The fast track to precision motion. Linear modules and Cartesian ...
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IndustrialHydraulicsElectric Drives<strong>and</strong> Controls<strong>Linear</strong> Motion <strong>and</strong>Assembly TechnologiesPneumaticsServiceAu<strong>to</strong>mationMobileHydraulics<strong>The</strong> <strong>fast</strong> <strong>track</strong> <strong>to</strong> <strong>precision</strong> <strong>motion</strong>.<strong>Linear</strong> <strong>modules</strong> <strong>and</strong> <strong>Cartesian</strong> robotsfrom Bosch RexrothYour performance advantage in assembly, packaging, <strong>and</strong> h<strong>and</strong>ling
2IntroductionEngineered solutionsfor <strong>precision</strong> linear <strong>motion</strong>Get the ready-<strong>to</strong>-go linear <strong>motion</strong> solution that fits your applicationby talking <strong>to</strong> the application experts. Whether you need pick-<strong>and</strong>place,parts transport, or parts positioning, Rexroth linear <strong>modules</strong>can do it better, <strong>fast</strong>er, <strong>and</strong> for less. From semiconduc<strong>to</strong>rfabrication <strong>to</strong> au<strong>to</strong>motive assembly <strong>to</strong> packaging, we’ll help youadd flexibility <strong>and</strong> performance <strong>to</strong> optimize your application.From components <strong>to</strong> <strong>modules</strong>We started with leadership inlinear <strong>motion</strong> components,application expertise, <strong>and</strong>integration. With a broad rangeof world-class components, wecombined them in<strong>to</strong> 12 familiesof linear actua<strong>to</strong>rs. So you saveengineering time <strong>and</strong> hassles,cut risk, <strong>and</strong> get a linear <strong>motion</strong>solution that’s designed for yourapplication. Count on <strong>fast</strong>delivery <strong>and</strong> worldwide supportfor even greater convenience.<strong>Linear</strong> <strong>to</strong> <strong>Cartesian</strong>:taking the complexityout of complex needsBeyond individual axes,we combine <strong>modules</strong> in<strong>to</strong>multi-axis <strong>Cartesian</strong> systems.Designing <strong>Cartesian</strong> systemsrequires solving <strong>to</strong>ughengineering challenges—something we do every day.Save time by selecting anengineered solution fromBosch Rexroth. You’ll have moretime <strong>to</strong> optimize other parts ofyour application with the peaceof mind knowing you havelinear systems designed <strong>to</strong>work right out of the box.Application expertisefor the perfect fitWe thrive on challenges.And we have the applicationengineering <strong>and</strong> industryexperience <strong>to</strong> ensure you getwhat you need <strong>and</strong> not justwhat we have <strong>to</strong> sell. Ourapplication engineers use ourproprietary FastAxis software<strong>to</strong> size <strong>and</strong> specify your linearmodule. No more hit <strong>and</strong> miss,or costly cycles of testing <strong>and</strong>re-engineering. We get it rightthe first time.Beyond <strong>modules</strong><strong>to</strong> complex applicationsIf you’re a system integra<strong>to</strong>r,Rexroth provides <strong>precision</strong>robotics from one axis <strong>to</strong>six axes, <strong>and</strong> everything inbetween—as well as thealuminum framing <strong>to</strong> makethe machine guarding. In fact,no other company can <strong>to</strong>uchRexroth in the range ofproducts we can supply formore complex systems:conveyors, pneumatics, controls,even ergonomic workstations.And since every one of ourproducts is designed withflexibility at its core, you canbuild exactly the au<strong>to</strong>mationsystem you need, with the bestin-classequipment you expect.<strong>The</strong> end of tradeoffsEngineering is the art ofmanaging tradeoffs. Compareour linear <strong>modules</strong> withcompeti<strong>to</strong>rs’. We give youfewer tradeoffs <strong>and</strong> moreperformance: higher speeds,higher capacities, <strong>and</strong> higher<strong>precision</strong>—<strong>and</strong> we lead theindustry in achieving moreperformance in every categoryof linear actua<strong>to</strong>r.
3You’ll find Rexroth <strong>modules</strong> everywherePackaging <strong>and</strong> Material H<strong>and</strong>lingAssemblyRexroth linear actua<strong>to</strong>rs are boosting productivity worldwidein applications such as compound packaging, stacking, sorting,palletizing, <strong>and</strong> even gentle food h<strong>and</strong>ling.Pick-<strong>and</strong>-place, parts positioning, <strong>and</strong> machine <strong>to</strong>olpositioning—we offer <strong>modules</strong> for everything from small parts<strong>to</strong> heavy-duty au<strong>to</strong>motive applications. Whether you’re guiding<strong>to</strong>ols for machining or welding or moving heavy au<strong>to</strong>motivecomponents, Rexroth linear actua<strong>to</strong>rs can h<strong>and</strong>le yourrequirements with ease.Semiconduc<strong>to</strong>rMedicalCleanroom-certified Precision <strong>and</strong> Compact Modules satisfyapplications from simple positioning <strong>to</strong> gantry-style robots fortransporting wafer pods.Rexroth <strong>modules</strong> find use in applications from dispensing <strong>to</strong> labau<strong>to</strong>mation, where multipoint positioning <strong>and</strong> smooth operationare critical. Cleanroom-certified <strong>modules</strong> bring best-in-classperformance in sensitive environments.
