ROS_ MG English (2)

7/28/2019 ROS_ MG English (2)

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MADE IN I TALY

Nextgeneration

Evolution is done

MG Monoguide

recirculating linear rollers bearing


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Grinding machine mod. PLATINUM TH made from Rosa Ermando SpA

for MG monoguide slide ways finishing


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INDEX

1.

PRODUCTDESCRIPTIONANDFEATURESOFMGMONOGUIDES 1. Productidentificationcodes

2. GENERALTECHNICALDATA 1. Accuracyclassesandtolerances 2. Slidingaccuracy 3. Preloadclasses

4. Allowedaccelerationandspeed

5. Operatingtemperatures 6. Constructionmaterials 7. HCPanticorrosioncoating 8. Sizetables

9. Staticanddynamicloadcapacity.Allowablemoments 10. ToplubricationSizetable 11. Guidesthatcanbescrewedfromthebottom 12. Life 13. Stiffnessdiagram

3. DESIGNOFTHERECIRCULATINGLINEARROLLERBEARING MONOGUIDE 1. Calculationbase-Definitionof dynamicandstaticloads andallowablemoments

2. Calculationprogrammetodesignthemonoguide

4. ACCESSORIES5. LUBRICATION 1. Greasing 2. Oiling 3. Lubricationaccessories

6. INSTALLATIONANDASSEMBLY 1. Fasteninginstructions 2. Accuracyof assemblysurfaces 3. Assemblytypes

p.8

p.10p.10p.10p.11

p.11p.11p.11p.12p.14

p.15p.15p.16p.18

p.28

p.32

p.35

p.41p.43

p.43p.46

p.48

p.50p.51


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MG45LCMonoguideonCNClathe(TecnoVphotos-kindpermit)


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1.MGMONOGUIDE

PRODUCTDESCRIPTION

ANDFEATURES

1. Productidentificationcodes


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1.

ThenewMGmonoguidemanufacturedbyRosaSistemiisanadvancedtechnicalsolutionforhigh-techindustries.Themonoguideissuitableforhighloads,greatstiffnessandhighreliability,especiallyformachinetools.

STREAMLINEDROLLERSLIDEWAYSThegeometriesandthedirectionsoftherollerslidewayswerecalculatedbymeansofFEMaccordingtoeachindividualpreload,thusassuringthebestperformancesofloadcapacitiesandobtainableaccuraciesallthetime.

ROLLERSWITHLOGARITHMICPROFILETherollersaremanufacturedaccordingtothemostrecentknowledgeaboutrollingelement-relatedtheory,thusassuringhighstiffness,maximumloadcapacityandlonglife.

INNOVATORYLUBRICATIONSYSTEMTheintroductionofthelubricantintothefrontheadiscontrolledbymeansof checkvalves.Thesevalvesareinstalledonbothsidesofthecarriageslidewaysandpreventthelubricantfromflowingbackwhilesliding.Withminimumquantitiesoflubricant,independentlyfromtheassemblyposition,theperfectdistributionovertheslidewayswillbeassured.

LUBRICATIONVERSATILITYEachfrontheadofthecarriagehas4lubricationinputs:twosideinputs,onefrontinputandoneontheotherside.SLIDINGUNIFORMITYThankstostreamlinedradiusesforinternalrecirculatingsystems,pulsationphenomenaarereducedtotheminimum,thusofferingalowresistancetotheforwardmovement.

INNOVATORYDESIGNTheaccuratestudyofallplasticelementsinthecarriageenabledreducedtheinterferencesintheinternalrecirculatingsystems,thusincreasingrelevantreliabilityandlife.

PROTECTIONOFTHECARRIAGETheslideways arewell protectedby meansof cross-wise and longitudinalgasketsthatassuregoodsealing(alsoincontaminatedenvironments).


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INTERCHANGEABILITYThenarrowconstructiontolerancesassuretheinterchangeabilityofthecarriages.Bothsidesoftheguidecanbeusedasareference.

ADDITIONALPROTECTIONSUpondemand,itispossibletosupplyadditionalwipersandscrapers.

LONG-LIFELUBRICATIONAspecificadditionalheadallows long lubricationduration, thuspreventingadditionalcostsforthepurchaseofalubricationstation.

ANTICORROSIONCOATINGThecarriagesandtheguidescanbesuppliedwithaHCPanticorrosion

coating.

METALPROTECTIVESTRIPThestripthatprotectsandcoversthefasteningholespreventsclosingcapsfrombeingused,thusconsiderablyreducingtheoverallassemblytimesandmakingthewipingoperationmoreeffective.


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1.1 Productidentificationcodes

MG 35 SC 2 Q1 P2 IIL598Producttype

Carriagesytpe

SC:narrow-shortSL:narrow-long

LC:wide-shortLL:wide-long

Numberofcarriagesontherail

Railsize(25,35,45,55)

Railson

sameplane

Accuracyclass(Q0,Q1,Q2,Q3)

Raillenght(mm)

Preload(P2,P3)

Order sheet

Customer: Order n:

MG monoguide

Size q25q35q45q55

Carriage type qLCqLLqSCqSL

Number of carriages on the rail qxqx.

