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Manual Book:
BLO 80 2.1 C 30
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Characteristics In most respects aerostatic bearings are ideally suited for use in high-speed machines. Their low friction provides high mechanical efficiency and minimizes bearing heating problems. They are quiet and smooth running and do not add to sound and vibration levels of the machine in the way that high-speed ball bearing do. Applications One of the most important fields of application of aerostatic bearings is undoubtedly on machine tools where the ra
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CONTENTS 1. Fundamental Safety Instructions. 3 2. Warranty notice. 5 3. Attention – Daily Check Before starting the spindle 6 4. System general description. 7 5. Aerostatic Spindle Label. 7 6. Installing the spindle. 8 7. Removing the spindle from the machine. 9 8. Specification for High – Speed Air Spindle. 10 9. Electrical Motor Specification. 11 10. Brushless DC Motor 12 11. Diagrams: a) Torque & Power Vs. Rotation Speed 13
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FUNDAMENTAL SAFETY INSTRUCTIONS 1. Basic operation and designated use of the machine. 1.1 The machine has been built in accordance with state of the art standards and recognized safety rules. Nevertheless, its use may constitute a risk to life and limb of the user and of the third parties, or cause damage to the machine and to other material property. 1.2 The machine must only be used in technically perfect conditions in accordance with its designated use and the instructions set out in
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3.5 Do not allow persons to be trained or instructed or persons taking part in a general training course to work on or with the machine without being permanently supervised by an experienced person. 3.6 Work on the electrical system and equipment of the machine must be carried out only by a skilled electrician or by instructed person under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations. 4. Safety instructions gover
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6.2 Work on the electrical system or equipment may only be carried out by a skilled electrician himself or by specially instructed personnel under the control and supervision of such electrician and in accordance with the applicable electrical engineering rules. 6.3 If provided for in the regulations, the power supply to parts of machine, on which inspection, maintenance and repair work has to be carried out, must be cut off. Before starting any work, check the de-energized parts for the pr
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ATTENTION DAILY CHECK BEFORE OPERATING THE SPINDLE 1. For first time installation, look at “Installing the spindle” paragraph. 2. Check air supply (5-6 bar.) 3. Check ventilation exits. 4. Check for free movement of the shaft. 5. The spindle must be securely clamped to the machine and clear from any distraction. 6. Check for electric connections and command (community grounding). 7. Start the spindle.
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SYSTEM GENERAL DESCRIPTION TOP VIEW SIDE VIEW 7
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INSTALLING THE SPINDLE 1. Remove the spindle from its package. 2. Follow the machine’s safety and installation instructions. 3. Clamp the spindle to the machine - using 4 screws (M5 - minimal length 15 mm). Note: Locate the spindle on the position pins; 4. Remove plugs from air connections (2). 5. Connect inlet air pipe Ø6 mm to “AIR IN” (AI). 6. Connect outlet air pipe Ø6 mm to “AIR OUT” (AO) or you may use a
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REMOVING THE SPINDLE FROM THE MACHINE Note: Always lift the spindle from the body and not from the shaft. 1. Turn off the spindle. Make sure the shaft has stopped before continuing. 2. Follow the machine’s safety and installation instructions. 3. Disconnect power cable. 4. Disconnect signal cable. 5. Turn off air supply. 6. Disconnect air pipes from the spindle. 7. Remove wheel D-400 (ø65 mm). 8. Remove wheel D-1400 (ø76 mm). 9. Close AO and AI holes with plastic plugs x2.
