Modular sensor bearings - Schaeffler...Rolling bearings The basic load ratings and speeds valid for a rolling bearing remain unchanged even if the bearing is used within the product

Schaeffler VarioSenseModular sensor bearings

Foreword

The machine and equipment building sector is characterised bythe trend towards intelligent, networked machines. It is becoming increasingly important to gain information about the operating mode of machinery. Everywhere that machine components move, there is a need for data on measurement values such as velocities, speeds, forces or temperatures. The bearing position is often the ideal location for collecting these data. The high precision of rolling bearings and the accuracy of the adjacent construction facilitate high quality of measurement at this point.Bearings with integrated speed or angular position measurement have existed for many years. In general, these are products thathave been specially developed for a specific application. With the Schaeffler VarioSense, Schaeffler is now introducing a product series that, through the combination of standard rolling bearings and a modular sensor concept, facilitates a flexible, rapid and economical solution for a wide variety of applications. This makesit possible to realise not only one, but a combination of different measurement values for each standard rolling bearing.

Expanding product range In a first stage, deep groove ball bearings with integrated speed measurement are being offered. In the second stage, the measure-ment values of temperature and displacement are added, wherethe displacement allows a conclusion to be drawn as to the load on the bearing. The customer can then, depending on his requirements, select a configuration that contains precisely the sensor functions required.The modular concept of the sensor unit facilitates implementationin the future of further sensor functions, both with regard to further measurement values and additional functionalities such as wireless signal transmission. These additions can be integrated in the sensor unit without additional space requirements. Schaeffler is already working on the expansion of Schaeffler VarioSense to include other bearing types and sizes as well as other sensor functions.

Current product informationalways online

This edition of this publication describes the status of product information at the time of publication. The publication will be continuously modified and supplemented to reflect the expanding product range.The current edition of TPI 253 is already available for download at:■ www.schaeffler.de/std/1D55.

2 TPI 253 Schaeffler Technologies

Schaeffler Technologies TPI 253 3

Page

Contents

Features Design...................................................................................... 4

Sensor functions....................................................................... 5Speed measurement ............................................................ 5Temperature measurement................................................... 5Displacement measurement ................................................. 5

Product variants ....................................................................... 6

Interfaces ................................................................................. 7Interfaces of interface unit.................................................... 7Interfaces in pure speed measurement ................................. 7Plug connections.................................................................. 8

Rolling bearings........................................................................ 9Deep groove ball bearings of Generation C............................ 9

Rating life ................................................................................. 10Interface unit and sensor unit ............................................... 10Rolling bearings ................................................................... 10

Ordering designation ................................................................ 11

Design andsafety guidelines

Design of the bearing position................................................... 12Locating bearing arrangement .............................................. 12Stationary outer ring............................................................. 12Shaft and housing ................................................................ 12

Mounting dimensions ............................................................... 13Sensor/bearing unit ............................................................. 13Connection cables and plug connections .............................. 13Interface unit........................................................................ 14

Shielding.................................................................................. 15

Pin assignment of connection on sensor unit............................. 15

Pin assignment of connection on interface unit.......................... 16

Supply of voltage to sensor unit ................................................ 17

Supply of voltage to interface unit ............................................. 17

Speed signals........................................................................... 18Pull-up resistors ................................................................... 18Sign for direction of rotation ................................................. 18Characteristics ..................................................................... 19

Mounting and operation............................................................ 19

Operating limits ........................................................................ 20Exclusion criteria.................................................................. 20Ambient conditions .............................................................. 20

Dimension table Schaeffler VarioSense,deep groove ball bearings, Generation C ................................... 22


Schaeffler VarioSense

Features A fundamental feature of Schaeffler VarioSense is its modular design, which allows a configuration of the sensors that is flexibly and ideally matched to the application, Figure 1. In order to further increase the possible applications, Schaeffler is working onthe integration of further sensor functions and the expansion ofthe available bearing types and sizes.

The following sections describe the product portfolio availableas standard. For requirements extending beyond these or where there is a need for customer-specific product configurations,please consult Schaeffler.