Set for top lubrication qDAL

Rail lenght .mm

L5 (distance of first hole) .mm

Metal protective strip q(NP)

Number of rails grinded in line q1q2q3

Rail screwed from the botton qFBAccuracy class qQ0qQ1qQ2qQ3

Preload class qP2qP3

Caps typeqTPMG(Plastic)qTOMG(Brass)qTAMG(Steel)

Caps number ..pcs/rail

Additional end seals/wipers

qTPA

qTPNBR

qTPVIT

Long-life cartridge lubrication qTLL

Lubricant typeqGreaseqOil

Complete code:

Lato rif. ALTO

Lato rif. BASSO DAL sx

DAL dx

TTL dx

TTL sx

DAL sx

DAL dx

TTL dx

TTL sxRef. side HIGH

Ref. side LOW

TLL sx DAL dx

DAL sx

TLL sx

TLL dx

DAL dx

DAL sx TLL dx


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GENERALTECHNICALDATA

1. Accuracyclassesandtolerances 2. Slidingaccuracy

3. Preloadclasses 4. Allowedaccelerationandspeed

5. Operatingtemperatures

6. Constructionmaterials 7. HCPanticorrosioncoating

8. Sizetables 9. Staticanddynamicloadcapacity.Allowablemoments 10. ToplubricationSizetable

11. Guidesthatcanbescrewedfromthebottom 12. Life

13. Stiffnessdiagram

2.


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2.

TheMGmonoguidesareavailablein4accuracyclasses:Q0,Q1,Q2,andQ3

Thetolerancesinassemblydimensionsaremeasuredfromthecentreofthecarriageandinthesamepositionoftheguide

Theslidingaccuracyofthecarriageovertheguideismeasuredfromthecentreofthecarriage

2.1 Accuracyclassesandtolerances

Dimensiontolerances Accuracyclass

Q0 Q1 Q2 Q3Tolerance on H assembly di-mension (variation comparedwiththenominaldimension)

5m

10m

20m

30m

ToleranceonA1assemblydi-

mension(variationcomparedwiththenominaldimension)

5m

7m

20m

20m

DimensiondifferenceHbetweenthecarriagesofthesameguide

3m 5m 7m 15m

DimensiondifferenceA1betweenthecarriagesofthesameguide

3m 5m 7m 15m

ParallelismerrorCdimensionsfromA-B

Seebelowgraphic

2.2 Slidingaccuracy

Parallelismerrorincarriagesliding30

25

20

15

10

5

0

0 500 1000 1500 2000 2500 3000 3500 4000

Q3

Q2

Q1

Q0

Parallelisme

rrorinmicrons

Guidelengthinmm

2.3 Preloadclasses

Thepreloadincreasesthestiffnessoftheguide,butinfluencesthelifeand

theresistancetothemovement.Thetwopreloadclassesthataresuggestedcanmeetthedifferentapplicationneeds.


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Speed Vmax

=3m/s

Acceleration amax

=50m/s2

Allowableoperatingtemperatures from-10Cto+80C

Higheraccelerationsandspeedsarepossibleaccordingtopreload,load,lubricationandassemblypositionvalues.Inthesecases,itisadvisabletocontactourengineeringdepartment.

2.4 Allowedaccelerationandspeed

Preloadclass Preload Accuracyclass

P2 0.08C Q0|Q1|Q2|Q3

P3 0.13C Q0|Q1|Q2|Q3

P2 forhighstiffnesswithaverage-highloadsandvariablevibrationsP3 formaximumstiffnesswithhighimpactstressesorvibrationsandhigh loads/moments

2.5 Operatingtemperatures

2.6 Constructionmaterials

Carriage: HardenedalloysteelGuide: HardenedsteelRollers: HardenedbearingsteelPlasticpar ts: POM-PEIGF30-TPE

Incaseofparticularapplications,athinhardened-chromiumanticorrosiontreatmentisavailable.

HCPtechnicalfeatures:

Thickness:2-4m Surfacewithdullsilverfinish Untreatedrollingelementsandthreads

Maximumlengthoftheguidetobetreated:2m.Incaseoflengths longerthan2m,useseveralin-lineguides AvailableforaccuracyclassesQ1,Q2andQ3

2.7 HCPanticorrosioncoating


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LC/LL-carriagestype

Dimensions(accordingtotheDIN645/1standards)

2.8 Sizetables

Size H A A1 A2 H1 B L L1 L2 L3 L4 L5 N S S1 G G1 F1 F2 F3 M Q K

25LC36 70 23.5 23 24.5 29.5

90.2 6245 4 0 30 14 57 11 M8 9 6.5 7 11 11.5 7.5 5.5

14

25LL 109.7 81.5 23.7

35LC48 100 33 34 32 41

119.3 8062 52 40 19 82 15 M10 12 10 9 15 17 8 7.9

15.5

35LL 142.3 103 27

45LC60 120 37.5 45 40 50

147.3 101.380 60 52.5 25 100 18 M12 15 12 14 20 19 10 8

17.6

45LL 179.8 133.8 33.9

55LC

70 140 43.5 53 48 57

173 120

95 70 60 29 116 20 M14 18 13.5 16 24 22 12 9

21.5

55LL 215 162 42

LC LL


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Size H A A1 A2 H1 B L L1 L2 L4 L5 N S1 G F1 F2 F3 M Q K