4OverviewFlexible choice,exceptional performanceOver the last 20 years, we’ve evolved a broad lineup of <strong>modules</strong><strong>to</strong> meet the ever-changing needs of a variety of industries. We’veupped the performance in <strong>precision</strong>, speed, <strong>and</strong> load capacity,pushed the technological envelope, <strong>and</strong> helped countlesscompanies create smarter, more agile, <strong>and</strong> more capableau<strong>to</strong>mation. And all that experience is ready <strong>to</strong> work for you.<strong>The</strong> proven performersPrecision engineering.<strong>The</strong> highest st<strong>and</strong>ards ofmanufacturing. Superiorfit <strong>and</strong> finish. It’s ouruncompromising attention<strong>to</strong> every detail that means youget world-class products <strong>and</strong>the confidence that theywill meet our publishedspecifications <strong>and</strong>, therefore,your needs.<strong>Linear</strong> Modules (MKR, MKK,MLR): workhorse of industries<strong>The</strong> <strong>modules</strong> that started it allnearly 20 years ago, the <strong>Linear</strong>Module family goes the distancein performance <strong>and</strong> durabilitywith a Ball Rail ® guide systemfor long lengths <strong>and</strong> high loadcapacities. <strong>The</strong> linear <strong>modules</strong>line includes the belt-drivenMKR <strong>and</strong> MLR Modules <strong>and</strong>,for additional accuracy, the ballscrew-drivenMKK Module.Compact Modules (CKR, CKK):compact <strong>and</strong> capableCompact Modules are an idealsolution for applications withheavy moment loads. Ratherthan adding a separate outboardguide <strong>to</strong> carry a heavy momentload, Compact Modules use twointernal Ball Rail Systems <strong>and</strong>either a belt (CKR) or ball screw(CKK) drive. <strong>The</strong>se <strong>modules</strong>offer unmatched combinationsof speed, <strong>precision</strong>, <strong>and</strong> loadcapacity—a perfect exampleof how we are eliminatingtradeoffs <strong>and</strong> giving you theopportunity <strong>to</strong> do more.Ball Rail Tables (TKK):heavy duty for heavy loadsFor extremely dem<strong>and</strong>ingapplications such as those inthe au<strong>to</strong>motive industry, TKKBall Rail Tables h<strong>and</strong>le loadsup <strong>to</strong> 132,500 N. Using a ballscrew drive <strong>and</strong> dual Ball RailSystem with four long runnerblocks per carriage, TKK Tablesare heavy-duty units offeringexceptional <strong>precision</strong>.Precision Modules (PSK):small, precise, <strong>fast</strong>PSK Precision Modules combinesmall size with advancedtechnologies <strong>to</strong> achieve highaccuracies <strong>and</strong> increasedthroughput. For cleanroom<strong>and</strong> contamination-sensitiveapplications in semiconduc<strong>to</strong>r<strong>and</strong> life science industries, the<strong>modules</strong> are available withcleanroom Class 10 certification.With a machined steel frame,the Precision Modules are idealfor applications requiring highstiffness <strong>and</strong> low deflection,including glass scribing<strong>and</strong> machining.
5How <strong>to</strong> pick the right linear actua<strong>to</strong>r. Selection guidelines: LOSTPEDLOSTPED is an acronym used by Rexroth engineers <strong>to</strong> select <strong>and</strong> size a module for any given application.By evaluating all critical fac<strong>to</strong>rs for each application, we can help you get exactly the right system—<strong>and</strong> avoidextra costs <strong>and</strong> wasted time that result from <strong>modules</strong> that provide <strong>to</strong>o little (or <strong>to</strong>o much) performance.Here’s what LOSTPED st<strong>and</strong>s for:Load. Consider both static <strong>and</strong> dynamic loads, fac<strong>to</strong>ring in the potential for changing requirementsor misuse.Orientation. <strong>The</strong> plane of travel affects loads <strong>and</strong> system design. For example, vertical <strong>and</strong> invertedloads can place different dem<strong>and</strong>s on linear bearings <strong>and</strong> drive mechanisms.Speed. Speed <strong>and</strong> acceleration determine basic hardware choices (such as ball screw or belt drive)<strong>and</strong> other variables such as load.Travel. Travel distance includes both the length of movement (the stroke) <strong>and</strong> the <strong>to</strong>tal movementincluding safety travel at each end. Long strokes require careful alignment of bearings <strong>to</strong>avoid added friction <strong>and</strong> debilitating fatigue. Short strokes may not allow the bearings <strong>to</strong> beproperly lubricated.Precision. Travel accuracy <strong>and</strong> repeatability of final position are essential, <strong>and</strong> feedback encoders maybe required for ultraprecise positioning. Fac<strong>to</strong>rs such as deflection, system stiffness, <strong>and</strong> mountingcan influence success in achieving the desired <strong>precision</strong>.Environment. Extreme conditions of temperature <strong>and</strong> humidity, dust <strong>and</strong> dirt, corrosive liquids <strong>and</strong>gases, or, by the same <strong>to</strong>ken, cleanroom requirements, can affect the need for additional sealing,pressurized slides, or flexible shields.Duty cycle. Duty cycle affects the life of the system. High-duty-cycle applications require additionalcooling of the mo<strong>to</strong>r <strong>and</strong> more frequent lubrication of the bearings.LOSTPED gives designers the basicfac<strong>to</strong>rs for selecting the proper system.Rexroth application engineers can helpyou spec <strong>and</strong> size the best solution withour FastAxis specification/design software.In general, the main fac<strong>to</strong>rs are speed,travel, <strong>and</strong> load capacity.
