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Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
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MP-Series™ Integrated Linear Stages
Mike WoelfelProduct Marketing Manager/Kinetix Linear Motion
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 2
Topics
1. Product Line Overview
2. Application
3. Maintenance
4. Commercial Information
2. Setup and Programming
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 3
Topics
1. Product Line Overview
2. Application
3. Maintenance
4. Commercial Information
2. Setup and Programming
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 4
Product Line Overview
• A “linear stage” is a linear actuator that is designed to support heavy loads and tolerate moment loads.
• To achieve this goal, linear stages have two parallel high-precision linear guide bearings.
Linear guide bearings
Tensioner for Belt Drive
Carriage Load Plate
Carriage Fastened to Belt
Extruded Aluminum Housing
Nylon Roller Bearings
Synchronous (Timing) Belt
“Rod-less Actuators” are similar to linear stages except they use a single linear bearing or nylon roller bearings that have much lower load capacity
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 5
Product Line Overview
• Linear stages can be driven by ballscrews, synchronous timing belts, or linear motors.• Synchronous timing belts and linear motors are typically used when applications require high
speeds and relatively low force.• Timing belt systems can achieve speeds up to 3 meters/sec. Linear motor system can achieve
speeds up to 5 meters/sec.• Because the cost of linear motor components continues to drop and they can achieve higher
speeds than timing belts, MP-SeriesTM Integrated Linear Stages are designed with ballscrew and linear motor technology.
Linear motor driven MP-SeriesTM Linear
Stage
Ballscrew driven MP-SeriesTM Linear Stage
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 6
Product Line Overview
• You may not know if you need a linear motor or ballscrew driven linear stage - only the application requirements.
• MP-SeriesTM Integrated Linear Stages allow the designer to select a linear actuator based on the desired performance and not worry about the internal drive mechanism.
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 7
Product Line Overview
• Even though they can carry very heavy loads, most linear stages are designed for high precision applications in clean environments.
• MP-SeriesTM Integrated Linear Stages are design for industrial environments and industrial applications
MP-Series Direct Drive (linear motor driven) Linear Stage
Unique extruded base lowers cost and maintains structural integrity
Cable track module that can be replaced in <15 minutes
Strip seal provides IP30 environmental
rating
Heavy duty cable and connectors compatible with MP-Series accessories
Access to grease ports without disassembly
Home-to-hard-stop eliminates limit and home switches
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 8
Product Line Overview
• MP-SeriesTM Integrated Linear Stages are designed for easy integration• Mounting can be accomplish using “toe-clips”, T-nuts, and thru-holes in the
base of the stage.• XY configurations can be created using existing mounting holes and adapter
plates will be available in the future for additional configurations.
XY “Stacked” System using existing mounting holes in
carriage and base of stages
Adapter plates (future) will allow “cantilever”
configurations
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 9
Product Line Overview
Design Phase Cost Savings Eliminates mechanical design, selection, and integration of multiple
components from different suppliers Reliable, tested performance from single integrated actuator Comprehensive support from Rockwell Automation’s sizing and selection tools
– Integrated Architecture Builder and Motion Analyzer Assembly Phase Cost Savings
Eliminate assembly of motor, coupler, adapter, and ballscrew Eliminate installation, wiring, and alignment of home and over-travel sensors
Commissioning Phase Cost Savings Complete integration with RSLogix 5000 software
Support Phase Cost Savings Integrated device eliminates reliability problems that occur when products from
separate manufacturers are bolted together. Pre-calculation of lubrication intervals based on number of cycles, speed, and
acceleration alerts user to periodic maintenance (future)
MP-Series Integrated Linear Stages simplify...
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 10
Product Line Overview
• Custom linear stage designs and linear motor components are available from the Rockwell Automation/Anorad Division
Lengths beyond 2 meters
Custom stage and tooling
Linear motor components
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 11
Product Line Overview
• MP-SeriesTM Integrated Linear Stages are available in 3 frame sizes (base widths): 150 mm, 200 mm, and 250 mm.
