The Drive & Control Company

Compact Modules CKRwith Ball Rail Systemsand Toothed Belt Drive

RE 82 615/2003-04

2

Rexroth Linear Motion Technology

Ball Rail Systems Standard Ball Rail SystemsSuper Ball Rail SystemsBall Rail Systems with aluminium Runner BlockHigh-Speed Ball Rail SystemsCorrosion-resistant Ball Rail SystemsWide Ball Rail Systems

Ball Rail Systems with Integrated Measuring SystemClamp and Brake Units for Ball Rail SystemsRacks for Ball Rail SystemsMiniature Ball Rail SystemsCam Roller Guides

Roller Rail Systems Standard Roller Rail SystemsWide Roller Rail SystemsHigh-load Roller Rail SystemsRoller Rail Systems with Integrated Measuring SystemClamp and Brake Units for Roller Rail SystemsRacks for Roller Rail Systems

Linear Bushings and Shafts Linear Bushings, Linear Sets,Shafts, Shaft Support Rails, Shaft Support Blocks

Ball Transfer UnitsTraditional Technical Parts

Ball Screw Assemblies

Linear Motion Systems Linear Motion Slides – Ball Screw– Toothed Belt

Linear Modules – Ball Screw– Toothed Belt– Gear Rack– Pneumatic Drive– Linear Motor

Compact Modules – Ball Screw– Toothed Belt– Linear Motor

Precision Modules – Ball Screw

Ball Rail Tables – Ball Screw– Linear Motor

Controllers, Motors, Electrical Accessories

Elektric Cylinders

RE 82 615/2003-04

3

Compact Modules CKR

RE 82 615/2003-04

A Single Solution for Many Applications 4

Product Overview (General) 6

Product Overview with Load Capacities 10

Construction 12

Technical Data 14

Calculations 17

CKR 12-90 18– Components and Performance Data 18– Dimensional Drawings 20

CKR 15-110 22– Components and Performance Data 22– Dimensional Drawings 24

CKR 20-145 26– Components and Performance Data 26

– Dimensional Drawings 28

Switch Mounting 30

Servomotors 32

Mounting Accessories and Instructions 34

Lubrication Connection 35

Documentation 36

Ordering Examples 38

Inquiry/Order Form 39

Compact Modules CKR

4RE 82 615/2003-04

A Single Solution forMany Applications

• Driving

• Transporting

• Positioning

The Applications

Length

Load Capacities and Moments

Static Loading

Speed

Accessories

Documentation

Complete SystemsIncluding Drive Unit

Switch Mounting

Height

5 RE 82 615/2003-04

The Solution

RexrothCompact Modules

Servomotor Type MKD or MSMwith LP Gear Reducer (plus Control)

Switching without Switch Cam overthe Entire Travel Range

Clamping Fixtures, Motor Mounts,Connection Plates, Connection Elements

Frictional TorqueFrictional Load Measurements, Lead DeviationPositioning Accuracy

40 mm to 65 mm

up to 5,500 mm

Load Capacity C up to 56,530 NLongitudinal Moments ML up to 2,820 NmTorsional Moments Mt up to 1,910 Nm

up to 200 kg

up to 5 m/s

Compact Modules CKR

6RE 82 615/2003-04

Construction

– Extremely compact precision aluminum profile (main base structure)with two integrated Ball Rail Systems for optimal movement of heavyloads at high speeds

– Ready-to-install Compact Modules in selectable lengths up to Lmax

– Short or long aluminum carriage lengths available, depending onapplication load

– Driven by a pre-tensioned, steel-cord reinforced polyurethanetoothed belt

Optional Components

– Maintenance-free digital servo drives with integrated brake andpre-installed feedback

– Gear Reducer type LP

– REED or HALL sensor switches available

– Socket with terminals for connecting switches

– Aluminum profile cable duct for easy mounting of switches

Compact Modules are precision, ready-to-install linear systemsoffering high performance within a compact envelope–dimensions andselectable length, combined with an economical price-to-performanceratio and fast delivery

Product Overview

Optimal movement, high loadcapacity, high rigidity throughtwo integrated, pre-loaded ballrail guides

High travel speed, with highprecision and low noise,lengths up to 5,500 mm

Identical outer dimensions, matchingaccessories and add-on componentsto (ball screw driven) Type CKKCompact Modules

7 RE 82 615/2003-04

Pilot bore and tapped mounting holes for simplemotor installation

Adjustable switches over the entire travel range;switch activation by magnet built into carriage

Belt guided by aluminum channel whichseals out debris and contaminants

Economical maintenance ofthe Ball Rail Systems throughcentralized lubrication (grease)system. Acccess ports on topof carriage and either sideof extrusion

Precision alignment and securemounting of attachments thanks tothreaded bores and dowel pin holesin the carriage

Idler (non-drive) end with integral belttensioning system. Pulley ball bearingsare lubricated for life

Gear Reducer: A variety of gear ratios allow anoptimal match between the load and the drivemotor inertia

Ratio i = 3i = 5i = 10

Compact Modules CKR

8RE 82 615/2003-04

Product Overview

MKD 25B-144-KG1MKD 41B-144 KG1MKD 71B-061 KG1

MSM 030 CMSM 040 B

Digital ServomotorType MSM

Digital ServomotorType MKD

Motor SelectionBased on the drive and control system

To provide a cost-effective solution for everycustomer application, several motor/drivecombinations are offered.