Design The sensors for the recording of measurement values are integrated in a sensor unit fitted on the side of the bearing, Figure 2. This is connected via a cable by means of a detachable plug connection with an interface unit. This carries out conversion and preparationof the measurement signals resulting from the measurement of temperature, displacement and speed. The interface unit also hasan LED for display of the operating mode and a flange plug for customer-side connection.If a product configuration is selected that contains speed measure-ment as the only sensor function, the interface unit is not necessary.

� Rolling bearing� Measurement ring

� Sensor cluster

Figure 1Modular sensor concept

12 3

0016

1B47

0016

1B47

� Sensor unit� Rolling bearing

� Cable� Detachable plug connection

� Interface unit� Customer-side connection

� LED for operating mode

Figure 2Design

4

7

5

1

2

3

6

000B

104A

000B

104A


Sensor functions Sensors for speed, temperature and displacement can be integrated in the sensor unit.

Speed measurement The speed sensor records the signals from a magnetic scale thatis connected to the inner ring of the bearing. As an output signal,the sensor delivers two phase-offset signals. With the aid ofthe signals, speeds of up to 15 000 min–1 as well as the directionof rotation can be determined.

Temperature measurement The temperature sensor records the temperature in the vicinity ofthe bearing outer ring. The resolution is 0,5 K.

Displacement measurement In the measurement of displacement, the radial displacement between the inner ring and outer ring is recorded.From this, information can be derived about the load on the bearing and the adjacent construction.The measurement of displacement is subject not only to the radial load but also to a series of other influences such as axial load,tilting and temperature. These influences must be taken into consideration in the interpretation of the measurement results.In order to ensure correct interpretation of the displacement measurement in relation to the bearing load, we recommend comprehensive analysis of the application and advisory work by Schaeffler.



Product variants The concept of Schaeffler VarioSense allows the versatile combi-nation of different sensors. Each combination of sensors is assigned a product configuration. The product configurations available as standard are shown below, see table. The dimensions of the sensor unit and thus of the requisite design space are identical for all product configurations. Further combinations of the available sensor functions are available by agreement.

Product configurations

1) Available as prototype.

In addition to the combination of sensors, the product selection process allows the variation of other product characteristics suchas the sealing of the bearing or the internal clearance. A product variant is clearly described by means of the ordering designation,see page 11.

Product configuration

Sensor Interface unit

Speed Temperature Displacement

001 ● – – Optional

0021) ● ● – ●

0031) ● ● ● ●

0041) – – ● ●

● Component of product configuration


Interfaces The interface unit forms the interface between the sensor unitfitted to the bearing and the customer system for processing ofthe measurement results.

Interfaces of interface unit All product variants that have at least one more sensor function in addition to speed measurement are equipped with an interface unit.The interface unit has the following interfaces, Figure 3:■ Flange socket for connection of the sensor unit.■ Flange plug for the customer-side connection.

This interface is used for the output of measurement signals and status as well as the supply of voltage.

■ USB communication interface, integrated in the flange plug for customer-side connection.This interface is used to access the interface unit via a Windows PC, for example to install firmware updates or perform settingsin the interface unit (such as weighting of the analog output). Schaeffler provides special installation software for this interface.

■ RS485 interface, integrated in the flange plug for customer-side connection.Data such as measured values and status messages can be outputted to the customer-side application or controller, via this communication interface, on request.

■ LED for display of the operating and error status.Display is carried out by means of different colour and flashing modes.

Interfaces in purespeed measurement

The product configuration 001, in which the only sensor function is speed measurement, does not have an interface unit. In this case, the cable on the sensor unit forms the external interface.

� Flange socket for connectionof sensor unit

� LED for operating mode� Flange plug

for customer-side connection,with integrated USB communication

interface and integrated RS485 interface

Figure 3End face of interface unit

1 2 3

000B

0F5D

000B

0F5D



Plug connections The coupling for connection to the 12-pin customer interface ofthe interface unit must be ordered separately, see table and Figure 4.The table also includes the plug connections for the interface unit and sensor unit that are included in the scope of delivery according to the product configuration.Orders can be placed directly with the relevant supplier usingthe following address details:

Ordering numbersof plug connections

1) Ordering numbers of plug connections used by Schaeffler. When ordering plug connections directly from the manufacturer, the customer is responsible for checking the current order numbers.