25SC40 48 12.5 23 24.5 33.5

90.2 62 3530 14 35 M6 9 7 11 11.5 7.5 9.5

19

25SL 109.7 81.5 50 21.2

35SC55 70 18 34 32 48

119.3 80 5040 19 50 M8 12 9 15 17 8 14.9

21.5

35SL 142.3 103 72 22

45SC70 86 20.5 45 40 60

147.3 101.3 6052.5 25 60 M10 18 14 20 19 10 18

27.6

45SL 179.8 133.8 80 33.9

55SC

80 100 23.5 53 48 67

173 120 75

60 29 75 M12 19 16 24 22 12 19

31.5

55SL 215 162 95 42

SC/SL-carriagestype

Dimensions(accordingtotheDIN645/1standards)

SC SL


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LC/LL

Size C(N) C0(N) Mt(Nm) Mt0(Nm) ML(Nm) ML0(Nm)

25LC/SC 28700 57600 431 863 285 570

25LL/SL 38900 76800 583 1150 491 970

35LC/SC 53300 99000 1179 2192 674 1253

35LL/SL 72600 136000 1595 3014 1187 2243

45LC/SC 95000 184000 2617 5070 1538 2979

45LL/SL 119500 242200 3293 6672 2444 4951

55LC/SC 132600 256000 4503 8707 2576 4981

55LL/SL 176000 351000 5977 11915 4470 8910

SC/SL

2.9 Staticanddynamicloadcapacity.Allowablemoments

DynamicloadC(100km)


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All carriage typesare prepared for top lubrication.SC and SL modelsare

providedwithaspacerequippedwithO-ringtocompensateforthedifferenceinheight.Toplubricationmustbespecifiedintheorder.Pleaseseetheinstructionsonpage8.

Itisnotpossibletodrilltheheadsaftertheassembly,asthechipscreatedduringthisoperationmayclogthelubricationchannels.

25 35 45 55

K

LC 14 15.5 17.6 21.5

LL 23.7 27 33.9 42.5

SC 19 21.5 27.6 31.5

SL 21.2 22 33.9 42.5

D 10 10 10 10

D1 3 4.5 4.5 4.5

Theyareavailableforallaccuracyclasses

Size 25 35 45 55

Z 12 15 19 22

E M6 M8 M12 M14

AsforL4andL5dimensions,seetablesonpage12-13

2.10Toplubrication-sizetable

2.11Guidesthatcanbescrewedfromthebottom


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2.12Life

Testbench

Resultsofthetests

Rosa Sistemientrusted the machine tooldivisionof the laboratory (WZL)

withintheInstituteofTechnologyofAquisgranawiththetaskofperformingthe lifetests for the newMGmonoguide. During the endurancetests,thestiffnessofthecarriagewasmeasured,aswell.

Thetestprovidesforthesimultaneouscheckof4guides,eachofwhichisequippedwithacarriage.

Technicaldata

Testconditionsforthelinearrollerbearing

accordingtothestandardsDIN631

LoadcoefficientMG35 C/P=3

LoadcoefficientMG25/45/55 C/P=2

EndurancewithC/P=3 3893km

EndurancewithC/P=2 1050Km

Testspeed 120m/min

Maximumstroke 2000mm

Acceleration 10m/s

Lubricant OilVG-ISO220

AccordingtotheDIN631standards,enduranceisconsideredastobeachievedifthesurfacesoftheslidewayshavenoPitting>0.3xrollerdiameter.

AlltestsconcerningtheMG35modelwereinterruptedafterastrokeequalling4260and4870km.Despitethelongdistanceinkilometresthatwascovered,wedetectedtheabsenceofdamagetotheslideways.

Thestiffnessvaluesareveryimportantparametersfortheaccuracyofamachinetoolandforcalculatingthelifeoftheguidesystembeingused.RosaSistemiwasconvincedthatthecorrectmeasurementofthestiffnessintherecirculatinglinearrollerbearingmonoguidewasacrucialrequirementtobecertified.


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Theforceismeasuredbymeansofapiezoelectricsensorthatisinstalledbetweenthehydrauliccylinderandtheassemblyplatewherethecarriageisfastened.

Tocorrectlymeasure thedeformation,an incrementalopticalr uler wasusedtogetherwithfourjumperedstrainmeterswitha0.1resolution.Tohaveareliabledeformationforcecurve,eightmeasurementcyclesareperformedforeachtypeofcarriage,andthentheaveragevalueswillbecalculated.

Measurementresults

Themeasurementof thestiffnessincompressionandtractionconditionsaccordingtotheabove-mentionedmodesallowedestablishingthedeforma-tion-forcecurvesforalltypesofcarriage.ThediagrambelowshowsthecurveforMG35LCP3.

Guide

Piezoelectricsensor

Assemblyplate

Strainmeter

Settingofthetesttomeasurethestiffness

Stiffness MG35

Force [N]

Deformation[m]


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2.13Stiffnessdiagram

StiffnessMG25LC

StiffnessMG25LL

Deforma

tion

(m)

Traction stress Load F (kN)

Compression stress

Deformation(m)


Compression stress


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StiffnessMG25SC

StiffnessMG25SL

Deform

ation

(m)


Compression stress

Deformation

(m

)


Compression stress


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StiffnessMG35LC

StiffnessMG35LL

Deform

ation

(m)


Compression stress

Deformation

(m)


Compression stress


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StiffnessMG35SC

StiffnessMG35SL

Deformation

(m

)


Compression stress

Deforma

tion

(m)


Compression stress


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StiffnessMG45LC

StiffnessMG45LL

Defor

mation

(m)


Compression stress

Deformation(

m)


Compression stress


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StiffnessMG45SC

StiffnessMG45SL

Deformation(m)


Compression stress

Defor

mation

(m)


Compression stress


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StiffnessMG55LC

StiffnessMG55LL

Deform

ation

(m)


Compression stress

Deformation

(m)


Compression stress


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StiffnessMG55SC

StiffnessMG55SL

Deformation

(m)


Compression stress

Deformation

(m)


Compression stress


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DESIGNOF

MGMONOGUIDE

1. Calculationbase-Definitionofdynamicandstaticloads andallowablemoments 2. Calculationprogrammetodesignthemonoguide

3.