When sizing the module, always take themotor-drive combination into consideration.

9 RE 82 615/2003-04

DKC

Digital Drive UnitECODRIVE

The cost-effective solution forsingle- and multi-axis systems

Compact Modules are available completewith motor, drive unit, and control.

DKC

Digital Drive UnitECODRIVE Cs

Compact, dynamic solutionfor the lower end of theperformance range.

Compact Modules CKR

10RE 82 615/2003-04

Type Overview with Load CapacitiesType Designation (size)Compact Modules are identified bydesignating the Type and the Size.

Respective structures without drive alsocomply with type and size designation

Type Guideway Drive Unit Compact Module

CKR

RexrothCompactModule

Ball Rail System Toothed Belt Drive

Type Size

C K RSystem = C = Compact Module

Guideway = K = Ball Rail Systems

Drive = R = Toothed Belt Drive

Dimensionsof guideway =

Framedimensions =

Compact Module (Example) = 20-145

(mm)

A

11 RE 82 615/2003-04

Overview of Compact Moduleswith permissible loads

CKR 20-145 145 x 65 34,800 56,530

CKR 12-90 90 x 40 4,620 7,500

In consideration of the desired operatinglife, general loads up to 20% of thedynamic values (C, Mt, ML ) have beenshown as acceptable.

Suitable Loads(recommended value on the bases ofpast experience)

Compact Module Dimensions A x H (mm) Dynamic Load Capacity C (N)

CKR 15-110 110 x 50 14,000 22,740

In this respect, the following must not beexceeded:

– The maximum permissible load

– The permissible drive torque

– The permissible speed

short carriage long carriage

H

A

C

CCL

C

Note: All Compact Modules are also available without a drive unit.

Compact Modules CKR

12RE 82 615/2003-04

StructureStructure1 Toothed Belt

2 Drive End Assembly

3 Carriage Versions

• Short carriage versionwith two runner blocks

• Long carriage versionwith four runner blocks

4 Main Body

5 Tensioning End Unit Assembly(Idler End)

Accessories:

6 Switch

7 Cable Duct

8 Sockets/Plugs

11 Motor

12 Gear Reducer type LP

8

6

7

34

2

11

12

1

5

13 RE 82 615/2003-04

Construction ofGear Reducer LPFor all Compact Modules, a planetarygearbox can be installed via a flange. Theflange serves as a mounting point for thegearbox to the Compact Module. Thisdirect connection eliminates the need fora coupling, thereby minimizing torsionaldeflection.

Different gear ratios are available:i = 3 (only for CKR 20-145)i = 5i = 10

1 Servomotor2 Gear Reducer3 Flange4 Drive End Assembly5 Compact Module Base Structure

2

1

5

4

3

Compact Modules CKR

14RE 82 615/2003-04

Technical Data

E = 70,000 N/mm2Modulus of Elasticity E

General Technical DataLoad capacities and moments

Compact Carriage Maximum Permissible Forces Maximum Permissible Moments

Module Length Fy1 Fy2 FX Mt ML

(N) (N) (N) (Nm) (Nm)

102 4,620 4,120 1,195 110 16

156 7,500 6,700 2,170 180 210

170 10,760 5,380 3,120 170 40

215 17,480 8,740 5,060 280 370

180 26,760 13,380 7,760 580 130

240 43,470 21,730 12,600 950 1,080

Maximum permissible loads

Compact Carriage Belt Dynamic Dynamic Planar Moment Moved Maximum Specific

Module Length Type Load Capacity C Moments of Inertia Mass Length Belt Stretch

of Guideway Mt ML Ix Iy mb Lmax Cspec

(N) (Nm) (Nm) (cm4) (cm4) (kg) (mm) (N · m)/mm

CKR 20-145

CKR 15-110

CKR 12-90

CKR 12-90

CKR 15-110

CKR 20-145

102 4,620 110 16

156 7,500 360 240

170 14,000 350 80

215 22,740 570 960

180 34,800 1,170 260

240 56,530 1,910 2,820

12.81 115.3 0.50 3,000 350

32.68 282.9 0.87 4,500 1,050

87.50 903.9 1.67 5,500 1,225

AT 3

ATL 5

AT 5

Lengths over Lmax (for CKR 12-90 and CKR 15-110) available on request. See ordering example for length calculation.