• Stroke lengths up to 2 meters are available
150 mm frame size MPAS-x6xxxx
200 mm frame size MPAS-x8xxxx
250 mm frame size MPAS-x8xxxx
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 12
Technical – Internal Construction
Direct Drive Linear Stages
• 5 micron resolution magnetic linear encoder (not considered field replaceable)
• Allows speeds up to 5 meters/sec with Kinetix 2000, Kinetix 6000, and Ultra3000 servo drives
Heavy duty bumper springs (see manual for energy absorption rating)
Rollers in carriage support top cover
Linear motor magnet track (not considered field replaceable)
• Replaceable cable track module
• Includes cable leads with MPF/MPS style connectors
Only direct drive linear stages are available with and without cover/seal systemPrecision linear guide bearings (not field replaceable)
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 13
Technical – Internal Construction
Ballscrew Linear Stages
Ballscrew in 5 mm/rev and 20 mm/rev lead
Not available uncovered due to potential for grease to be thrown from ballscrew
Jaw style flexible coupler (field replaceable)
Motor Catalog NumberScrew Lead
MPAS Ballscrew Linear Stage
MPLS-A220H-VJ42AA 20 mm 230V w/o brakeMPLS-A220H-VJ44AA 20 mm 230V w/brakeMPLS-B220H-VJ42AA 20 mm 460V w/o brakeMPLS-B220H-VJ44AA 20 mm 460V w/brakeMPLS-A210E-VJ42AA 5 mm 230V w/o brakeMPLS-A210E-VJ44AA 5 mm 230V w/brakeMPLS-B210E-VJ42AA 5 mm 460V w/o brakeMPLS-B210E-VJ44AA 5 mm 460V w/brake
MP-Series servo motor with absolute multi-turn encoder
programmed to limit speed and torque to prevent ballscrew damage (field replaceable)
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 14
• MP-Series Integrated Linear Stage Catalog Number Key
Product Line Overview
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 15
150mm Frame Size Performance
A6xxx1-V05SxA 5 200 (7.9) 521 (117) 1212 (272)
A6xxx2-V20SxA 20 1124 (44.3) 462 (104) 968 (218)
B6xxx1-V05SxA 5 200 (7.9) 521 (117) 1212 (273)
B6xxx2-V20SxA 20 1124 (44.3) 462 (104) 968 (218)
A6xxxB-ALMO2C (No Cover)
105 (24) 359 (81)
A6xxxB-ALMS2C (Covered)
83 (19) 312 (70)
Screw Lead mm
N/A
50um + 50um/300mm
Drive Mechanism and Feedback Type
Ballscrew with absolute multi-
turn rotary encoder
±15µm 100µm + 20µm/m
120-660
Linear Motor with incremental
linear encoder
± 60µm
Catalog Number MPAS-
Stroke
Length1 mmMax. Velocity2
mm/sec (in./s)
Cont. Stall Force N (lbs)
Peak Stall Force N (lbs)
120-11405000 (196.9)
Bi-directional Repeatability
Accuracy
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 16
200mm Frame Size Performance
A8xxx1-V05SxA 5 200 (7.9) 521 (117) 1212 (273)
A8xxx2-V20SxA 20 1124 (44.3) 462 (104) 968 (218)
B8xxx1-V05SxA 5 200 (7.9) 521 (117) 1212 (273)
B8xxx2-V20SxA 20 1124 (44.3) 462 (104) 968 (218)
A8xxxE-ALMO2C (No Cover)
189 (43) 456 (103)
A8xxxE-ALMS2C (Covered)
159 (36) 399 (90)
B8xxxF-ALMO2C (No Cover)
189 (43) 456 (103)
B8xxxF-ALMS2C (Covered)
159 (36) 399 (90)
120-1020
140-19405000 (196.9)
50um + 50um/300mm
100µm + 20µm/m
Screw Lead mm
N/A
Ballscrew with absolute multi-
turn rotary encoder
± 60µm
Linear Motor with incremental
linear encoder±15µm
Drive Mechanism and Feedback Type
Catalog Number MPAS-
Stroke
Length1 mmMax. Velocity2
mm/sec (in./s)
Cont. Stall Force N (lbs)
Peak Stall Force N (lbs)
Bi-directional Repeatability
Accuracy
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 17
250mm Frame Size Performance
A9xxx1-V05SxA 5 200 (7.9) 521 (117) 1212 (273)
A9xxx2-V20SxA 20 1124 (44.3) 462 (104) 968 (218)
B9xxx1-V05SxA 5 200 (7.9) 521 (117) 1212 (273)
B9xxx2-V20SxA 20 1124 (44.3) 462 (104) 968 (218)
A9xxxK-ALMO2C (No Cover)
285 (64) 680 (153)
A9xxxK-ALMS2C (Covered)
245 (55) 601 (135)
B9xxxL-ALMO2C (No Cover)
285 (64) 680 (153)
B9xxxL-ALMS2C (Covered)
245 (55) 601 (135)
N/ALinear Motor with
incremental linear encoder
±15µm 100µm + 20µm/m140-19405000 (196.9)
120-1020
Screw Lead mm
Ballscrew with absolute multi-
turn rotary encoder
Drive Mechanism and Feedback Type
± 60µm
Catalog Number MPAS-
Stroke
Length1 mmMax. Velocity2
mm/sec (in./s)
50um + 50um/300mm
Cont. Stall Force N (lbs)
Peak Stall Force N (lbs)
Bi-directional Repeatability
Accuracy
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 18
Force and speed available from Allen-Bradley linear actuators
MPAS Direct Drive
Hig
her S
peed
sH
ighe
r Spe
eds
Higher Forces
Higher Forces
MPAI
Max. SpeedMax. Cont.