6<strong>Linear</strong> ModulesMKK, MKR, <strong>and</strong> MLR <strong>Linear</strong> Modules.A heritage of h<strong>and</strong>ling <strong>to</strong>ugh applicationsOur original MKK, MKR, <strong>and</strong> MLR <strong>Linear</strong> Modules are still asvital <strong>and</strong> hardworking as when they were first introduced.Working worldwide for over 20 years, the family has continuallyevolved <strong>to</strong> meet the latest dem<strong>and</strong>s of linear <strong>motion</strong> <strong>and</strong>au<strong>to</strong>mation. <strong>The</strong>se versatile performers offer high-speed<strong>and</strong> long-stroke transport.<strong>Linear</strong> Modules areavailable in three mainstyles <strong>to</strong> meet a varietyof needs.High rigidity overlong distances<strong>Linear</strong> Modules featurea rugged anodized aluminumframe <strong>to</strong> provide the rigidityrequired for carrying heavyloads over long distances up<strong>to</strong> 12,000 mm with <strong>precision</strong><strong>and</strong> speed.With every <strong>Linear</strong> Module,you get a ready-<strong>to</strong>-mountassembly in any specifiedlength, with a full rangeof accessories, includingservo mo<strong>to</strong>rs <strong>and</strong> drives.Type Guideway Drive Unit <strong>Linear</strong> ModuleMKKMKRMLRBall Rail ® SystemBall Rail ® SystemCam Roller GuidePrecision Ball ScrewAssemblyToothed Belt DriveToothed Belt DriveTo keep the overall dimensionalenvelope small, a <strong>precision</strong>gearbox can be integratedin<strong>to</strong> the pulley system on beltdrivenunits.T-slots in the frame <strong>and</strong>carriage make it easy <strong>to</strong>mount linear <strong>modules</strong> <strong>to</strong> a base<strong>and</strong> <strong>to</strong> attach loads. In addition<strong>to</strong> internal sealing of the linearbearings <strong>and</strong> ball screw, externalpolyurethane, stainless-steelsealing strips, or polyurethanecoatedfabric bellowsprovide excellent protectionagainst contamination.MKK <strong>Linear</strong> Modules<strong>The</strong> MKK uses a Ball Rail ®System <strong>and</strong> <strong>precision</strong> ball screwassembly <strong>to</strong> achieve high thrustforces, accurate positioning,<strong>and</strong> excellent repeatability.<strong>The</strong> carriage providesone-point lubrication for <strong>fast</strong>,convenient maintenance of therunner blocks <strong>and</strong> ball nut.<strong>The</strong> integrated <strong>precision</strong>ball screw offers lengths <strong>to</strong>5000 mm—about 40% greaterthan the closest competition—with maximum speedsof 1.5 m/s.MKR <strong>Linear</strong> Modules<strong>The</strong> MKR uses a Ball RailSystem <strong>and</strong> highly tensioned<strong>to</strong>othed belt drive fordem<strong>and</strong>ing speed <strong>and</strong> loadrequirements. Offering speedsup <strong>to</strong> 5 m/s, the MKR h<strong>and</strong>lesloads <strong>to</strong> 68,060 N over distances<strong>to</strong> 12,000 mm.MLR <strong>Linear</strong> Modules<strong>The</strong> MLR uses a Cam RollerGuide <strong>and</strong> pretensioned<strong>to</strong>othed belt drive <strong>to</strong> achievehigh speeds up <strong>to</strong> 10 m/s withloads <strong>to</strong> 31,000 N. Cams haveadjustable preloading <strong>to</strong>provide nonslip startups,while rollers on the side ofcarriage allow very-high-speedapplications. Shafts <strong>and</strong>cams are stainless steel forwashdown compatibility.
7Typical ApplicationsAs an industry workhorse, Rexroth <strong>Linear</strong> Modules provide flexible,versatile solutions in a wide range of applications.MedicalPackagingPrintingSemiconduc<strong>to</strong>rPharmaceutical manufacturingTransportingS<strong>to</strong>rage <strong>and</strong> retrievalMedical device manufacturingTray formersCase packingCar<strong>to</strong>nersPrint head positioningScanningInspectionCleaningWafer transportEngineer’s CornerHousing <strong>and</strong> Frame DesignCritical <strong>to</strong> the design ofany linear actua<strong>to</strong>r is thehousing or frame, whichcontributes not only <strong>to</strong>system rigidity, but also <strong>to</strong>the module’s overallweight, mounting flexibility,<strong>and</strong> serviceability. We’vedesigned our housings <strong>to</strong>take full advantage of theperformance capabilities of our best-in-classcomponents. Three main housing materials are used:Extruded aluminum allows longer continuous lengths.Extruded housings are light weight <strong>and</strong> offer mountingflexibility due <strong>to</strong> the T slots located on the side of theextrusion. <strong>The</strong> most widely used housing material,extruded aluminum, is used in the <strong>Linear</strong> Module <strong>and</strong>Compact Module families.Machined baseplates provide higher accuracy <strong>and</strong> areference edge <strong>to</strong> maintain absolute <strong>precision</strong> <strong>to</strong> themounting surface, as with TKK Ball Rail Tables.MKR <strong>Linear</strong> Modulesspeed up thepackaging processfor milk car<strong>to</strong>ns.Machined steel housings used with PSK PrecisionModules have an integral Ball Rail machined in<strong>to</strong>the base, yielding a package that combines compactdimensions with an extremely stiff, low-deflection design.CKKCKRMKKMKRPSKTKK
8Compact ModulesCKK <strong>and</strong> CKR Compact Modules.Low profile, outst<strong>and</strong>ing performance<strong>The</strong> Compact Module family uses two Ball Rail ® Systems <strong>to</strong>achieve exceptional performance, providing high capacity for roll,pitch, <strong>and</strong> yaw moments. Additionally, the <strong>modules</strong> are availablewith a choice of one or two carriages. <strong>The</strong> resulting stability meansthese <strong>modules</strong> combine high speed, high <strong>precision</strong>, <strong>and</strong> high loadcapacity <strong>to</strong> surpass anything in their class.Saving space withoutsacrificing performanceTo achieve a compact design,the belt or ball-screw drivemechanism is in-line with thedual Ball Rail Systems, resultingin a low-profile module. Bothan aluminum cover plate <strong>and</strong>polyurethane sealing stripsprotect internal componentsfrom contamination.Switch-mounting arrangementsshow how attention <strong>to</strong> detail<strong>and</strong> smart engineering giveyou a superior product. Unlikemost linear <strong>modules</strong> in thisclass, Compact