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3.

3.1 Calculationbase-Definitionofdynamicandstaticloads

andallowablemoments

Therearemainlytwomethodstocorrectlydesignthemonoguide.Thefirstmethod isthemanual calculationbyusingthe formulas thatarelistedbelow.Thesecondmethodusesacomputerizedcalculationprogramme

thatwillneedtheconsultancyof RosaSistemis engineers(seepage 32)afterhavingdetectedallnecessarydata.

DynamicloadvalueC

DefinitionaccordingtotheDINISO14728-1standard

Radial load, invariable in size and direction, which cantheoreticallybeabsorbedbyalinearrollerbearingforan

expectedlifeof100kmofcovereddistance.

StaticloadvalueCo

DefinitionaccordingtotheDINISO14728-2standard

Staticloadinloaddirection,whichcorrespondstoastress

of4000Mpa,calculatedinthecentreof thecontactpoint

thatismoresubjecttotheloadbetweentherollingelement

andtheslidingway.

Torsionalmoment

ofdynamicloadMt

Comparisondynamicmomentaroundthelongitudinal

axisXthatcausesaloadequallingthedynamicload

valueC.

Momentofdynamiclon-

gitudinalloadML

ComparisondynamicmomentaroundthecrossaxisY

ortheverticalaxisZthatcausesaloadequallingthe

dynamicloadvalueC.

Torsional moment of

staticloadMto

Comparisonstaticmomentaroundthelongitudinalaxis

XthatcausesaloadequallingthestaticloadvalueCo.

Longitudinalmoment

ofstaticloadML0

ComparisonstaticmomentaroundthecrossaxisYor

theverticalaxisZthatcausesaloadequallingthestaticloadvalueCo.


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To correctly design the recirculating linear roller bearing monoguide, thefollowinginstructionsmustbefollowed.

HowtoestablishexternalforcesandmomentsTheneedsforaccuracy,qualityof surfacefinishingandofproductioncycletimesinfluencethedesignofthemonoguide.Inmodernmechanicalindustries,themaximumallowedelasticdeformationisstrictlyconnectedtothesizeoftheselectedguide.Tocalculatethelifeandthedeformations,youmustdetectallexternalforcesandthemomentsthatinfluencethesystemaccordingtotherelevantvalue,directionandapplicationpoint.

Whenestablishingthetotalequivalentstress,youmusttakeintoconsiderationmaximumloadsandinstantimpactstresses,too.

DistributionofforcesandmomentsovertheindividualcarriagesIn preload conditions (almost constant stiffness), the force componentsthatinfluencethecarriages(traction,compressionandsideforces)canbecalculatedbyusingwell-knownmechanicsformulas,bytakingintoconsiderationthecrosswiseandlongitudinaldistanceofthecarriages.

EquivalentbearingstressTocalculatethelife,everypartialstressgeneratedbyaloadwillbesummarisedintheso-calledequivalentbearingstressF

r

.

Anexternalload,whichrestsonthecarriagewithanyinclination,willbesplitupintothecomponentsF

yandF

zwiththefollowingformula:

F

r Equivalentbearingstress(N)

Fy ValueoftheexternalforceoverthecarriageintotheYdirection(N)

Fz

ValueoftheexternalforceoverthecarriageintotheZdirection(N)

HowtoestablishpreloadsanddisplacementsToincreasethestiffnessandtheaccuracyofaguidesystem,itisadvisabletousepreloadedcarriages.Theselectioncriteriaarelistedonpage11.Theforcesthatinfluencethecarriagescausethedeformationsthatcanbequantifiedbythestiffnessdiagramsonpage18.

Howtocalculatethelife

The forces that act over the monoguide, the selected preload value, thedynamicloadCandthelifeprobabilityarethefactorsthatinfluencetherelevantlife.


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ActualloadoftheequivalentbearingPToestablishtheactualloadoftheequivalentbearingP,youmustconsiderthecarriagepreload,too.

Fr Equivalentbearingstress(N)

Fpr

Preloadforce(Fpr=CP%)(N)P Equivalentactualload(N)

Iftheloadappliedoverthecarriageishigherthanthepre-loadforceby2.9times,thecarriagewillhavenopreload.Inthiscase,thepreloadforcewillnotinfluencetherelevantlife.

WithFr2.9F

pr

P=Fr

Iftheappliedloadislowerthan2.9timescomparedwiththepreloadforce,partofthelatterwilljointheactualloadoftheequivalentbearingP.Incaseoflimitedloads,itisnecessarytokeeppartofthepre-load,thusassuringtherollingoftherollersandpreventingslippingphenomena.