■ Franz Binder GmbH & Co. Elektrische Bauelemente KGRötelstraße 27 · 74172 Neckarsulm · Germanywww.binder-connector.de

■ Phoenix Contact Deutschland GmbHFlachsmarktstraße 8 · 32825 Blomberg · Germanywww.phoenixcontact.com

Plug connection Manufac-turer

Manufacturer ordering number1)

� Flange plug Phoenix 1441943

� Flange socket Binder 09 0428 90 08

Flange socket (alternative) Binder 09 0428 30 08

� Plug Binder 99 0425 10 08

� Coupling with cable, free connection end:

Cable length

0,5 m Phoenix 1437083

1,5 m Phoenix 1430129

3 m Phoenix 1430132

5 m Phoenix 1430145

10 m Phoenix 1430158

� Coupling without cable (alternative to �) Binder 99 1492 812 12

Figure 4Plug connection

2

3

1

45

000B

1051

000B

1051


Rolling bearings The product series Schaeffler VarioSense currently provides the fol-lowing standard rolling bearings with integrated sensor technology:■ single row deep groove ball bearings of Generation C in

the sizes 6205-C to 6210-C.For the future, the plan is to expand the product series Schaeffler VarioSense to include other rolling bearing types and sizes.

Deep groove ball bearingsof Generation C

Deep groove ball bearings of Generation C correspond in their structure to single row standard deep groove ball bearings but are specially optimised in relation to:■ significantly quieter running■ even more effective sealing■ a further reduction in the already very low frictional torque.These optimisations were achieved by means of design modifications such as new seals and cages, improvements in bearing kinematics and refined manufacturing processes.

Sealing of bearings Within the product series Schaeffler VarioSense, the bearings are available with the following seals:■ gap seals on both sides 2Z■ lip seals on both sides 2HRS.

Lubricating greases Within the product series Schaeffler VarioSense, the bearingscan be supplied with various lubricating greases in accordancewith customer request. Selection of the lubricating grease is based on the information given in the publication TPI 165.Upon customer request, other lubricating greases are also available, however these must be checked in advance in conjunction withthe sensor unit. If necessary, please contact Schaeffler.

Further information ■ TPI 165, Deep Groove Ball Bearings, Generation C■ Catalogue HR 1, Rolling Bearings.



Rating life The rating life of the interface unit, sensor unit and rolling bearing must be considered separately.

Interface unit and sensor unit The rating life of the interface unit and sensor unit is achieved if one of the following criteria is exceeded:■ 25 000 operating hours■ operating life of 10 years.The data on the rating life apply in each case for one specific temperature spectrum, see table.

Temperature spectra

Rolling bearings The basic load ratings and speeds valid for a rolling bearing remain unchanged even if the bearing is used within the product series Schaeffler VarioSense. The calculation methods established forthe design and rating life calculation can be applied unchanged.

Further information ■ Catalogue HR 1, Rolling Bearings.

Temperature Time proportion of rating life

Interface unit Sensor unit

Without displacement measurement

With displacement measurement

°C % % %

–40 6 1 1

–20 – 4 4

0 – 10 10

+23 20 25 25

+50 65 30 30

+60 8 25 25

+80 1 – –

+105 – – 5

+125 – 5 –


Ordering designation The structure of the ordering designation is shown in Figure 5.

Figure 5Ordering designation

SB

6205to6210

C

A

L

AB

1

E

2Z2HRS

001to 004

Configuration of sensorand interface unit

SB6206C-A001/LA1E-2HRS-..