Mass

Compact Module Carriage Drive Type Mass Additional MassLength (kg) Gear Reducer LP(mm) (kg)

102

156

170

215

180

240

CKR 12-90

CKR 15-110

CKR 20-145

without driveDrive i = 1without driveDrive i = 1without driveDrive i = 1without driveDrive i = 1without driveDrive i = 1without driveDrive i = 1

0.0045 · L + 0.790.0045 · L + 0.990.0045 · L + 0.980.0045 · L + 1.180.0075 · L + 1.650.0075 · L + 1.910.0075 · L + 1.900.0075 · L + 2.160.0124 · L + 2.680.0124 · L + 3.490.0124 · L + 3.280.0124 · L + 4.09

–2.48

–2.48

–2.48

–2.48

–4.14

–4.14

Mass calculation without motor and switch.

Mass formula: Mass (kg/mm) · Length L (mm) + Mass of all parts of fixed lengths(carriage, drive end, idler end, etc.) (kg) + additional mass (kg)

15 RE 82 615/2003-04

ML

ML

C

Mt

Fy2

FxFx

Fy1

ML

CC

Note for dynamic load capacitiesand moments

The dynamic load capacities and momentsare based on 100 000 m of travel.

However, in many cases, only 50 000 m isassumed.

For this, the following comparison applies:

Values C, M t and ML from the tableshould be multiplied by 1.26.

Compact Module with Short Carriage

Compact Module with Long Carriage

Roll Moment

Pitch Moment

Yaw Moment

Yaw Moment

Compact Modules CKR

16RE 82 615/2003-04

CKR 12-90i = 1

Gear Reducer

1 8.0 90.05 1.6 18.0

10 0.8 9.0

CKR 15-110

CKR 20-145

i = 1

Gear Reducer

1 13.5 120.05 2.7 24.0

10 1.4 12.0i = 1

Gear Reducer

1 32.5 165.03 10.8 55.05 6.4 33.0

10 3.2 16.5

Technical Data

Drive Data

Compact Drive Type Gear Reducer Max. Drive Lead Belt Width Tooth Max. Belt BeltModule Ratio Torque Constant Type b Pitch Drive Elasticity

i Ma (mm/rev) (mm) T Transmission Limit(Nm) (mm) Force Fzul

F(N) (N)

AT 3 35 3 560 1,600

ATL 5 50 5 980 4,200

AT 5 70 5 1,238 4,800

Belt Data

17 RE 82 615/2003-04

Calculations

Frictional Torque Data Compact Module Motor Gearbox Type i MRS MRLP

(Nm) (Nm)

CKR 12-90

CKR 15-110

CKR 20-145

MKD25B-144

MSM030CGear Reducer 5, 10 0.060.58

MKD25B-144

MSM030CGear Reducer 5, 10 0.061.42

MKD41B-144

MSM040CGear Reducer 3, 5, 10 0.152.04

Mass Moment of InertiaFor Handling:

6 · JM ≥ Jfr

For Machining:

1.5 · JM ≥ Jfr

Jfr = Mass Moment of Inertia ofAdditional Load (kgm2)

JM = Mass Moment of Inertia ofMotor (kgm2)

Frictional Torque

With motor mounting via flangeand coupling: MR = MRS

MR = Frictional Torque atMotor Shaft (Nm)

MRS = Frictional Torque of System (Nm)

MRLP = Frictional Torque ofthe Gear Reducer (Nm)

i = Gear Ratio

iMR =

MRS + MRLP

With motor mounting via gear reducer:

Nominal Life Expectancy in Meters:

Nominal Life Expectancy in Hours:

Formulas

Nominal Life Expectancy

L10 = Nominal Life Expectancyin Meters (m)

L10h = Nominal Life Expectancyin Hours (h)

C = Dynamic Load Capacity (N)Fm = Mean Equivalent

Dynamic Load (N)v = Speed (m/s)L10h =

3600 · vL10

Fm

L10 = ( )C 3· 10 5

Compact Modules CKR

18RE 82 615/2003-04

Components and Order Configuration Data CKR 12-90

(03.34.00)

Without Drive

Shaftfor

Motor

withoutkeyway

i = 1

withkeyway

i = 1

GearReducer

Len

gth

102

mm

Len

gth

156

mm

OA01

(03.34.10)

MA01

(03.34.10)

MA02

(03.34.12)

MA03

(03.34.20)

MG01

MG02

(03.34.20)