Modules allowswitches <strong>to</strong> be protected fromcontamination by mountingthem within the cable duct.What’s more, they are actuatedby magnets in the carriage,reducing the number of parts<strong>and</strong> increasing the reliabilityof the system.As with all Rexroth linearactua<strong>to</strong>rs, Compact Modulesare fully supported withmo<strong>to</strong>rs, servo drives, <strong>and</strong>other accessories.CKK Compact ModulesCKK Compact Modules usea <strong>precision</strong> ball screw <strong>to</strong>drive movement along thetwo Ball Rail Systems. <strong>The</strong>ball screw is <strong>to</strong>lerance grade 7<strong>to</strong> provide positioning accuracyof 52 microns per 300 mmof travel.For the semiconduc<strong>to</strong>r <strong>and</strong>medical industries, CKKCompact Modules arecleanroom certified forClass 100 applications. <strong>The</strong>lightweight aluminum frame<strong>and</strong> low-profile design make the<strong>modules</strong> ideal for combiningin<strong>to</strong> multi-axis assembly <strong>and</strong>h<strong>and</strong>ling applications.CKR Compact ModulesCKR Compact Modules aredriven by a <strong>to</strong>othed belt <strong>to</strong>achieve <strong>fast</strong>er speeds <strong>and</strong>longer lengths. With lengthsover 5000 mm, CKR Modulesoffer nearly twice thestroke capability ofcompetitive <strong>modules</strong>.CKK <strong>and</strong> CKR CompactModules accelerate multi-pointwelding application.
9Typical ApplicationsCompact Modules find use in applications where high performanceis critical <strong>and</strong> a low profile is desired.MedicalPackagingAu<strong>to</strong>motiveSemiconduc<strong>to</strong>rDrug discoveryMicroarrayingLiquid dispensingMedical device manufacturingTray formersCase packingCar<strong>to</strong>nersComponents assemblyMachiningWeldingIon implantationTestingInspectionEngineer’s CornerBall Rail ® SystemWhat’s inside makesa difference. That’swhy Rexroth linearactua<strong>to</strong>rs are builtaround our Ball RailSystem. To offer thehighest payloadcapacities <strong>and</strong> thehighest speeds, weuse the best linearguide systemavailable. RexrothBall Rail Systems feature innovative block <strong>and</strong> racewaydesigns that allow higher speeds <strong>and</strong> a 30% increase indynamic load capacity.Our Ball Rail runner blocks also boast a revolutionarylubrication system that uses a foam insert <strong>to</strong> releaselubrication over time, virtually eliminating maintenance.Recommended lubrication is every 5 <strong>to</strong> 10 millionmeters—longer than the expected life of the equipmentin many applications. And with advanced sealingoptions, contamination isn’t an issue in keeping theunit running free <strong>and</strong> reliably.Optional ball chain technology provides smoothoperation <strong>and</strong> a noise reduction of up <strong>to</strong> 6 dBa—for thesmoothest, quietest running linear guides you’ll find.<strong>The</strong> use of two Ball Rail Systemsoptimizes running characteristics whilemoving heavy loads at high speeds, withreduced deflection in roll, pitch, <strong>and</strong> yaw.Rexroth Ball Rail Systems provide the foundation forour linear <strong>modules</strong>, offering better axial loading, quietperformance, <strong>and</strong> high load capacities.Type Guideway Drive Unit <strong>Linear</strong> ModuleCKKCKRBall Rail ® SystemBall Rail ® SystemPrecision Ball ScrewAssemblyToothed Belt DriveCompactModulesare availablein two mainstyles <strong>to</strong>meet a varietyof needs.
10Ball Rail Tables <strong>and</strong> Precision ModulesPSK Precision Modules<strong>and</strong> TKK Ball Rail ®Tables.From wafer fabs <strong>to</strong> au<strong>to</strong>motive assemblyRexroth PSK Precision Modules <strong>and</strong> TKK Ball Rail Tables representthe two extremes of linear <strong>motion</strong>, bracketing the <strong>Linear</strong> Modules<strong>and</strong> Compact Modules families: carrying heavier loads <strong>and</strong>achieving higher <strong>precision</strong> in a compact package. <strong>The</strong> PSK offershigh accuracy, low deflection, <strong>and</strong> an extremely small profile, whilethe TKK has twice the load capacity of the MKK family.PSK PrecisionModules offer <strong>fast</strong>travel <strong>and</strong> excellentpositioning.PSK Precision ModulesCertified for Class 10 cleanroomapplications, PSK PrecisionModules use a <strong>precision</strong> ballscrew <strong>and</strong> zero-backlash ballnut <strong>to</strong> achieve high accuracy atspeeds up <strong>to</strong> 1.6 m/s. Speed isalso enhanced with doublefloating bearings in thenondriven end—a st<strong>and</strong>ardfeature for Rexroth that is no<strong>to</strong>ffered by other manufacturers.<strong>The</strong> bot<strong>to</strong>m line is that PSKModules are up <strong>to</strong> 40% <strong>fast</strong>erthan other <strong>modules</strong> in theirsize range—with positioningaccuracy of 10 microns <strong>and</strong>repeatability of 5 microns.<strong>The</strong> machined steel baseprovides an accuratemounting reference <strong>and</strong>35% less deflection thancompetitive products—allowing precise axis alignment<strong>and</strong> high travel accuracy.To provide flexibility inintegrating the module in<strong>to</strong>equipment, mounting can beaccomplished either throughholes in the base or byclamping fixtures, anotheroption offered exclusivelyby Rexroth.PSK Precision Modules areavailable with one or twoaluminum or steel carriages,so you can get the best matchof weight <strong>and</strong> load capacity.Sealing is another area wherePSK Precision Modules shine—offering a higher level ofprotection than competitive<strong>modules</strong>. Precision Modulesinclude a stainless steel sealingstrip for excellent protectionagainst contamination inmetal cutting or biohazardousenvironments. <strong>The</strong> tightseal also allows a vacuum<strong>to</strong> be easily applied incleanroom applications.TKK Ball Rail TablesWe begin with a machined steelor aluminum baseplate <strong>and</strong> addtwo Ball Rail Systems <strong>and</strong> fourlong runner blocks <strong>to</strong> achievethe highest load <strong>and</strong> momentcapacities in the industry.Driven by large-diameter ballscrews for high thrust force<strong>and</strong> speed capabilities, TKKBall Rail Tables are designedfor loads up <strong>to</strong> 132,500 N <strong>and</strong>speeds up <strong>to</strong> 1.6 m/s.