Product configuration

Bearing with sensor technology

Type

Basic designation ofdeep groove ball bearing

Basic designation of bearing

Generation C

Suffix of bearing

Generation A, from April 2017

Sensor generation

Cable to left

Cable direction

Company Binder, no. 99 042510 08, 8-pin M9Free connection end, without plug

Plug

Cable length = 0,5 m

Cable length

CE Conformity

Certification

Gap seals on both sidesLip seals on both sides

Bearing sealing

Suffixes, for example for bearing cage,lubricating grease or internal clearance

Further specification of bearing

000A

6393

000A

6393



Design andsafety guidelines

Design of the bearing position The rigid connection between the sensor unit and bearing results in special requirements for the design of the bearing position.

Locating bearing arrangement Due to the cable connection at the outer ring, use as a non-locating bearing would require the sliding seat to be located betweenthe inner ring and the shaft. However, as a sliding seat is not recommended on a rotating shaft, Schaeffler precludes the useof Schaeffler VarioSense as a non-locating bearing.The bearing may only be used as a locating bearing.Use as a non-locating bearing is not permitted.

Stationary outer ring Due to the cable connection arrangement, Schaeffler VarioSenseis restricted to applications with a stationary outer ring.A means of preventing rotation of the outer ring must be provided by the customer.

Further information ■ BA 47, Schaeffler VarioSense, user manual.

Shaft and housing Due to the encoder, the shaft shoulder, Figure 6, must not exceeda maximum diameter, see table.The shaft diameter in the area of the bearing seating surface must be selected such that the maximum expansion of the bearing inner ring, see table, is not exceeded.

Shaft requirements

The bearing position should be designed such that no radial forces can act on the sensor ring and encoder. Otherwise, there is a riskof the adhesive bond shearing off.

� Preferred pressing direction� Sensor ring

� Encoder

Figure 6Design of the bearing arrangement

1

2

3

d

000B

5949

000B

5949

Bearing Maximum diameter dof shaft shoulder

Maximum expansionof bearing inner ring

mm �m

6205-C 31,4 20

6206-C 36,5 20

Other bearings Please contact Schaeffler Please contact Schaeffler


Mounting dimensions This section contains the mounting dimensions and other dimensions of components of Schaeffler VarioSense.

Sensor/bearing unit The width of the sensor unit is identical for all sensor units that are combined with deep groove ball bearings of series 62.Including the bonding gap between bearing and sensor unit,this value is 7,2 mm.Further dimensions are shown in the dimension table,see page 22.The dimensions of the deep groove ball bearings used in the sensor unit correspond to the standard dimensions of these bearings.

Further information ■ TPI 165, Deep Groove Ball Bearings, Generation C■ Catalogue HR 1, Rolling Bearings.

Connection cables andplug connections

The specification of the connection cable between the sensor uniton the bearing and the interface unit is independent of the product configuration, see table and Figure 7.

Dimensions

In the case of product configuration 001 (pure speed measurement), the connection cable is supplied without a plug.In the case of product configuration 002, 003 and 004, delivery with a plug is only possible, since the plug is necessary for connection to the interface unit.

The connection cable is not suitable for drag chain use. As a result, the connection cable must be laid statically.To avoid cable movements as a result of vibrations, we recommend attaching fixings to the cable at 5 cm intervals.

Designation Product configuration

001 002, 003, 004

Cable length Y m 0,5

Cable diameter dK mm 3,8 � 0,2

Minimum bending radius of cable mm 35

Plug diameter DS mm 14

Delivery Without plug – Standard –

With plug – – Standard

Figure 7Dimensions

DS

dK

Y00

0B19

6400

0B19

64



Interface unit The dimensions of the interface unit, Figure 8, are identical forall product configurations and all bearing sizes.

Figure 8Interface unit

34,5�0,5

2�16�0,517�0,517�0,5

3�0,25

65,2�0,25

2�41�0,125

2�49�0,125

(4�4)

130,2�0,25

2�117,6�0,3

100�0,25

4�4,6�0,25

000B

0F6E

000B

0F6E


Shielding In order to ensure electromagnetic compatibility, the cable ofthe sensor unit is shielded. If you require further information on shielding, please consult Schaeffler.