WithFr


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Expectedlifeinmetres

LExpectedlife(m)CDynamicloadvalue(N)PEquivalentactualload(N)a

1Lifeexpectancy

Ifthelengthofthestrokesandthefrequencyofthestrokesnareconstantfortheentirelife,thefollowingformulacanbeusedtoestablishthelifeinworkinghours.

LhExpectedlife(h)

LExpectedlife(m)sLengthofthestroke(m)nFrequencyofthestrokes(min-)v

mAveragedisplacementspeed(m/min)

CalculationofthestaticsafetycoefficientTheequivalentstaticloadP

0shouldkeepwellbelowthevalueoftheallowed

staticloadC0.

ThecoefficientSisdefinedastheratiobetweenthenominalstaticloadC0

andtheequivalentstaticloadP0,andquantifiesthesafetyagainstpermanent

deformationsoftherollingelementsandtheslideways.Basically,asforthedeformationoftherollingsurfaces,itisthemaximumvalueofthestress,whichcanalsobeveryshort.

Expectedlife

Conditionsof use So

Maximumstiffness,greatimpactstressesandvibrations 6

Highstiffness,variableandaverageimpactstresses,vibrations 4

Uniformstresses,lightvibrations 3


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S0 StaticsafetycoefficientC

0 Staticloadvalue(N)

P0 Equivalentstaticloadvalue(N)

FyFz Externalstaticforces(N)M DynamicloadmomentinthedirectionsX,Y,Z(Nm)M

t0M

L0 Allowablecrossorlongitudinalstaticmomentinonecarriage(Nm)

3.2 Calculationprogrammetodesignthemonoguide

Thecalculationmodetodesignthemonoguidethatisdescribedinparagraph3.1isextremelycomplexandcanbeusedonlyforsimpleapplications.Forthisreason,RosaSistemioffersacomputerizedcalculationservicetoitsownCustomerstosimplifythemanualcalculationoftheformulas.

Resultsthatcanbeobtainedwiththecalculationprogramme Necessarysize/dimension Optimalpreload Elasticdisplacementoftheworkpointbyeffectoftheappliedloads Expectedlife Staticloadsafetyfactor

The elastic displacement calculation takes into consideration the actualnon-linearstiffnessesoftheindividualcarriages.Theelasticdisplacementsduetothermalexpansionsandelasticdeformationsofmachinestructurearenottakenintoconsideration.

Necessarydataforthecalculationprogramme Dimensionsofallmachineaxesanditemstobeprocessed Positionofbarycentres Geometryoftheguideswithindicationofthenumberofguidesandcarriages, longitudinalandcrosswisecentredistancesofthecarriages Positionoftheaxesinthespaceandofthedistancesonetotheother (distancesofthereferencepointsoftheadjacentaxes) Positionoftransmissionelementscomparedwiththecorresponding referencepointoftheaxis Positionoftheloads(momentsandforcesapplicationpoints) Strokesofallaxes Speedandaccelerationsoftheaxes

Withdifferentloads:overallloadswithspeed,acceleration,strokeand percentagetimevalue,sizeanddirectionoftheforcesandthemomentsthat influencetheworkpointaccordingtoeachindividualappliedload.


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DatasheetforanX-Ysystem

Dimensionsm

1N m

2N m

3N

Barycentresx

m1mm y

m1mm z

m1 mm

xm2

mm ym2

mm zm2 mm

xm3

mm ym3

mm zm3 mm

Geometryofguides/carriagesl1

mm l2

mm

b1 mm b2 mm

Positionoftheguidesx

B1 mm y

B2mm z

B3mm

Positionofthetransmissiony

A1mm z

A1mm

xA2

mm zA2

mm

Forceapplicationpointx

F1mm y

F1mm z

F1mm

Strokes

xmm s

ymm

Accelerationa

xm/s2 a

ym/s2

Applicationofforcesandactingmoments

Nr Cicles Fx(N) Fy(N) Fz(N) Mx(Nm) My(Nm) Mz(Nm)1234

Workingcycle(stroke/time)

Nr SpeedofaxisXv(m/min)Timet(%)

Strokes(mm)

SpeedofaxisYv(m/min)

Timet(%)

Strokes(mm)

1234

Asanexampleofthenecessarydataforacorrectdesign,seethetablesandthedrawingsbelow.


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35/5635

ACCESSORIES4.


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Monoguideaccessories

PlasticcapsTPMG

Theyareusedtocoverthefasteningholesof theguideandareincludedinthestandardsupply.Thecapsshouldnottobeusedincaseofmetalchips,especiallyif theyarehot;indeed,itisadvisabletousethecapswithprotectedaxesorinenvironmentsthatarenotverydirty.

BrasscapsTOMGTheyareusedincaseofthermalandmechanicalstresses,metalchipsor

ratherif anabsolutelysmoothguidesurfaceisrequired.Theyaresuppliedondemandintheorder.

SteelcapsTAMGTheyareusedincaseof highthermalormechanicalstressesorinworkingenvironmentscharacterisedbychipremoval.Thecoveringcapincludesacapandapressurecollarsuppliedapart.Beforeinstallingthecapsintotheguideholes,bothpartsmustbeembedded.Inordertocorrectlyfixthem,itisadvisabletousethespecificassemblytoolDMT.Theyaresuppliedondemandintheorder.

4.