11Typical ApplicationsChoose Precision Modules for applications that dem<strong>and</strong> exceptional<strong>precision</strong> <strong>and</strong> Ball Rail Tables for the big jobs.MedicalAu<strong>to</strong>motiveSemiconduc<strong>to</strong>r<strong>The</strong> TKK Ball Rail Tablesachieve high accuracy throughthe use of Class 7 ball screws<strong>and</strong> zero-backlash ball nuts.An optional bellows-stylecover offers excellent oil <strong>and</strong>contamination resistance.Switches can be mountedinternally for additionalprotection or externally foreasy access.Drug discoveryMicroarrayingLiquid dispensingMedical device manufacturingParts transferComponents assemblyMachiningWeldingIon implantationTestingInspection<strong>The</strong> combination of heavyload capability <strong>and</strong> positioningaccuracy in TKK Ball RailTables make the units idealfor increasing the flexibilityof au<strong>to</strong>motive assembly. A newgeneration of programmable<strong>to</strong>ols is providing new levels ofagility <strong>and</strong> flexibility <strong>to</strong> h<strong>and</strong>lea wider range of needs.Engineer’s CornerPrecision Ball ScrewsBall screwsefficiently convertrotary <strong>motion</strong> in<strong>to</strong>linear <strong>motion</strong>—allowing highspeeds, high loadcapacities, <strong>and</strong>precise positioning.And since Rexrothball screws give youthe performance ofa ground screw ata rolled screw price,we can pack moreperformance in<strong>to</strong>our <strong>modules</strong> at a better overall value <strong>to</strong> our cus<strong>to</strong>mers.Our 150,000 Dn rating is twice the industry norm,permitting the screws <strong>to</strong> achieve twice the speedwith no loss in <strong>precision</strong>.Ball screws offer <strong>fast</strong> transport <strong>and</strong> accurate positioning.<strong>The</strong>y combine high axial load capacity with high rigidity.Ball nuts feature internal ball recirculation for extrasmooth operation, while a unique lubrication system <strong>and</strong>high-contact seals keep dirt out <strong>and</strong> lubrication in forlong-term reliability.Precision manufacturing <strong>and</strong> an optimized ball racewaymake Rexroth ball screws exceptionally smooth <strong>and</strong>quiet running.Rexroth ball screws are known worldwide for theirconsistent high quality <strong>and</strong> smoothness. <strong>The</strong> sameengineering that makes them the ball screw of choiceinside a machine <strong>to</strong>ol also puts <strong>to</strong>p performance insideour PSK, CKK, MKK <strong>and</strong> TKK <strong>modules</strong>.Rexroth <strong>modules</strong> bringflexibility <strong>to</strong> numerousau<strong>to</strong>motive applications:body positioning, flexible<strong>to</strong>oling, <strong>and</strong> both heavy<strong>and</strong> light assembly.
12CMS: How <strong>to</strong> combine <strong>modules</strong><strong>Cartesian</strong> Motion Systems.<strong>Linear</strong> <strong>motion</strong> in multiple axes<strong>Cartesian</strong> Motion Systems (CMS) are formed by integratingRexroth Compact Modules <strong>and</strong> EcoDrive Cs servo mo<strong>to</strong>rs<strong>and</strong> drives in<strong>to</strong> 1-, 2-, or 3-axis robotic systems. We’ve taken thecomplexity out of designing such systems, helping you reducethe time required <strong>to</strong> design, specify, <strong>and</strong> install a design-fromscratchsolution.CMS on-lineSelection Tool <strong>and</strong>CAD Configura<strong>to</strong>rsave hours in thedesign cycle of<strong>Cartesian</strong> systems.<strong>Cartesian</strong> <strong>motion</strong> made easyTo fulfill a variety of needs,we’ve created 17 differentconfigurations with a variety ofsizes <strong>and</strong> orientations.With up <strong>to</strong> three axes, the CMSis designed for payloads up <strong>to</strong>45 kg, speeds up <strong>to</strong> 1.0 m/s,<strong>and</strong> acceleration rates up <strong>to</strong>15 m/s 2 . Depending on thechosen axis combination <strong>and</strong>size, the CMS can executestrokes up <strong>to</strong> 1000 mm in theX axis <strong>and</strong> 700 mm in the Y <strong>and</strong>Z axes. <strong>The</strong> range of <strong>motion</strong>provided makes the CMS idealfor pick-<strong>and</strong>-place applicationsin assembly cells <strong>and</strong> attransfer stations, as well asfor packaging, dispensing, <strong>and</strong>other h<strong>and</strong>ling applications.Complete, ready-<strong>to</strong>-go system<strong>The</strong> CMS combines CompactModules with mountingbrackets, servo mo<strong>to</strong>rs, drives,cables, cable management, <strong>and</strong>other necessary components <strong>to</strong>form a complete, ready-<strong>to</strong>installsystem with a variety ofcommunication interfaces. <strong>The</strong>system is pre-parameterized,so it is ready <strong>to</strong> “plug <strong>and</strong> play”in<strong>to</strong> your application,resulting in considerablereductions in installation <strong>and</strong>debugging times.Selection made easyOur CMS Selection Tooldrastically reduces the time <strong>and</strong>effort needed <strong>to</strong> size <strong>and</strong> select a<strong>Cartesian</strong> system. Instead ofsizing each axis - linear module,mo<strong>to</strong>r <strong>and</strong> drive—<strong>and</strong>specifying brackets <strong>and</strong> cablemanagement, engineers usethe CMS Selection Tool <strong>to</strong>select the appropriate CMSwithin minutes. Once theCMS is selected, a single clickgenerates a quote <strong>and</strong> sendsit <strong>to</strong> the fac<strong>to</strong>ry, saving thetime required <strong>to</strong> configurepart numbers <strong>and</strong> requestquotations for each component.Servo drives with a varietyof fieldbus connections<strong>The</strong> Compact Modulesare driven by RexrothEcoDrive Cs servo driveswith a power rating of 400or 750 W. <strong>The</strong>se economicaldrives will operate from 1- <strong>and</strong>3-phase supply networks withan input power of up <strong>to</strong> 230 V.<strong>The</strong> maintenance-free, highlydynamic mo<strong>to</strong>rs are available in