Force23 in/sec
(580 mm/sec)2000 lbs-force
(8900 N)
MPAS Ball-screw
Max. SpeedMax. Cont.
Force
44 in/sec(1124 mm/sec)
117 lbs-force(521 N)
MPAS Direct Drive
Max. SpeedMax. Cont.
Force
197 in/sec(5000 mm/sec)
65 lbs-force(285 N)
MPAI Screw Driven (Future)
Product Line Overview
MPAS Screw Driven
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 19
• Wide range of features− 230V and 460V versions− Direct drive (linear motor) and ballscrew versions− Brake motors available on ballscrew versions− Stroke lengths up to 2 meters− IP30 Environmental rating− High resolution multi-turn absolute encoders on ballscrew versions− Incremental linear encoders on direct drive linear stages− Field replaceable cable track system on direct drive linear stages
• Approvals− UL and CSA listed− CE marked for applicable directives− Complies with European RoHS (Restriction of Hazardous Substances)
requirements
• Allen-Bradley quality and support− Globally supported and built to order in USA (no more than 15 business day lead-
time)− Fully supported by Rockwell Automation Logix controllers and Kinetix servo
systems− Uses standard Allen-Bradley bulletin 2090 motor power and feedback cables
MP-SeriesTM Integrated Linear Stages Summary
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 20
Topics
1. Product Line Overview
2. Application
3. Maintenance
4. Commercial Information
2. Setup and Programming
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 21
Application – Selection and Sizing
• From a sizing perspective, MP-SeriesTM Integrated Linear Stages are virtually identical to MP-SeriesTM rotary servo motors except the performance parameters are expressed in linear units:– Peak Force– Continuous Force– Linear Speed
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 22
• Sizing MPAS linear stage system is done using Motion Analyzer software (version 4.4 or later)
Instead of creating a user defined linear actuator, just select “Allen-Bradley Integrated Linear Stage”
Application – Selection and Sizing
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 23
• Mechanism Select mounting
option
Direct drive, ballscrew, or either
Application – Selection and Sizing
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 24
Motion Analyzer presents the data as you would expect for a rotary servo motor except the performance is shown in linear units
Application – Selection and Sizing
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 25
Motion Analyzer estimates the life of linear bearings, ballscrew, strip seals, and cable track
Application – Selection and Sizing
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 26
Typical Applications
CartoningCartoning DispensingDispensing Small AssemblySmall Assembly
Life ScienceLife ScienceLarge AssemblyLarge Assembly Electronic Inspection &Electronic Inspection &AssemblyAssembly
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 27
Application – Mechanical Integration
Actuator Product Specifications:1. Actuator type: Direct drive linear motion.2. Stage travel direction: See attached diagram below.3. Moving slide temperature: 80°C (176°F) max.4. Total moving mass: 6.2 kg (13.6 lb)*5. Total static friction: < 22.24 N (5 lb) (open), < 31.13 N (7 lb) (sealed and covered).6. Operating ambient temperature: 0°C to 40°C (32°F to 104°F).7. Storage ambient temperature: -30°C to 70°C (-22°F to 158°F).8. Relative humidity: 5% to 95% non-condensing.9. Liquid / dust protection: IP30 (for covered unit only).10. Vibration: 0.1 grms/v Hz, 30 to 2000 Hz.11. Repeatability : ± 15 µ m12. Accuracy : 100 µ m + 20 µm per meter (at 20 °C)13. Straightness : 10 µm + 50 m/m14. Flatness : 10 µm + 50 m/m15. Static Moments Pitch 268 N-m Yaw 311 N-m Roll 92 N-m16. Static Loads Radial 5,506 N Reverse Radial 2,367 N Lateral 2,753 N17. Mechanical stop/Bumpers: Potential Energy 37.3 Joules (330 in-lb)18. Warranty: a) Strip Seals : 10 Million cycles or 10,000 km in clean dry non-contaminating envirornment b) Bearings : 10,000 km or 1 year with a max load of 25 lb centered on slide, 1 meter travel in clean dry non-contaminating envirornment with lubrication intervals every 5000 km or three months c) Cables: 10 Million Cycles
A SIZE SHEET 2 OF 5
*Moving mass includes the slide assembly and motor coil
10000004249DOCUMENT NUMBER
DESCRIPTION00
MPAS-A6xxxB-ALMx2C,ESEVER.