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SPECIFICATION FOR HIGH-SPEED AIR SPINDLE Rotation speed – 2K ~ 75K [rpm] Air supply Pressure :5~7 [bar] Flow rate :30-40 [lpm] Filtering :0.01 [µm] Dew point :lower then 15 [ C] Oil residue :lower then 0.1 [ppm] Static run-out of the rotor Radial direct. (max) :0.35 [µm] Thrust direct (max) :0.35 [µm] Dynamic run-out of the rotor Radial direct(max) :1 [µm] Thrust direct. (max) :1 [µm
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ELECTRICAL MOTOR SPECIFICATION Size Constants: • Maximum Rated Torque : Tr = 2.13 [Nm] • Maximum Continuous Stall Torque • @ Temp. Rise 100 [ºC] : Tc = 0.30 [Nm] • Motor Constant : Km = 0.03 [Nm/ √w] • Electrical Time Constant : Te = 0.46 [msec] • Mechanical Time Constant : Tm = 3 [msec] • Angular Acceleration (theoretical) : 800000 [rad/sec²] • Thermal Resistance : TPR =0 .65 [ºC/watt] • Maximum Coggi
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BRUSHLESS DC MOTOR Maximum Continuous Stall Torque (T ) is the amount of torque produce at zero speed, which results C in a 100 Cº rise in temperature. Generally the highest operation temperature that should be allowed is 150 Cº and is a combination of the ambient temperature and the temperature rise for a given operating condition. Maximum rated Torque (T ) is the amount of torque that the motor can produce without demagnetizing R the rotor. The torque is only available for short du
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Torque & Power Vs. Rotation Speed 1600 0.3 0.25 1200 Nominal Power 0.2 0.15 800 0.1 400 0.05 0 0 0 20 406080 0 20 406080 Vsp [krpm] Vsp [Krpm] Vsp [Krpm] - Rotation Speed Conditions T [Nm ] - Spindle Torque 1. Temp Rise less then 100° C. Pw [w ] - Power 2. Continuous operation at a load point. 3. The curves assume a 25°C ambient environment. 4. No external loads. Continuous Duty Speed/Torque Curves for 100°C Temperature Rise. The continuous duty speed/torque curves pr
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Radial Stiffness Vs. Air Pressure Ps[bar] Sr[N/m] 20 2 1.5 16 Sr=[13.642*ln(Ps)-7.956] \ 2 2.5 4.544 12 3 7.031 Theoretical curves 8 3.5 9.134 4 Ps [bar] - Spindle air pressure. 4 10.956 Sr [N/ µ ] - Radial Stiffness. 0 4.5 12.563 5 14 CONDITION 012345678 5.5 15.3 1. No Rotation. Ps [bar] 6 16.487 6.5 17.579 Axial Stiffness Vs. Air Pressure 7 18.59 15 Ps[bar] Sa[N/m] Sa=6.425*ln(Ps)-1.454 2 3 10 2.5 4.434 Theoretical curves 5 3 5.605 3.5 6.596 Ps [bar] - Spindle air pressure. 0 Sa [N/ µ ] - Axia
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Vsp[Krpm] Vf[Volt] Voltage Constant ( BEMF) 5 9.27 150 10 18.54 120 V = 1.854*V f sp 15 27.81 90 20 37.08 60 Vsp [Krpm] - Rotation Speed 25 46.35 30 30 55.62 Vf [Volt] - Voltage between two phases. 35 64.89 0 40 74.16 0 10 20304050 6070 45 83.43 Vsp [Krpm] 50 92.7 55 101.97 Current Vs. Rotation Speed 60 111.24 3 65 120.51 0.04*Vsp 2.5 I = 0.159*e f 2 70 129.78 If [Amp] - Current Phases. 5 1.5 0.194 1 10 0.237 Vsp [Krpm] - Rotation Speed. 0.5 15 0.289 CONDITION 0 20 0.353 1. Driv
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Raw Materials Data The Spindle is mayd from the following materials: Stainless steel: SAE 303, SAE 2316. Brass SAE 40, Copper. Polymers: Delerin Chemical composition SAE 303 SAE 2316 BRASS SAE 40 COPPER Cu %C 0.15 %C 0.34 %Cu 58.1 %Cu 99.96 %Si 1 %Si 0.16 %Pb 2.83 %Pb 0-8 %MN 2 %MN 0.88 %Al 0.01 %Bi 0-1 %P 0.2 %P 0.025 %Fe 0.29 %S 0.15-0.4 %S 0.003 %Ni 0.1 %CR 17-19 %CR 15.12 %Sn 0.24 %MO 0.6 %MO 0.91 %Ni 8--10 %Ni 0.53 Mechanical properties SAE 303 SAE 2316 Hardness HB 262 235 0.2% proof stre
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SPINDLE MODES Length[mm] 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 1.25 1 0.75 1 0.5 2 0.25 3 0 4 5 -0.25 6 -0.5 -0.75 -1 -1.25 17
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SPINDLE BALANCING Why is balancing important? Force (F) generated by unbalance can be calculated from formula: 2 F(Kg)= 0 . 001 x(gmm)x(RPM/ 1000 ) r 2 F(Kg)= 0 . 001 x(w x r)x(RPM/ 1000 ) where w = Unbalance weight in grams r = Radius in millimetres Effects of Unbalance Reduced component life. Bearings, seals, windings, rotor bars, foundations, supports. Impaired clearancs / tolerances. Component displacement, Reactive misalighment. Resonance. Flexing of critical speed rotors. Excessive vibra