MG03

MG04

without

right

left

both sides

50

01

02

03

04

10

11for

Gea

r Re

duce

r

01

01

02

02

Part Number, Length Type = .... Guideway = .. Drive = .. Carriage = ..(and Dim. Drawing)

0364-300-00 , .... mm

For Gear Reducer

With Drive (i = 1)

01

01

MG01

MG03

MG04

MG02

1 Sh

aft

2 Sh

afts

Performance values for horizontal operation with Servomotor MSM 030C and Drive DKC **.*-0121)

Connection Voltage: 1 x 230 V

Performance Data for Gear ReducersPerformance values for horizontal operationwith Servomotor MKD 25B-144 and Drive DKC **.*-0401)

Connection Voltage: 3 x 400 V

Gear Reducer Ratio i = 5 i = 10

Mass (kg) 2 4 6 8 10 2 4 6 8 10Acceleration Time t (ms) 54 69 84 99 114 88 97 106 114 123Acceleration Distance s (mm) 65 83 101 119 137 53 58 63 69 74Acceleration a (m/s2) 44.1 34.6 28.4 24.2 21.0 13.6 12.4 11.3 10.5 9.7Speed v (m/s) 2.4 1.2Repeatability (mm) 0.1 0.1

Gear Reducer Ratio i = 5 i = 10

Mass (kg) 2 4 6 8 10 2 4 6 8 10Acceleration Time t (ms) 16 22 27 33 38 23 26 29 33 36Acceleration Distance s (mm) 7 10 12 15 17 5 6 7 7 8Acceleration a (m/s2) 56.4 41.7 33.1 27.4 23.4 19.7 17.2 15.3 13.8 12.5Speed v (m/s) 0.90 0.45Repeatability (mm) 0.10 0.10

The tables contain performancevalue examples for gearbox-motorcombinations. They are intended to serveas a guide for selecton; exact values mustbe calculated based on individual cases.

1) See catalogs "Controllers, Motors, Electrical Accessories" catalog RE 82 710 (under preparation) and DSC, ECODRIVE Cs" catalog RDE 82 725.

19 RE 82 615/2003-04

FrictionalTorque

PositionAccuracy

02

05

01

Stan

dard

repo

rt

Mea

sure

men

tre

port

Motor Type

00

00

Motor Attachment2) = .. Motor = .. 1st, 2nd + 3rd Switch = .. Documentation = ..Cable Duct= ..

Socket/Plug = ..

i = 5 i = 10

11 12 MKD 25 B

MSM 030 C

MKD 25 B

MSM 030 C

31 32

11 12

31 32

Gear Reducer

50

72

72

50

2) Motor Attachment also available without motor (enter "00" for Motor on the order form)3) Version without Brake4) Version with Brake

00Without SwitchWithout Cable Duct

21REED-Switch

22HALL-SensorPNP-NC

23HALL-SensorPNP-NO

27HALL-SensorNPN-NC

28HALL-SensorNPN-NO

10Cable Duct

17Socket/Plug

Drive Data without Motor (i = 1) Drive Pulley Diameter 28.65 mm

Lead Constant 90 mm

Belt Type AT 3, Width 35 mm, steel reinforced

Moment of Inertia (short carriage) (0.85 + 0.00032 · L) · 10-4 kgm2

Moment of Inertia (long carriage) (1.08 + 0.00032 · L) · 10-4 kgm2

73

73

3)

4)

3)

4)

Compact Modules CKR

20RE 82 615/2003-04

Ø34H7

1.8 deep 49.5

19.5 28

L

L / 2

59

28

40

31.5

Ø10h6

13.5 13.5 38 13.5 13.5

156

20

Dimensional Drawings CKR 12-90

All dimensions in mm

Drawings not to scale

03.34.12

Version MA03

03.34.00

Version OA01

03.34.10

Versions MA01 and MA02

Excess Travel

156 (long carriage)

102 (short carriage)

M4 - 8 deep(4x)

M4 - 8 deep(8x)

Ø 4H7 - 8 deep(4x)

Lubrication point forgrease, sealed withM4 set-screw

Long Carriage

Central lubrication nipplefor grease

Max. Travel

2

Effective stroke2

Effective stroke2

Max. Travel

2

90

49.5

40

3P9

25 2 h=3

31.5

59

90

3P9

25 2 h=3

3P9

25

2 h=3

Ø10h6

Ø10h6Ø10h6

31.5

31.5

59

90

Excess Travel

21 RE 82 615/2003-04

03.34.20

Version MG01, MG02, MG03 and MG04Motors MKD 25B and MSM 030C

Ø 4H7 - 8 deep(2x)

M4 - 8 deep(4x)

Short Carriage

Lubrication point forgrease, sealed withM4 set-screw

L = (stroke + 2 · excess travel) + LT + 25 mm

For an example of length calculation, seeordering example

To calculate the length of theCompact Module:

102

90

27

7.6

39

40

13.5 13.5

B

A

20

A

4.8

3.2

1.8

3.2

1.3

B

2

5.2

4.2

4

337

(MKD

25B

)27

2.5

(MSM

030

C w

/ bra

ke)

239.