Pin assignment of connectionon sensor unit

In the case of product configuration 001 (pure speed measurement), the cable for the sensor unit is delivered as standard with four stripped and tinned cable ends, see table.The customer can also fit the cable for the sensor unit with an 8-pin plug, see table and Figure 9.

Connection of the sensor unitfor product configuration 001

Signal direction Signal Cable colour Pin

Input Supply of voltage to sensor unit Red 2

Ground Black 5

Output Pulse trace A (speed; Open Collector) White 6

Pulse trace B (speed; Open Collector) Blue 1

Figure 9Pin numbering of plug

on sensor unit

7

6

5

4

3

2

1

8

000A

2D60

000A

2D60



Pin assignment of connectionon interface unit

In addition to various signals, the 12-pin flange plug also transmits the supply of voltage, see table and Figure 10.

Pin assignment of flange plug

The signal assignment of the current outputs in the flange plug depends on the product configuration, see table. Other assignments are possible by agreement.The signal assignment of product configuration 003 is set at the factory. The customer can change this setting via the USB interface. Schaeffler provides special installation software for parameter assignment.

Signal assignmentof current outputs

(factory setting)

1) In the case of product configuration 001,the interface unit is not necessary but can be ordered as an option.

2) Product configuration can be ordered in the future.

Signal direction Signal Pin

Input Supply voltage 5

Ground 8

USB supply voltage 10

Output Pulse trace A (speed; Open Collector) 1

Pulse trace B (speed; Open Collector) 3

Current output 1, 4 mA – 20 mA,signal assignment,see table Signal assignment of current outputs (factory setting)

2

Current output 2, 4 mA – 20 mA,signal assignment,see table Signal assignment of current outputs (factory setting)

9

Digital error output 7

Input/output(bidirectional)

USB-D– 11

USB-D+ 12

RS485– (half-duplex) 4

RS485+ (half-duplex) 6

Figure 10Pin numbering of flange plug

1

10

11 12

2

3

4

56

7

8

9

000A

2D5E

000A

2D5E

Productconfiguration

Signal

Current output 1 Current output 2

0011) Speed –

0022) Temperature Speed

0032) Temperature Displacement

0042) Displacement –


Supply of voltageto sensor unit

The supply of voltage to the sensor unit is usually carried outvia the interface unit. With product configuration 001 (pure speed measurement), an interface unit is not required. In this case,the customer must observe the following information for connecting the sensor unit, see table.

Supply of voltagefor product configuration 001

(without interface unit)

If supply voltages are above the stated range, the sensor unit will be electrically destroyed.

Supply of voltageto interface unit

The supply of voltage to the interface unit, see table, is carried outvia the 12-pin flange plug.

Supply of voltage andovercurrent protection

for interface unit

If supply voltages are above the stated range, the interface unit will be electrically destroyed.

Designation Value

Supply voltage Nominal DC 24 V

Tolerance range DC 4,5 V – DC 30 V

Designation Value

Supply voltage Nominal DC 24 V

Tolerance range DC 14 V – DC 28 V

Overcurrent protection necessary on customer side

Current 0,8 A

Tripping characteristics 0,1 A2s – 0,15 A2s



Speed signals The information on speed signals applies irrespective of whetherthe connection is made with or without an interface unit.

Pull-up resistors The outputs for speed signals A and B are designed as Open Collector outputs. Suitable pull-up resistors must be provided onthe customer side, Figure 11.

We recommend standard values for the pull-up resistors asa function of the pull-up voltage, see table.

Recommended pull-up resistors

The maximum permissible through current is 110 mA.This limit value is observed as a result of the pull-up resistors.

Sign for direction of rotation In the case of speed measurement, the sign for direction of rotation is positive in an anti-clockwise direction when viewing the open cable outlet, see Figure 12.

� Sensor unit without interface unit(product configuration 001)

� Sensor unit with interface unit� Pull-up resistors

Figure 11Connection of the pull-up resistors

123

4

56 7

8

910

11 12

5

1

3

8

1 2

3Colour coding Pin assignment

red

white

blue

black

supply voltage

pulse trace A

pulse trace B

ground 0016

6579

0016

6579

Pull-up voltage, DC Pull-up resistor

V �

5 270

12 680

24 1 500

� Positive direction of rotation

Figure 12Sign for direction of rotation

1

000A

CBD

A00

0ACB

DA


Characteristics Characteristics of speed signals A and B, see table.