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AssemblytoolforsteelcapsDMTTheassemblytoolDMTisusedtocorrectlyassemblethesteelcapsthatareintroducedintotherelevantholesbymanuallypressingthelever.

Itissuppliedondemandintheorder.

StriptoprotectandcoverthefasteningholesoftheguideTheuseofthecoveringstripconsiderablysimplifiestheperformanceoftheoperationsduringthefasteningofthemonoguide.

Afterhavingassembledandaligneditonthebedplateof themachine,theprotectionstripwillbeintroducedintothegrooveof theguide,andthenfastenedwithtwoheadsattheends.

Advantages:

Corrosion-resistantmaterial(stainlesssteel) Particularlytoughconfigurationthankstotheincreasedthickness Anchoringtoaspecialprecisiongrooveandfasteningtotheends withtwoclosingheads Preventsclosingcapsfrombeingused,thusconsiderablyreducing thegeneralassemblytimesandmakesthewipingactionmoreeffective

EndsealTPAThestainlesssteelwiperprotectsthescraperringsthatarebuilt-ininthefrontheadsofthecarriageandforpossibleadditionalendsealsTPNBR/TPVIT.Inparticular,itiseffectiveinthepresenceofhotchipsandcoarsedirtparticlesthankstotheminimumclearancebetweenthewiperandtheguide.

Dimensionsaccordingtothetablebelow.

Size S K

25 1 2.6

35 1 3.3

45 1.5 4

55 2 4.8


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AdditionalendsealTPNBR/TPVITTheendsealsTPNBRandTPVITofferaneffectiveadditionalprotectiontothemonoguides that work in very dirty environments. They can be directlyassembledonthecarriageswithouttheneedtodisassemblethelatter.

FeaturesoftheNBRversion Excellentstabilityinthepresenceofoil Excellentmechanicalfeatures Workingtemperaturefrom-30Cto+110C

FeaturesoftheVITONversion Excellentstabilityinthepresenceofaggressivecoolantsandoils Excellentmechanicalfeatures Workingtemperaturefrom-30Cto+200C

TheTPNBR/TPVITendsealscanbeusedtogetherwiththemetalTPAendseal.

Size S2 K

25 6 2.6

35 6 3.3

45 6 4

55 7 4.8

Long-lifelubricationcartridgeTLLThecartridgeTLLallowsacapillarylubricationof theslidewaysbyusingminimumquantitiesof lubricant.Indeed,byusingaspecialsyntheticmaterial,

justthenecessaryquantityof lubricantflows:thisway,there-lubricationtimewillbeextendedasmuchaspossible.Itisadvisabletouseitindryandcleanenvironments,alwaysincombinationwiththesteelwipersTPA.

Foracorrectfunctionality,itisadvisabletousetwocartridgesTLLfor eachcarriage(oneoneachside) Thedistributionofthelubricantisassuredinallassemblypositions ThecartridgesTLLcanberecharged Useonlyhigh-qualitymineraloilDIN51517CLPorDIN51524HLPwith ISOVG220viscosity Lubricationintervalupto5000kmormaximumevery12months (variableaccordingtotheuse) Reductionofthecostsrelatingtothelubricationsystem Lowenvironmentalimpactthankstoaminimumconsumptionoflubricant

TheTLLlubricationunitsshouldnotbeusedinthepresenceoflubricatingoil-coolantsindirectcontactwiththeguides.


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Size S1 K

25 16 2.6

35 20 3.3

45 23 4

55 27 4.8

LinClampclampingsystemsLinClampclampingsystemsweredesignedforstaticanddynamiclocks(emergency).

Pneumaticcompactsystem(6bars)Active(lockingwithair)orpassive(lockingwithnoair)system

ExcellentlockingabilityevenincaseofgreaseAvailableforallsizesLowercostscomparedwithhydraulicandelectricsolutions

Forfurtherinformation,callRosaSistemisengineeringdepartment.

BellowsThebellowsareusedasanadditionalprotectionagainstdustandwatersplashes.For further information and designs, call Rosa Sistemis engineeringdepartment

AssemblyguideTheplastic-materialassemblyguideisusedtotranspor tthecarriageandifitisnecessarytoremovethelatterfromthemonoguide.

Alwaysleavetheassemblyguideinthecarriagetopreventlosingtherollersandasadustprotection.


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41/5641

LUBRICATION5. 1. Greasing 2. Oiling 3. Lubricationaccessories


42/5642

5.

Lubrication

Deliverycondition

Warning

Lubricationfitting

Greasing:featuresandadvantages

Oiling:featuresandadvantages

ThefrontheadofthecarriageisaparticularandinnovatoryfeatureofRosaSistemismonoguide.Indeed,eachdistributionchannelisequippedwithacheckvalvethatallowsthelubricanttobedosedandtakentotheslidewayswith

minimumpulsesinanyassemblyposition.

Suitablelubricationassuresthecorrectoperationof theguide.Indeed,thelubricantprotectsagainstcorrosionandpollutingagents,thusreducingwearandfriction.Youcanuseoil,greaseandliquidgrease(lowviscosity).

At delivery, the carriages and the guides are protected with high-qualitysemi-syntheticoil.Thisprotectionissufficienttoperformthefirstassembly.Before the commissioning, you must perform the first lubrication of the

carriagesaccordingtothefollowinginstructions.