5 (M

SM 0

30C

w/o

bra

ke)

101

14

Ø10h6

31.5

Compact Modules CKR

22RE 82 615/2003-04

Components and Order Configuration Data CKR 15-110

(03.44.00)

Without Drive

Shaftfor

Motor

Withoutkeyway

i = 1

Withkeyway

i = 1

GearReducer

Len

gth

170

mm

Len

gth

215

mm

OA01

(03.44.10)

MA01

(03.44.10)

MA02

(03.44.12)

MA03

without

right

left

both sides

50

01

02

03

04

01 02

Part Number, Length Type = .... Guideway = .. Drive = .. Carriage = ..(and Dim. Drawing)

0364-400-00 , .... mm

With Drive (i = 1)

01

(03.44.20)

MG01

MG02

(03.44.20)

MG03

MG04

10

11

01 02

For Gear Reducer

01

For

Gea

r Re

duce

r

MG01

MG03

MG04

MG02

1 Sh

aft

2 Sh

afts

Performance values for horizontal operation with Servomotor MSM 030C and Drive DKC **.*-0121)

Connection Voltage: 1 x 230 V

Gear Reducer Ratio i = 5 i = 10

Mass (kg) 2 4 6 8 10 3 6 9 12 15 18 21Acceleration Time t (ms) 60 79 98 117 136 89 107 125 143 162 180 198Acceleration Distance s (mm) 96 126 156 187 217 71 86 100 115 129 144 158Acceleration a (m/s2) 53.6 40.7 32.8 27.4 23.6 18.0 14.9 12.8 11.2 9.9 8.9 8.1Speed v (m/s) 3.2 1.6Repeatability (mm) 0.1 0.1

Performance Data for Gear ReducerPerformance values for horizontal operationwith Servomotor MKD 25B-144 and Drive DKC **.*-0401)

Connection Voltage: 3 x 400 V

Gear Reducer Ratio i = 5 i = 10

Mass (kg) 1 2 3 4 3 6 9 12 15 18 21Acceleration Time t (ms) 16 19 23 26 25 32 39 46 53 59 66Acceleration Distance s (mm) 9 12 14 16 8 10 12 14 16 18 20Acceleration a (m/s2) 76.7 62.5 52.7 45.6 23.8 18.7 15.4 13.1 11.4 10.1 9.1Speed v (m/s) 1.2 0.6Repeatability (mm) 0.1 0.1

The tables contain performancevalue examples for gearbox-motorcombinations. They are intended to serveas a guide for selecton; exact values mustbe calculated based on individual cases.

1) See catalogs "Controllers, Motors, Electrical Accessories" catalog RE 82 710 (under preparation) and DSC, ECODRIVE Cs" catalog RDE 82 725.

23 RE 82 615/2003-04

FrictionalTorque

PositionAccuracy

02

05

01

i = 5 i = 10

11 12

31 32

11 12

31 32

Gear Reducer

00Without SwitchWithout Cable Duct

21REED-Switch

22HALL-SensorPNP-NC

23HALL-SensorPNP-NO

27HALL-SensorNPN-NC

28HALL-SensorNPN-NO

10Cable Duct

17Socket/PlugSt

anda

rdre

port

Mea

sure

men

tre

port

Motor Attachment2) = .. Motor = .. 1st, 2nd + 3rd Switch = .. Documentation = ..Cable Duct = ..Socket/Plug= ..

00

00

50MKD 25 B

MSM 030 C

MKD 25 B

MSM 030 C

50

Motor Type

Drive Data without Motor (i = 1) Drive Pulley Diameter 38.20 mm

Lead Constant 120 mm

Belt Type ATL 5, Width 50 mm, steel reinforced

Moment of Inertia (short carriage) (2.50 + 0.00136 · L) · 10-4 kgm2

Moment of Inertia (long carriage) (3.81 + 0.00136 · L) · 10-4 kgm2

72

72

2) Motor Attachment also available without motor (enter "00" for Motor on the order form)3) Version without Brake4) Version with Brake

73

73

3)

4)

3)

4)

Compact Modules CKR

24RE 82 615/2003-04

Ø42H7

2 deep60.5

24.5

35

L

L / 245

66

33

31.5

Ø14h6

215

25 3525 25 25

Dimensional Drawings CKR 15-110

All dimensions in mm

Drawings not to scale

03.44.12

Version MA03

03.44.00

Version OA01

03.44.10

Version MA01 and MA02

Excess Travel Excess Travel

215 (long carriage)