13two frame sizes. <strong>The</strong> high powerdensity within a compactenvelope—short overall length<strong>and</strong> minimized mo<strong>to</strong>r mountdimensions—is optimallymatched <strong>to</strong> the RexrothCompact Modules. <strong>The</strong> highIP65 protection rating allowsthe mo<strong>to</strong>rs <strong>to</strong> be used in widelyvarying process conditions.Equipped with comm<strong>and</strong>communication <strong>modules</strong> likethe SERCOS interface, ProfibusDP, CANopen or DeviceNet,the Rexroth drives integrateeasily in<strong>to</strong> different au<strong>to</strong>mationconcepts. Thanks <strong>to</strong> theiropen interfaces <strong>and</strong> UL <strong>and</strong>international certifications,the drives can be usedanywhere in the world; ourglobal presence guaranteeslocal support for all users.CMS solutions save youtime <strong>and</strong> moneySelecting a prebuilt CMS systemcan significantly simplify thetask of achieving a multi-axissolution, slashing the timerequired <strong>to</strong> design, spec, buy,assemble, <strong>and</strong> test a <strong>Cartesian</strong>system. While any make-versusbuydecision must fac<strong>to</strong>r thecosts <strong>and</strong> time required foryour specific circumstances,the table below shows a typicalinstance—<strong>and</strong> the nearly90% savings that accrue.Make versus buy analysisActivity Cus<strong>to</strong>m-built system Prebuilt systemCost Time Total cost Time Total cost($/hr) (hr) ($) (hr) ($)Design Concept 80 4 320 1 80Design 80 8 640 0 0Engineering Size/select products 80 3 240 0.5 40Issue RFQs 80 0.5 40 0.5 40Evaluate quotes/costs 80 2 160 1 80Purchasing Create BOM 30 2 60 0.5 15Set-up P/Ns 30 3 90 0.5 15Receive 30 2 60 0.5 15products/uncrateEngineering Assemble 60 8 480 0.5 30Test 60 2 120 1 60Debug/modify 60 4 240 0 0Re-test 60 2 120 0 0Run-in 60 4 240 0 044.5 $2,810 6 $375Get complete solutionsby combining linearactua<strong>to</strong>rs, SCARArobots, <strong>and</strong> conveyorsfor high productivity.Savings of prebuilt over cus<strong>to</strong>m-built 87% 87%
14Cus<strong>to</strong>m CapabilitiesCus<strong>to</strong>m <strong>Cartesian</strong> Systems…When your needs don't fit the parameters of our pre-configuredsystems, our cus<strong>to</strong>m <strong>Cartesian</strong> Systems save you time <strong>and</strong> money,<strong>to</strong>o. Heavy payload? Extended stroke? High speeds? We'll helpyou build any configuration you need, <strong>and</strong> our skilled applicationengineers will make sure you get it right the first time. Count on usnot only for linear actua<strong>to</strong>rs, but mo<strong>to</strong>rs, drives, <strong>and</strong> controllers.Have it your way<strong>The</strong> strength of our wideproduct offering meansthat we can help you cus<strong>to</strong>mizea <strong>Cartesian</strong> or Gantry system<strong>to</strong> fit your exact requirements,both technically <strong>and</strong>economically. And sincewe're experts at providingthe right linear <strong>motion</strong> system,we save you hours of preciousengineering time by pickingthe right <strong>modules</strong> <strong>and</strong> pairingthem with Rexroth drives <strong>and</strong>mo<strong>to</strong>rs for the absolute bestfit. And we can deliver this<strong>to</strong> you as a kit with a singlepart number, so you get up<strong>and</strong> running <strong>fast</strong>. In <strong>precision</strong><strong>motion</strong> control, no oneoutperforms Rexroth.Light <strong>to</strong> heavy, large <strong>to</strong> smallFor large gantry systems, turn <strong>to</strong>Rexroth <strong>Linear</strong> Modules (MKR,MKK, <strong>and</strong> MLR). With theirrigid aluminum extrusions,they can span long distanceswith minimal deflection.If your <strong>Cartesian</strong> applicationrequires a smaller footprintthan our CMS product line,the PSK Precision Module isthe solution with the smallestdimensions available. Despiteits small dimensions, the PSKdoesn’t compromise on loadcapacity. With an integralBall Rail ® System inside amachined steel frame, the PSKoffers high load capacity <strong>and</strong>excellent stiffness.For two-axis systems requiringmaximum load capacity <strong>and</strong> thehighest travel accuracy, the TKKBall Rail Table is the solution.With two Ball Rail Systems<strong>and</strong> large-diameter ball screwsmounted on a machined steelor aluminum base plate, youcan be sure that your heavyload,high-<strong>precision</strong>application can be h<strong>and</strong>ledby the Ball Rail Table.Count on ourapplication expertiseBosch Rexroth can also helpyou choose the best systemcomponents for your multi-axisapplication. Our applicationengineers are highlyexperienced in sizing, selecting,<strong>and</strong> optimizing multi-axissystems. Our FastAxis sizingsoftware allows us <strong>to</strong> quickly<strong>and</strong> confidently recommendthe most suitable solution <strong>to</strong>meet your performance targets.