(+)
(-)
N N0 105 359
0.75 87 3411.07 81 3352.00 69 3233.40 55 553.87 0 0
N N0.00 105 3590.75 87 3411.07 81 3353.40 55 3094.57 45 2994.98 42 2965.00 42 2955.00 0 0
Note: Nm torque values shown are converted from tested lb-in data.
A SIZE SHEET 4 OF 5
Fcont 115V
SPEED mm/sec
Fpeak 115V
SPEED mm/sec
FORCE (Open)
FORCE (Open)Fcont 230V
Fpeak 230V
DOCUMENT NUMBER
10000004249
00DESCRIPTION
MPAS-A6xxxB-ALMx2C,ESEVER.
MPAS-A6xxxB-ALMO2C Performance with 2094-AM01 at 230 VAC 3 phase Converter Input and with 2093-AM01 at 115 VAC 1 phase input,
40C Actuator Ambient(See note for continuous performance)
0
50
100
150
200
250
300
350
400
0 1 2 3 4 5 6
SPEED (m/sec)
Fo
rce
(N
)(1
.0 N
= 0
.22
48
lb)
Fpeak 115VFcont 115VFpeak 230VFcont 230V
Calculated Performance Chart
Stage without cover
Engineering Documentation for MP-Series Integrated Linear Stages
ESM (Engineering Specification – Mechanical) Provides dimensions and mounting information
ESE (Engineering Specification – Electrical) Provides performance and electrical information
Available on RA web-site in August
Solid model CAD files
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 28
Topics
1. Product Line Overview
2. Application
3. Maintenance
4. Commercial Information
2. Setup and Programming
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 29
Setup with Logix/Kinetix/Ultra System
• RSLogix 5000 Version 16 with motion database version 4.6• Kinetix 6000 and Kinetix 2000 Servo Drives with firmware version 1.96.06• SERCOS and non-SERCOS Ultra3000 Servo Drives with firmware
version 1.52• MP-Series Integrated Linear Stages users manual provides instructions
for setting RSLogix 5000 motor properties• Use the linear stage tuning procedure described in the users manual• Use home-to-current homing mode
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 30
Setup with RSLogix5000
• Settings for the Drive/Motor Tab
Table from linear stage
users manual
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 31
Topics
1. Product Line Overview
2. Application
3. Maintenance
4. Commercial Information
2. Setup and Programming
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 32
Maintenance
• Replaceable components include:– Strip seals– Cable track module– Top and side covers– Rotary motors
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 33
Bearing lubrication ports (x4)
Maintenance
• Lubrication must be performed on linear bearings– Additional ballscrew lubrication port provided on ballscrew style MPAS– Requires grease gun kit– Greasing intervals and quantity of grease are specified in users manual
Direct Drive Linear Stage
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 34
Topics
1. Product Line Overview
2. Application
3. Maintenance
4. Commercial Information
2. Setup and Programming
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 35
Commercial Information
• Product launch: August 6th, 2007• Look for additional information and support materials:
– Selection Guide and User’s Manual– Product Profile– ESE and ESM drawings– Logix motion database