170 (short carriage)

M5 - 10 deep(4x)

M5 - 10 deep(8x)

Ø 6H7 - 6.5 deep (4x)

Lubrication point forgrease, sealed withM6 set-screw

Long Carriage

Central lubrication nipplefor grease

Effective Stroke2

Effective Stroke2

Max. Travel

2Max. Travel

2

60.5

4911

0

5P9

252 h=3

Ø14h6

31.5

66

110

5P9

5P9

252 h=3

252h=3

Ø14h6

Ø14h6

31.5

31.5

66

110

25 RE 82 615/2003-04

03.44.20

Versions MG01, MG02, MG03 and MG04Motors MKD 25B and MSM 030C

Ø 6H7 - 6.5 deep(2x)

M5 - 10 deep(4x)

Short CarriageLubrication point forgrease, sealed withM6 set-screw

L = (stroke + 2 · excess travel) + LT + 25 mm

For an example of length calculation, seeordering example

To calculate the length of theCompact Module:

328.

5 (M

KD 2

5B)

264

(MSM

030

C w

/ bra

ke)

231

(MSM

030

C w

/o b

rake

)

92.5

14

Ø14h6

31.5

34

25 25

41.5

50499.5

46

110

A

A

B

B

4.8

3.21.

8

3.2

1.38.

24.8

5.2

2.5

170

Compact Modules CKR

26RE 82 615/2003-04

Components CKR 20-145

(03.54.00)

Without Drive

Shaftfor

Motor

Withoutkeyway

i = 1

Withkeyway

i = 1

GearReducer

Len

gth

180

mm

Len

gth

240

mm

OA01

(03.54.10)

MA01

(03.54.10)

MA02

(03.54.12)

MA03

without

right

left

both sides

50

01

02

03

04

01 02

Part Number, Length Type = .... Guideway = .. Drive = .. Carriage = ..(and Dim. Drawing)

0364-500-00 , .... mm

With Drive (i = 1)

01

(03.54.20)

MG01

MG02

(03.54.20)

MG03

MG04

10

11

01 02

For Gear Reducer

01

For

Gea

r Re

duce

r

MG01

MG03

MG04

MG02

1 Sh

aft

2 Sh

afts

Performance Data for Gear ReducersPerformance values for horizontal operation with Servomotor MKD 41B-144 and Drive DKC **.*-0401)

Connection Voltage: 3 x 400 V

Gear Reducer Ratio i = 10

Mass (kg) 3 6 9 12 15 18 21 24 27 30Acceleration Time t (ms) 89 97 104 112 120 127 135 143 150 158Acceleration Distance s (mm) 74 80 86 93 99 105 111 118 124 130Acceleration a (m/s2) 18.5 17.0 15.8 14.7 13.8 12.9 12.2 11.6 11.0 10.4Speed v (m/s) 1.65Repeatability (mm) 0.1

Gear Reducer Ratio i = 5

Mass (kg) 3 6 9 12 15 18 21 24 27 30Acceleration Time t (ms) 58 70 83 96 109 122 134 147 160 173Acceleration Distance s (mm) 95 116 137 158 180 201 222 243 264 285Acceleration a (m/s2) 57.3 46.9 39.7 34.4 30.3 27.1 24.6 22.4 20.6 19.1Speed v (m/s) 3.3Repeatability (mm) 0.1

Gear Reducer Ratio i = 3

Mass (kg) 1 2 3 4 5 6 7 8 9Acceleration Time t (ms) 49 56 63 70 77 84 91 98 105Acceleration Distance s (mm) 122 139 157 175 192 210 228 245 263Acceleration a (m/s2) 102.6 89.6 79.5 71.5 64.9 59.5 54.9 50.9 47.5Speed v (m/s) 5.0Repeatability (mm) 0.1

27 RE 82 615/2003-04

Gear Reducer Ratio i = 10

Mass (kg) 3 6 9 12 15 18 21 24 27 30Acceleration Time t (ms) 26 29 33 37 41 45 49 52 56 60Acceleration Distance s (mm) 11 12 14 15 17 18 20 22 23 25Acceleration a (m/s2) 32.2 28.1 24.8 22.3 20.2 18.5 17.0 15.8 14.7 13.8Speed v (m/s) 0.8Repeatability (mm) 0.1

Gear Reducer Ratio i = 5

Mass (kg) 1 2 3 4 5 6 7 8 9 10Acceleration Time t (ms) 17 19 21 23 25 27 29 31 34 36Acceleration Distance s (mm) 14 15 17 19 21 22 24 26 28 29Acceleration a (m/s2) 99.8 88.4 79.3 71.9 65.8 60.7 56.2 52.4 49.1 46.2Speed v (m/s) 1.65Repeatability (mm) 0.1