15<strong>and</strong> complete controlBeyond linear <strong>modules</strong><strong>to</strong> complete controlCus<strong>to</strong>m systems don’t s<strong>to</strong>p withlinear actua<strong>to</strong>rs. Rexroth servodrives, controls, <strong>and</strong> mo<strong>to</strong>rs arethe perfect complement inachieving speed, accuracy, <strong>and</strong>reliability in single- <strong>and</strong> multiaxisapplication. As one of theworld’s foremost providers ofservo-based <strong>motion</strong> controlsystems, our tradition ofproduct excellence <strong>and</strong> ourlong-st<strong>and</strong>ing commitment <strong>to</strong>open systems allow us <strong>to</strong> offeryou the most flexibilityanywhere. With Rexroth drive<strong>and</strong> control electronics, you get<strong>precision</strong> <strong>motion</strong> control—along with easy installation,rapid commissioning with ouradvanced software, <strong>and</strong> longterm,reliable performance.EcoDrive: <strong>The</strong> industry-leadingcontrol platformFor heavy loads, high speeds,<strong>and</strong> long duty cycles, theEcoDrive servo drives <strong>and</strong> MKDmo<strong>to</strong>rs are known worldwidefor <strong>fast</strong> application <strong>and</strong> highperformance. <strong>The</strong>y are theperfect companions for MKK,MKR, MLR <strong>Linear</strong> Modules,TKK Ball Rail Tables, <strong>and</strong> CKRCompact Modules.<strong>The</strong> intelligent digital EcoDriveservo drives, for applicationsfrom 1 kW <strong>to</strong> 24 kW, arethe de fac<strong>to</strong> st<strong>and</strong>ard for<strong>motion</strong> control. With supportfor all common fieldbuspro<strong>to</strong>cols, EcoDrive offersintegrated technology functions<strong>and</strong> the highest speeds <strong>and</strong>positioning accuracy. Andwith simple installation, <strong>fast</strong>commissioning, <strong>and</strong> exceptionalperformance, the drives are theeconomical solution for linear<strong>motion</strong> control.Perfect for st<strong>and</strong>ard applications,MKD synchronous mo<strong>to</strong>rsfeature <strong>to</strong>rques from 3.5 <strong>to</strong>637 in-lb <strong>and</strong> speeds up <strong>to</strong>9000 rpm. A built-in resolveroffers high-resolution singleturn<strong>and</strong> absolute valueencoders with data memoryfor mo<strong>to</strong>r parameters.Compact solutionsfor high-performanceFor PSK Precision Modules,CKK Compact Modules,<strong>and</strong> the CMS system,EcoDrive Cs servo drives<strong>and</strong> MSM mo<strong>to</strong>rs give bigperformance in a small package.<strong>The</strong> EcoDrive Cs control unitsare available in four powerratings for applications under1 kW <strong>and</strong> all the st<strong>and</strong>ardfeatures of high-performancedigital drives. <strong>The</strong>y integrateall power supply, control <strong>and</strong>regulation electronics in thesmallest space.<strong>The</strong> MSM maintenance-free,compact mo<strong>to</strong>rs are availablein four sizes. <strong>The</strong> high powerdensity, short overall length<strong>and</strong> reduced flange dimensionsearmark them for machines inhighly dynamic processes.<strong>The</strong> enhanced type IP65 mo<strong>to</strong>rprotection allows them <strong>to</strong> beused in a wide variety of processenvironments. <strong>The</strong> mo<strong>to</strong>rsare available with or withoutholding brake, with incrementalor absolute encoder, <strong>and</strong> keyedor keyless shaft.
