural frequency of the spindle

unit to below the critical rotating frequency.

3. The cutting forces and the intrinsic weight of the tool may not overload the

bearings.

4. Ratio between the length and diameter, not greater than 3:1.

5. The tool must be perfectly balanced.

For a detailed description, of the specified prerequisites, refer to Table 4-11.

Mechanical Data

4.4 Tools and tool holders

4-57

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Table 4-11 Prerequisites for tools

Description

High speeds and cen-

trifugal forces

Depending on the tool diameter, at high speeds, extremely high centrifugal forces occur at

the tool. Only those tools may be used, without any restrictions, whose permitted speed lies

above the shutdown speed of the spindle. If a tool breaks at high speed, parts will be flung--

out at a high velocity and can cause significant damage.

Example: If a piece of a tool having a radius of 40 mm and a speed of 10,000 RPM is flung--

out, this reaches a velocity of 150 km/h.

Using tools with the permitted speed < shutdown speed

The following conditions must be observed:

SSpeed monitoring (refer to Chapter 1.2)

The threshold of the shutdown speed must lie below the permitted maximum tool speed.

If various shutdown speeds are used for different tools, then these must be matched to

the tool using the Tool Manager. For example, the speed monitoring function can be im-

plemented by defining gear stages (refer to Chapter 1).

SLimiting the programmable speed (refer to chapter 1.2)

The programmable maximum operating speed must lie at least 5 % below the shutdown

speed.

Do not allow the

natural frequency of

the spindle unit to drop

below the critical rota-

tional frequency

The resonant frequencies of the spindle support and spindle must always lie above the

speed permitted for the particular tool. As a result of a clamped tool, resonant frequencies

can be noticeably and undesirably reduced.

The danger associated with reducing the resonant frequencies is especially critical for:

SLong tools

SHeavy tools

STools with a large radius

Generally, the best smooth running characteristics are achieved when short tools are used;

when short tools are used, then these result in lower bearing stressing.

This means that the tools must be clamped so that their effective length is as short as pos-

sible.

The spindle manufacturer cannot define generally applicable limit data for tools. The reason

for this is that the resonant frequencies of the spindle support and spindle are not determined

just by the spindle alone, but mainly how the spindle is actually mounted in a mechanical

assembly. The machinery construction company (OEM), which is responsible for mounting/

installing the spindle, is responsible in providing the operating company with information and

data about the permissible range of dimensions and weights of tools.

In principle, a run--up test with the tool to be tested provides useful data. In this case, the tool

is slowly accelerated up to the maximum permissible speed and is kept at a high speed for

approximately one minute. The accelerating ramp should be slow. If the spindle runs

smoothly without any vibration during the acceleration phase and at the maximum speed,

then the tool can be released for operation. If a significant amount of noise or vibration occurs

while the tool is being accelerated or at maximum speed, the run--up test should be immedi-

ately stopped and the tool being tested should be classified as unsuitable or ”not released for

a specific speed”.

Cutting forces and own

weight

A worn cutting edge can cause the cutting force to be increased a multiple number of times.

This not only has a negative impact on the machining process but also on the bearing lifetime

as the permissible bearing loads are exceeded. We therefore recommend that the condition

of the cutting edge is continually monitored.

Mechanical Data

4.4 Tools and tool holders

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Table 4-11 Prerequisites for tools, continued

Description

Ratio between the

length and diameter

Tools should be used whose ratio between L and diameter ∅does not exceed a value of 3:1

and whose total weight of the tool insert lies below 4.5 kg.

The spindles are designed so that with these tools, the critical speeds lie above the

maximum spindle speed.

If tools are used whose dimensions deviate from this data, then the speed should be

calculated. In addition to limiting the speed as a result of critical speeds of the spindle/tool

system, speed limiting using technological data of the cutting process should be carefully

taken into consideration.

Tool holder

Tool employment

∅

Balancing Only the most finely--balanced tools in compliance with Q 6.3 may be used.

Standards to be carefully observed and fulfilled:

SVDI Directive 2056

SDIN EN ISO 15641

Notice

Balancing must be made after the tool insert has been inserted in the tool holder. It is

not permissible to individually balance the tool insert and tool holder without balanc-

ing the whole assembly.

A worn tool can have a noticeable negative impact on the balance quality. If vibration and

noise levels increase while a tool is being used, then the tool must be checked for wear and

the balance must also be re--checked.

Mechanical Data

4.4 Tools and tool holders

4-59

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

4.4.2 Tool holders

2SP1 motor spindles are available with several tool holders.