Drive Data without Motor (i = 1)Drive Pulley Diameter 52,52 mm

Lead Constant 165 mm

Belt Type AT 5, width 70 mm, steel reinforced

Moment of Inertia (short carriage) (8.91 + 0.00317 · L) · 10-4 kgm2

Moment of Inertia (long carriage) (14.49 + 0.00317 · L) · 10-4 kgm2

FrictionalTorque

PositionAccuracy

02

05

01

i = 5

Gear Reducer

00Without SwitchWithout Cable Duct

21REED-Switch

22HALL-SensorPNP-NC

23HALL-SensorPNP-NO

27HALL-SensorNPN-NC

28HALL-SensorNPN-NO

10Cable Duct

17Socket/Plug

Stan

dard

repo

rt

Mea

sure

men

tre

port

i = 3 i = 10

Motor Attachment2) = .. Motor = .. 1st, 2nd + 3rd Switch = .. Documentation = ..Cable Duct = ..

Socket/Plug = ..

00

00

10 12 10MKD 41 B

MSM 040 C

MKD 41 B

MSM 040 C

10

30 32

10 12

30 32

11

31

11

31

Motor Type

74

74

2) Motor Attachment also available without motor (enter "00" for Motor on the order form)3) Version without Brake4) Version with Brake

75

75

3)

4)

3)

4)

Performance values for horizontal operation with Servomotor MSM 040B and Drive DKC **.*-0181), Connection Voltage: 1 x 230 V

The tables contain performancevalue examples for gearbox-motorcombinations. They are intended to serveas a guide for selecton; exact values mustbe calculated based on individual cases.

1) See catalogs "Controllers, Motors, Electrical Accessories" catalog RE 82 710 (under preparation) and DSC, ECODRIVE Cs" catalog RDE 82 725.

Compact Modules CKR

28RE 82 615/2003-04

Ø49H7

2.5 deep

32

30

61

240

Ø19h6

71.5

L

L / 2

45

45

64

30

48

30 40 30 30

Dimensional Drawings CKR 20-145

Excess TravelEffective Stroke

2Effective Stroke

2

240 (long carriage)

180 (short carriage)

M6 - 12 deep(4x)

M6 - 15 deep(8x)

Ø 6H7 - 7.5 deep(4x)

Lubrication point forgrease, sealed withM6 set-screw

Long Carriage

All dimensions in mm

Drawings not to scale

03.54.12

Version MA03

03.54.00

Version OA01

03.54.10

Versions MA01 and MA02

Central lubrication nipplefor grease

Max. Travel

2

Max. Travel

2

71.5

6414

5

61

6P9

402 h=3.5

Ø19h6 Ø19h6

Ø19h6

64

145

402 h=3.5

6P9

6P9

402h=3.5

64

6161

145

Excess Travel

29 RE 82 615/2003-04

03.54.20

Versions MG01, MG02, MG03 and MG04Motors MKD 41B and MSM 040 B

M6 - 15 deep(4x)

Ø 6H7 - 7.5 deep(2x)

Short Carriage

Lubrication point forgrease, sealed withM6 set-screw

L = (stroke + 2 · excess travel) + LT + 25 mm

For an example of length calculation, seeordering example

To calculate the length of theCompact Module:

62

65649.5

B

A

145

A B

50

3030

180 4.8

3.2

1.8

3.2

1.3

8.2

4.85.

2

2.5

Ø19h6

61

370

(MKD

41B

)31

8.5

(MSM

040

B w

/ bra

ke)

284.

5 (M

SM 0

40B

w/o

bra

ke)

127

22

71

CKR Compact Modules

30RE 82 615/2003-04

Switch Mounting

SwitchMiniature switch with potted cable.

Versions:

– Hall Sensor (NC/NO) or– Reed Contact (Relay)

Assembly Note:

Switch mounting is permitted on onlyone side of the Compact Module (left orright) and should be done only after theCompact Module has been installed onits base structure.

A cable duct is needed to attach switches.

Switches are inserted in the upper T-slot(CKR 12-90 und 15-110) or in the lowerT-slot (CKR 20-145) of the cable duct, andsecured with set-screws.

Overview of the Switching System1 Socket and Plug2 Switch3 Cable Duct

(aluminum extrusion, black anodized)

Short stroke: Note the length ofthe switch and socket!