Ifyouuseacentralizedlubricationsystem,theadapterandtheoilinputnippleswillnotbeincludedinthesupply.Thestandardsupplyincludesonegreasenipplepercarriage.

Thefrontheadsofthecarriageareequippedwithseverallubricationpointslocatedinthefrontandonthesides,andprovidedwiththerelevantM6thread.Theaforesaidholes,atdelivery,areclosedbymeansofgrubscrews.Onthetopofthefrontheadthereisafittingfortheadditionaltoplubrication.Upondemand,thecarriageswillbesuppliedwithspecificO-ringsandadapters.

Asforthethicknessesandthedimensions,seeparagraph2.10onpage15.

RecommendedgreasetypeK(fluidgreasewithdensityclassNLGI0/1/2, accordingtotheDIN51825standard) Longerlubricationintervalsaccordingtothefeaturesoflubricatinggreases Reductionof operationnoise Increasedheatingathighspeeds Increasedtranslationforcecomparedwithoiling

Singlecentralizedlubricationsystemtobeusedsimultaneouslyforother mechanicalelements Quickandcontinuousexchangeoflubricant Bettercleaningofthemovingparts Decreasedheatingathighspeeds Selectoilviscosityaccordingtothespeed.Seetheinstructionsbelow:

v


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Grease/Liquidgrease

Initiallubricationbeforethestart-up

Followinglubrication

Followinglubricationinterval

Oil

Initiallubricationbefore

thestart-up

5.1 Greasing

Itisadvisabletousethefollowinggreasetypes:

GreaseaccordingtotheDIN51825standard,typeKP2K-20 (high-performancegreasebasedonlithiumsoap) LiquidgreaseaccordingtotheDIN51826standard,types: NLGI00andNLGI000

Immediately after the assembly, the carriages must be lubricated with thequantitiesthatarespecifiedinthetable.Duringthegreasingoperation,movethecarriageforastrokethatatleastcorrespondstothreetimesitsownlength.

Quantitycm/carriage MG25 MG35 MG45 MG55

LC/SC 1.9 2.9 5.3 8.4

LL/SL 2.2 3.7 6.6 10.6

Thetablespecifiesthecorrectvalues.

Quantitycm/carriage MG25 MG35 MG45 MG55

LC/SC 0.5 1.2 2.2 3.2

LL/SL 0.6 1.4 2.6 4

Incaseofshortstroke(shorterthantwicethelengthLofthecarriage),applyadoublequantityoflubricantbymeansof2lubricationpoints(onepereachhead)

Greasequantityaccordingtothetable

Load MG25 MG35 MG45 MG55

C/P>8 800km 500km 300km 200km5C/P


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Allcarriagetypes

Minimumquantityofoilallowedbyimpulse

Incaseofoiling,M6holesforthelubricationthatarenotusedinthefrontheadofthecarriagemustbehermeticallysealed.

Ifyouuselubricantsotherthanthespecifiedones,youmusttakeintoconsiderationtheneedtoreducethere-lubricationintervals,thereducedperformancesintermsofstrokesperformedandtheloadcapacity,aswellasthepossiblechemicalinteractionsbetweenplasticsandlubricants.

Thelubricantsthatcontainsolidparticles(graphiteorMoS2)shouldneverbeused.

Oilquantitycm3/carriageMG25 MG35 MG45 MG55

0.8 1.0 1.4 1.8

Incaseofshortstroke(shorterthantwicethelengthLofthecarriage),applyadoublequantityoflubricantbymeansof2lubricationpoints(onepereachhead).

Oilquantitycm3/carriage MG25 MG35 MG45 MG55

C/P8 400km 250km 125km 100km

cm 1.2 1.2 1.2 1.5

5C/P


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Inparticularconditionsofuse,suchasdirt,useoflubricating-oil-coolant,vibrationsorimpactstresses,youmustadaptthequantitiesoflubricanttotherealworkingconditions.Indeed,thequantitiesoflubricantthatarespecified

inthetablesrefertoidealconditionsofuse.As fortheapplications inasepticandvacuumenvironments,food industry,etc.pleasecallourengineeringdepartment.

Afollowingchangefromgreasetolubricatingoilispossible,butyouneedtoconnecttothefrontheadofthecarriagethatwasnotpreviouslyused(asthelubricationchannelsfullofgreasemaypreventtheoilfromflowing)

Incaseofgreasing,thelubricantmustbereplacednomatterhowaftertwoyearsduetogreaseageing.

HorizontalandverticalaxesonRosaErmandoSpAgrindingmachine.


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Lubricationnipple(includedinallsupplies)

45lubricationnipple

90lubricationnipple

Greasenipples

5.3 Lubricationaccessories

ReductionfittingG1/8-M6

Connectingfitting

Straightquickcoupling

Adjustable90quickcoupling

Fittings

Quickcouplings


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INSTALLATIONAND

ASSEMBLY

6.

1. Fasteninginstructions 2. Accuracyof assemblysurfaces

3. Assembly


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6.

6.1 Fasteninginstructions

Size Measures(mm)s R

1R

2

25 5 0,8 0,8

35 6 0,8 0,8

45 8 0,8 0,8

55 10 1,2 1,0

Toassuremaximumstiffnesstothecarriage(accordingtothediagramsonpage18-25),itisabsolutelynecessarytouseallfasteningholes.Thecarriagescanbefastenedintwoways: Useofthreadedholesasshowninfig.1fig.3. Thismethodispreferable,asitleadstoastifferfasteningasthe threadallowsusingascrewwithabiggerdiameter. Useofthepass-throughholesasinfig.2.Inthiscase,asfarasthe centralfasteningholesareconcerned,youmustusespecificsocket- headscrewsaccordingtotheDIN6912standard.