Table 4-12 Tool holders

Type Standard for speed Remark

SK 40 -- non--symmetrical DIN 69872, ISO 7388/1/2 Type A ≤10000 RPM 2SP125

CAT40 -- non--symmetrical ANSI B5.50-78, ISO 7388/1/2

Type B

≤10000 RPM 2SP125

BT 40 -- non--symmetrical

BT 40, 30_

MAS 403-1982, BT/PT30_

Version E1

≤10000 RPM 2SP125

BT 40 -- non--symmetrical

BT 40, 45_

MAS 403-1982 BT/PT45_

Version F1

≤10000 RPM 2SP125

HSK A63 DIN 69893-1, ISO 12164-1 ≤18000 RPM

≤15000 RPM

2SP120

2SP125

Drawings, dimension tables and tolerance data, refer to Chapter10.

B¦0.25

C¦0.25

DIN 69871 ISO/DIS 7388/1

0.02

DIN 69872 ISO/DIS 7388/2 Type A SK 40 44.45 94.25 88.25

¦0.25

Fig. 4-10 SK 40

Mechanical Data

4.4 Tools and tool holders

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

SK 40 44.45 84.50 79.25

J¦0.3

0.05

¦0.3

Fig. 4-11 CAT 40

E¦0.25

F¦0.25

MAS 403--1982 PT

0.02

MAS 403--1982 PT--2

30 °

BT/PT 30_44.45 100.35 93.35

¦0.25

Fig. 4-12 BT 40, 30°

Mechanical Data

4.4 Tools and tool holders

4-61

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

E¦0.25

F¦0.25

MAS 403--1982 BT

0.02

MAS 403--1982 PT--1

45 °

BT/PT 45_44.45 100.35 93.35

¦0.25

Fig. 4-13 BT 40, 45_

l12

9+0.09

HSK A63 12.54

63 5348.01 26 18 5 32 21

d1 d2 d9 f1 f3 h3 l1 l12

h10

¦0.04 0/--01 ¦0.1 +0.2/0 0/--0.2

Fig. 4-14 HSK A63

Mechanical Data

4.4 Tools and tool holders

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

Tool changer

A tool is changed depending on the machine tool using either a gripper or by di-

rectly gripping and placing the tool into a tool magazine.

Caution

In order to reliably prevent the spindle colliding with adjacent tools in the tool

magazine or in the tool gripper, depending on the particular spindle, certain

minimum clearances should be maintained (refer to Table 4-13 and Fig. 4-15).

Table 4-13 Minimum clearances for various tool holders

Motor spindle Tool holder Minimum clearance [mm]

2SP120VV-- 1 H VVV-- VDF2 HSK A63 A²100.0

2SP125VV-- VHV0V-- 1 D V2HSK A63 A²100.0

2SP125VV-- VHV0V-- 0 VV2SK40 A²100.0

HSK A63 SK 40

Fig. 4-15 Minimum clearance = dimension A

Mechanical Data

4.5 Clamping system and tool change

4-63

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

4.5 Clamping system and tool change

4.5.1 Clamping system

2SP1 motor spindles are equipped with a clamping system for automatic tool

changing. This clamping system is integrated in the spindle shaft and rotates with

the spindle.

The clamping system is designed for max. 5 tool change cycles per minute.

The pull--in force is provided by the spring system which rotates with the spindle.

The tool is safely and reliably maintained in the clamped position even when the

power fails and while the spindle is rotating. The magnitude of the pull--in force is

described in Chapter 10.1.

Clamping state sensors

The spindle is equipped with sensors to monitor the clamping state. The various

clamped states are detected by sensing the axial position of the clamping or actua-

tion system.

Table 4-14 Sensors to monitor the clamped state

2SP1 20

Sensor Message Type Remark

S1 Dependent on the measured voltage Analog sensor Basic equipment

S4 Position of the release cylinder NO contact Basic equipment

Table 4-15 Sensors to monitor the clamped state

2SP1 25

Sensor Message Type Remark

S1 Draw bar in the release position NO contact Basic equipment

S2 Tool is clamped NO contact Basic equipment

S3 Collet is closed without a tool inserted NO contact Basic equipment

Electrical data of the sensors, refer to Chapter 7.2.

Evaluation of the sensors to control the tool change, refer to Chapter 8.

!Warning

The mounting position of the clamped state sensors is carefully adjusted in the

factory. It is not necessary for end users to move the position of the sensors and it

is also strictly forbidden. The machinery construction company is responsible in

informing the operating company that it is not permissible to adjust the position of

the sensors.

Mechanical Data

4.5 Clamping system and tool change

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

4.5.2 Tool change

!Caution

It is only permissible to insert and release the tool when the motor spindle is at a

standstill (zero speed). The tool must be inserted up to the contact surface of the

clamping taper.

The clamping system is either actuated pneumatically or hydraulically using a

pneumatic or hydraulic cylinder.

Note

The air line between the compressed air source and the pneumatic/hydraulic

cylinder must have an adequate cross--section in order to keep the times to

establish pressure and reduce pressure of the pneumatic/hydraulic cylinder short.

Recommended cross--section for the air line to the pneumatic cylinder: 8 mm.