Characteristicsof the speed signals

The number of pulses per revolution is dependent on the bearing size, see table.

Pulses per revolution

Mounting and operation Comprehensive information relating to mounting, commissioning and operation can be found in the user manual.

Further information ■ BA 47, Schaeffler VarioSense, user manual.

Designation Value

Pulse duty factor 50% � 10%

Phase displacement 90° � 20°

Current consumption

nominal 10 mA

maximum 11 mA

Pitch Error (individual measurement period for revolution sum) –3% to +3%

Rise time 1,5 �s

Fall time 1,5 �s

Bearing Number of pulses per revolution

6205-C 56

6206-C 64

6207-C 72

6208-C 80

6209-C 88

6210-C 96



Operating limits Schaeffler VarioSense is intended exclusively for applications inthe machine and equipment building sector where no particular protection requirements apply.The exclusion criteria and ambient conditions stated below must be observed.

Exclusion criteria The following areas of application are excluded:■ explosive environments (ATEX)■ nuclear power■ aerospace■ rail■ military■ medical equipment.In addition to the areas of application that are explicitly excluded, Schaeffler VarioSense is also excluded from all other applicationsin which the use of the measurement values has an influenceon the safety of the machine or equipment itself, of the adjacent systems or of persons.

Ambient conditions Excluded ambient conditions:■ Magnetically or electrically conductive dusts or particles.Protection type in accordance with ISO 20653:■ The sensor and interface unit are designed in accordance with

the protection type IP67.Air pressure:■ The permissible ambient pressure for the sensor and interface

unit is in the range from 700 hPa to 1050 hPa.Temperature:■ The maximum storage and operating temperatures are depen-

dent on the sensors used and therefore differ in accordance with the product configuration, see table, page 21.


Temperature limits of sensor andinterface unit

In addition to the temperature limits of the sensor and interface unit, the permissible operating temperature of the bearing must always also be taken into consideration.

Further information ■ TPI 165, Deep Groove Ball Bearings, Generation C.

Component Temperature

Storage Operation

min. max. min. max.

°C °C °C °C

Sensor unit ofproduct configuration

001 +5 +40 –40 +125

002 +5 +40 –40 +125

003 +5 +40 –40 +105

004 +5 +40 –40 +105

Interface unit +5 +40 –40 +80


Schaeffler VarioSenseDeep groove ball bearings, Generation C

Seal 2HRS Seal 2Z

B

dD

000A

2D65

000A

2D65

B

dD

000A

318A

000A

318A

For further dimensions and characteristics of the bearings,see TPI 165, Deep Groove Ball Bearings, Generation C.

Dimension table · Dimensions in mm

Designation Dimensions

Sensor/bearing unit Bearing d D B

SB6205C 6205-C 25 52 22,2

SB6206C 6206-C 30 62 23,2

SB6207C 6207-C 35 72 24,2

SB6208C 6208-C 40 80 25,2

SB6209C 6209-C 45 85 26,2

SB6210C 6210-C 50 90 27,2

Schaeffler TechnologiesAG & Co. KG

Georg-Schäfer-Straße 3097421 SchweinfurtGermanyInternet www.schaeffler.de/enE-mail [email protected]

In Germany:Phone 0180 5003872Fax 0180 5003873

From other countries:Phone +49 9721 91-0Fax +49 9721 91-3435

Every care has been taken to ensure the

correctness of the information contained

in this publication but no liability can

be accepted for any errors or omissions.

We reserve the right to make technical

changes.

© Schaeffler Technologies AG & Co. KG

Issued: 2019, September

This publication or parts thereof may not

be reproduced without our permission.

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Documents

Modular sensor bearings - Schaeffler...Rolling bearings The basic load ratings and speeds valid for a rolling bearing remain unchanged even if the bearing is used within the product