Incaseofconsiderableloads,suitablycheckthefasteningoftheguidetothebedplate.

Size G2 Dimensionofthescrewsforthecarriages

V1 V2 V4 V5

ISO4762 ISO6912 ISO4762 ISO4762

4pieces 2pieces 6pieces 6pieces

25 10 M6x20 M6x16 M8x20 M6x18

35 13 M8x25 M8x20 M10x25 M8x25

45 14 M10x30 M10x25 M12x30 M10x30

55 20 M12x40 M12x30 M14x40 M12x35

Dimensionofthescrewsforthemonoguides

V3 V6

25 M6x30 M6x20

35 M8x35 M8x25

45 M12x45 M12x3055 M14x50 M14x40

Structureofshouldersurfaces

Installation/Fasteningscrews


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Ifnoshouldersurfaceisprovidedfor,thereferencevaluesforthemaximumallowablesideforcescanbeestablishedwiththehelpofthefollowingtable.TheaforesaidvaluesdependonthecapacityofthedynamicloadC,thetype

offasteningbeingusedandtheresistanceclassofthescrews.

Resistance

class

Allowablesideforce(N)onthecarriagewithoutshoulder

(Valuewithstaticfrictioncoefficient=0,125)

M6 M8 M10 M12 M14

6screws 6screws 6screws 6screws 6screws

8.8 4400 8100 13000 19000 26000

12.9 7500 13800 21900 32000 44000

Allowablesideforce(N)ontheguidewithoutshoulder

(exercisedbyacarriageontheguide)

8.8 3400 6200 13900 20000

12.9 5700 10600 23500 33700

ResistanceclassTighteningtorque(Nm)

ForfasteningscrewsDIN912/ISO4762

Frictioncoefficient=0,125

M6 M8 M10 M12 M14

8.8 10 24 48 83 130

12.9 16 40 81 135 215

Followtheinstructionsof thescrewmanufacturer:theywillalwaysbe binding ThescrewsaccordingtotheDIN6912standard,withsockethead, mustbetightenedincompliancewiththeinstructionsforclass8.8 If you use lubricating greases, the friction coefficient can be reduced even to half; therefore, the tightening torques must be propor tionallyreduced. Ifyoulubricatethefasteningscrewsoftheguideswithgreaseand tightenthem withadynamometricwrench,youwillobtainamore uniformtighteningforce,andthusaclearimprovementofthesliding

accuracy.

Allowablesideforcewhenthereisnoshoulder

Recommendedtighteningtorques


50/5650

To obtain the maximum allowable deviation value in height, subtract the

tolerancevalueofthedimensionH(seethetableabouttheaccuracyclassesonpage10)fromthevalueH1obtainedbymeansof thefollowingformula:

H1=Xb10-4

Calculationfactor Preloadclass

P2 P3

X 1,710-4 1.210-4

Toobtainthemaximumallowabledeviationvalueinlongitudinaldirection,subtractthetolerancevalueofthedimensionH(seethetableabouttheaccuracyclassesonpage10)fromthevalueH2obtainedbymeansofthefollowingformula:H2=Yl

Calculationfactor Carriagetype

LC/SC LL/SL

Y 4,510-5 3,510-5

Thespecifiedtolerancesarevalidalsofortheguidesandthecarriagesthatareassembledwithoutshoulders.TheparallelismerrorsA1andA2causeanincreaseinthepreload,butifthevaluesspecifiedinthetablearenotexceeded,theirinfluenceontheexpectedlifewillusuallybenegligible.

ParallelismAperpreloadclass(mm)

Size P2 P3

25 0,008 0,005

35 0,012 0,008

45 0,014 0,009

55 0,017 0,011

6.2 Accuracyofassemblysurfaces

Maximumallowabledeviation

inheight

Maximumallowabledeviationinlongitudinaldirection

Parallelismtoleranceforshouldersurfaces


51/5651

Sometypicaltypesofassemblyareshownontheside.Theydifferasperthetypeoffasteningforthecarriageandtheguide,aswellasperthepositionof endstopsurfacesinthemachine.MonoguideBothsidesupportsoftheguidecanbeusedasareferenceside.

CarriagesThegroundsidesurfaceisusedasareferenceside.

Complywiththefollowinginstructions:

Alwaysputthemonoguideagainstthesupportingendstop(ifavailable) Alwaystightenthescrewsinanalternatingwaybystartingfromthe centreoftheguideandpreferablybyusingadynamometricwrench Theguidesformedbyseveralpartsaremarkedwithnumbersinthe joints.Duringtheassembly,youmustmatchtheaforesaidnumbers. Always check that the guides are aligned one close to the other withoutleavingemptyspaces,eventinyones.

Asfortheassemblyoftheeguidesinseveralpar ts(nosideendstop),alignthejointsoftheguidesbyusinggroundshaftsandclamp,asshowninthepicture.

Assemblyexamples

Generalinstructionsfortheassemblyoftheguides

0

11

22

3

6.3 Assembly


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Notes


53/5653


54/5654


55/56


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