Recommended cross--section for the oil line to the hydraulic cylinder: 5 mm.

For longer compressed air lines using drag chains we recommend that the

flow--related pressure loss and the associated time to establish pressure in the

cylinder is theoretically estimated.

The details and the waiting times to be maintained, the control of the mechanical

sequences of the clamping and release operations are described in Chapter 8.2.

The operating and flow rate data of the pneumatic/hydraulic cylinder are described

in Chapter 6.3 and 6.4.

Values for clamping and release pressures refer to Table 10-2.

Mechanical Data

4.5 Clamping system and tool change

4-65

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

4.5.3 Tool changing for standard clamping systems

Releasing tool

Pressure is applied to the cylinder to release the tool. The actuation device re-

leases the tool from the tool holder so that it can be removed by the tool changing

gripper without any force being required.

Sensor S1 is adjusted so that for tools in compliance with the standard it supplies

the ”draw bar in the release position” signal.

When removing the tool, the appropriate control diagram must be taken into account:

Fig. 8-4: Automatic tool change (with S1 and S4) for 2SP120j

Fig.8-5: Manual tool change (with S2) for 2SP125j

Fig. 8-6: Automatic tool change (withS1, S2 and S3) for 2SP125j

!Caution

The released tool is only loosely located in the tool holder. It must be removed

after it has been released. If it is not removed, then it can simply fall out and cause

damage.

Jammed tools cannot be reliably detected using sensor S1.

Inserting and clamping the tool

The tool is drawn--in and clamped just using disk springs.

For this operation, for spindles with pneumatic cylinder, the air in the cylinder must

first be released. In order to shorten the tool change times, compressed air can be

additionally applied to the rear of the piston.

For spindles with hydraulic cylinder, the piston side must be relieved (the pressure

reduced) using an appropriate valve -- and pressure (hydraulic pressure) applied to

the rear of the piston.

For 2SP120V, the voltage of analog sensor S1 is measured to determine that the

tool has been correctly clamped.

For 2SP125V, digital sensor S2 indicates whether the tool has been correctly

clamped.

While inserting a tool, the release pressure must be switched through to the pneu-

matic or hydraulic cylinder until sensor S1 signals that the clamping system is

ready for tool insertion. The tool can only be inserted after this signal is present.

Mechanical Data

4.5 Clamping system and tool change

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

!Caution

The gripper must completely introduce the tool into the tool holder. It must prevent

the tool from either sliding or dropping--out until the clamped state has been

achieved (e.g. an appropriate signal from sensor S1 for 2SP120Vmotor spindles

or from sensor S2 for 2SP125Vuntil a specific voltage level has been achieved).

!Caution

The spindle may only rotate if the cylinder piston has withdrawn from the spindle

shaft and has not contact with it. This means that it is not permissible that a

release pressure is applied to the pneumatic or hydraulic cylinder!

When the release pressure is applied to the cylinder, the stationary cylinder piston

makes contact with the rotating clamping system of the spindle shaft. If it would be

in contact while the spindle is rotating, this would damage the clamping system.

This is the reason that spindle rotation may only be enabled if there is no release

pressure and the sensor system clearly indicates that a tool has been safely and

reliably clamped. While the spindle is rotating, the pressure feed to release the tool

must be safely and securely shut--off.

!Caution

The spindle may not rotate if it does not have a clamped tool!

If a clamping operation is carried--out without a tool being ready at the front for

insertion, then the collet and draw bar retract to behind their normal clamping

position. This status is permitted -- however, it is not permissible that the spindle

rotates at a high speed. Only slow spindle speeds of below 100 RPM are

permissible to position the spindle.

Mechanical Data

4.5 Clamping system and tool change

4-67

2SP1 Motor Spindle (PMS), 03/2007 Edition, 6SN1197--0AD04--0BP3

4.5.4 Changing tools for the HSK A63 Type C tool holder

Releasing tool

Pressure is applied to the cylinder to release the tool. The actuation mechanism

releases the tool from the tool holder.

Sensor S1 is adjusted so that for tools in compliance with the standard it supplies

the ”draw bar in the release position” signal.

When removing the tool, the appropriate control diagram must be taken into account:

See Fig. 8-4: Automatic tool change (with S1 and S4) for 2SP120j

For a holding clamping system, the tool is still held with a defined holding force in

the tool holder using springs. A tool can only be removed after first overcoming the

holding force. To do this, force must be applied by the tool changer.

Inserting and clamping the tool

While inserting a tool, the release pressure must be switched through to the pneu-

matic or hydraulic cylinder until sensor S1 signals that the clamping system is

ready for tool insertion. The tool can only be inserted after this signal is present.

For a holding clamping system, when the tool is inserted, it is initially only held in

the tool holder by the holding function of the springs without the tool being clamped

in the tool holder. The tool change gripper no longer has to hold the tool after it has

been inserted as this function is handled by the holding clamping system.