<strong>Linear</strong> ModulesCKK• Precision ball screw drive• Dual Ball Rail system• High load capacity incompact designCKR• Toothed belt drive• Dual Ball Rail system• Speed up <strong>to</strong> 5 m/sCMS• 1, 2 <strong>and</strong> 3-axis Systems• CKK Compact Modules<strong>and</strong> EcoDrive Cs mo<strong>to</strong>rs<strong>and</strong> drives• Reduced design <strong>and</strong>assembly timeAssembly• Exceptional pick-<strong>and</strong>-placeperformance• CKK <strong>modules</strong> for X-Y movement• Fast, accurate positioningMKK• Precision ball screw drive• Single Ball Rail system• High positioning accuracyMKR• Toothed belt drive• Single Ball Rail system• Cus<strong>to</strong>m lengths up <strong>to</strong>12,000 mmMLR• Toothed belt drive• Cam roller guide system• Speeds up <strong>to</strong> 10 m/sMedical• Cleanroom certified• Transport <strong>and</strong> bottling• Drug discovery• MicroarrayingPSK• Machined steel base• Precision ball screw drive• Integral rail guide system• High <strong>precision</strong>,high stiffnessTKK• Aluminum or steelmachined base• Precision ball screw drive• Dual Ball Rail system• Dynamic loads up <strong>to</strong>180,600 NCus<strong>to</strong>m Configurations• Have it your way• Multi-axis <strong>Cartesian</strong> or gantry• Wide range of hardwarefor <strong>fast</strong> configuration• Drives <strong>and</strong> mo<strong>to</strong>rsAu<strong>to</strong>motive• Body positioning withTKK table• Support for flexible,programmable <strong>to</strong>ols• Machine <strong>and</strong> weldingoperations• Parts transferElectric Drives <strong>and</strong> ControlsFor MKK, MLR, MKR, TKK, CKRFor PSK, CKK, CMSMKD• Synchronous mo<strong>to</strong>rs forst<strong>and</strong>ard applications• Nominal <strong>to</strong>rque from 3.5<strong>to</strong> 637 in-lb• Natural convection <strong>and</strong>surface ventilated• Nominal speed up <strong>to</strong> 9000 rpmEcoDrive• Compact, cost-effectivefor applications from 1 kW<strong>to</strong> 24 kW• Built-in <strong>motion</strong> control forindexing <strong>and</strong> otherstraightforward <strong>motion</strong>applications• Wide choice of interfacesMSM• Maintenance-free mo<strong>to</strong>rs• High power density• 4 sizes• Absolute or incrementalencodersEcoDrive Cs• Cost-effective drive/power supplyfor applications under 1 kW• Compact design, with st<strong>and</strong>arddigital drive features• Wide choice of interfaces• Rapid commissioning withDriveTop softwareFor complete information, visit www.boschrexroth-us.com
Flexibility <strong>to</strong> build cus<strong>to</strong>m solutions…A wide variety of hardware options make it simple <strong>to</strong> create cus<strong>to</strong>m multi-axis solutions. One-of-a-kind matched setsoptimize the assembly’s cost-effectiveness. Plus, the easy, straightforward integration <strong>and</strong> assembly save time.Possible multi-axis configurations…2X–Y X–Z 2X–Y–Z 2X–2Y–Zmatch perfectly with our aluminum framing system…<strong>and</strong> the hardware that lets you put it all <strong>to</strong>gether.
Bosch Rexroth Corporation<strong>Linear</strong> Motion <strong>and</strong>Assembly Technologies14001 South Lakes DriveCharlotte, NC 28273Telephone (800) 438-5983Facsimile (704) 583-0523Bosch Rexroth Corporation<strong>Linear</strong> Motion <strong>and</strong>Assembly Technologies816 E. Third StreetBuchanan, MI 49107Telephone (269) 695-0151Facsimile (269) 695-5363www.boschrexroth-us.comInternational offices:Asia:ChinaIndiaJapanMalaysiaAustraliaRussiaSingaporeSouth KoreaEurope:Austria Netherl<strong>and</strong>sBelgium NorwayBulgaria Pol<strong>and</strong>Czech Republic PortugalDenmark RomaniaFinl<strong>and</strong> SlovakiaFrance SpainGermany SwedenGreece Switzerl<strong>and</strong>Hungary TurkeyItalyUkraineUnited KingdomNorth America:Canada United StatesMexicoSouth America:Argentina VenezuelaBrazilFac<strong>to</strong>ry Au<strong>to</strong>mationRegional sales offices:CentralBosch Rexroth Corporation5150 Prairie S<strong>to</strong>ne ParkwayHoffman Estates, IL 60192-3707Telephone (847) 645-3600Facsimile (847) 645-0804Great LakesBosch Rexroth Corporation1701 Harmon RoadAuburn Hills, MI 48326-1549Telephone (248) 393-3330Facsimile (248) 393-2893NortheastBosch Rexroth Corporation99 Rainbow RoadEast Granby, CT 06026-0000Telephone (860) 844-8377Facsimile (860) 844-8595Bosch Rexroth Corporation2315 City Line RoadBethlehem, PA 18017-2131Telephone (610) 694-8300Facsimile (610) 694-8467SoutheastBosch Rexroth Corporation14001 South Lake DriveCharlotte, NC 28273-5544Telephone (704) 583-4338Facsimile (704) 583-0523U.S. business unit offices:Bosch Rexroth CorporationCorporate Headquarters5150 Prairie S<strong>to</strong>ne ParkwayHoffman Estates, IL 60192-3707Telephone (847) 645-3600Facsimile (847) 645-0804Bosch Rexroth CorporationIndustrial Hydraulics2315 City Line RoadBethlehem, PA 18017-2131Telephone (610) 694-8300Facsimile (610) 694-8467Bosch Rexroth CorporationElectric Drives <strong>and</strong> Controls5150 Prairie S<strong>to</strong>ne ParkwayHoffman Estates, IL 60192-3707Telephone (847) 645-3600Facsimile (847) 645-6201Bosch Rexroth CorporationPneumatics1953 Mercer RoadLexing<strong>to</strong>n, KY 40511-1021Telephone (859) 254-8031Facsimile (859) 254-4188Bosch Rexroth CorporationService Au<strong>to</strong>mation5150 Prairie S<strong>to</strong>ne ParkwayHoffman Estates, IL 60192-3707Telephone (847) 645-3600Facsimile (847) 645-08042315 City Line RoadBethlehem, PA 18017-2131Telephone (610) 694-8300Facsimile (610) 694-8467Bosch Rexroth CorporationMobile Hydraulics145 Southchase BoulevardFountain Inn, SC 29644-9018Telephone (864) 967-2777Facsimile (864) 962-5338©2004 Bosch Rexroth CorporationWestBosch Rexroth Corporation11 GoddardIrvine, CA 92618-4600Telephone (949) 450-2777Facsimile (949) 450-2790Printed in the United StatesPublication No.8981 500 331 9/04