Set-screw formounting

Active Surface

Hall SensorContact Type PNP NC/ NO

NPN NC/ NO

Operating Voltage 3.8–30 V DC

Current Draw max. 10 mA

Output Current max. 20 mA

Cable Length 2 m

Housing Protection Class IP 66

Short-Circuit Protection No

Wiring Schematic

Reed ContactContact Type Relay

Switching Voltage max. 100 V DC

Switching Current max. 0.5 A

Cable Length 2 m

Housing Protection Class IP 66

White: +3.8 ... 30 VDC

Green: Output

Brown:OV Ground

Brown

White

Green

Reed ContactHall-Sensor

IMPORTANT: 2 Switching points!

Hall Sensor and Reed Contact

12

3

6

6.5

35

5

3

31 RE 82 615/2003-04

503 4.5

Ø26

27.5

28.5

49

60

Part Number

Pos. For installation on: CKR 12-90, CKR 15-110, CKR 20-145

16-pin plug

Ordering of Switches andAccessories

Refer to the following table for partnumbers.

Accessories can also be orderedseparately.

Socket and PlugThe socket is installed on the side with theswitches.

The socket and plug have 16 pins.

The socket and switch are not wired.This allows optimal assignment of switchpositions during installation.

One plug is included.

The plug can be attached in threedirections (see illustration).

Cable DuctFunction:

– To attach and secure switches– Cable routing

Assembly Note:The cable duct is hooked into the T-slotsof the main body and secured withset-screws.

Set-screws are included.

CKR 12-90 and CKR 15-110 CKR 20-145

1 Socket/Plug

2 Switches

– Reed Contact

– Hall Sensor

3 Mounting Channel

0375-400-00

8616-009-03

PNP-NC 8616-010-03 / PNP-NO 8616-012-03

NPN-NC 8616-013-03 / NPN-NO 8616-014-03

0399-800-63

27.5

21.5

13

3

27.5

21.5

13

3

CKR Compact Modules

32RE 82 615/2003-04

ServomotorsType MKD

MKD 25B-144 KG1 Part Number 8611-050-03

MKD 41B-144 KG1 Part Number 8611-010-03

MKD 71B-061 KG1 Part Number 8611-011-03

Motor Data for Servomotors Type MKD

MKD 41B-144 KG1Motor

170 + 16

2.2

4.65

2.7

Maximum Effective Speed RPM nmax (min-1)

Rated Torque MN (Nm)

Maximum Torque Mmax (Nm)

Mass Moment of Inertia JM + JBr (10-6 kgm2)

Braking Torque MBr (Nm)

Mass with Brake mBr (kg)

MKD 71B-061 KG1

870 + 38

5.0

9.42

8.0

MKD 25B-144 KG1

30 + 8

1.0

2.25

0.9

Drawings not to scale

547

45o 45 o

20

Ø63

233

Ø40

j6

Ø9 k

6

2.5

Ø4.

5 8

45o 45 o

30

2.5

82Ø6.

6

Ø95

243

Ø50

j6

Ø14

k6

9.5

40

3

Ø95

j6

Ø19

k6

264

45o 45 o

115Ø9

Ø130

See "Controllers, Motors, Electrical Accessories" catalog RE 82 710 (under preparation)

33 RE 82 615/2003-04

NOTE:

Type MSM

MSM 030C-0300-NN-M0-CG1 with BrakePart Number 8611-073-03

MSM 030C-0300-NN-M0-CG0 without BrakePart Number 8611-072-03

Drawings not to scale

MSM 040B-0300-NN-M0-CG1 with Brake Part Number 8611-075-03

MSM 040B-0300-NN-M0-CG0 without BrakePart Number 8611-074-03

Motor Data Servomotors Type MSM

MSM 040 Bwith Absolute Encoder

Motor

Maximum Effective Speed RPM nmax (min-1)

Rated Torque MN (Nm)

Maximum Torque Mmax (Nm)

Mass Moment of Inertia JM + JBr (10-6 kgm2)

Braking Torque MBr (Nm)

Mass with Brake mBr (kg)

MSM 030 Cwith Absolute Encoder

5000 5000 4500 4500

1.3 1.3 2.4 2.4

3.8 3.8 7.1 7,1

17 17+3 67 67+8

– 1.27 – 2.45

1.5 1.9 3.1 3.8

Without Brake With Brake Without Brake With Brake

Motors are available completewith controls.

Ø4.

5

Ø50

h7

Ø14

h6

45 o

60171.5 w/ brake138.5 w/o brake

6

30

Ø70

45o

3

Ø6

45 o

Ø19

h6

Ø70

h7

80 157.5 w/o brake191.5 w/ brake

6

35

Ø90

45o

More informations see "DSC, ECODRIVE Cs" catalog RDE 82 725.

CKR Compact Modules

34RE 82 615/2003-04

5.5

11.5

8.5

3030

30

107

1140

4040

142

25

7

19.3

25

625

2525

87

8.5

3030

30

107

4.6

9

5

14.5

Mounting

Clamping Fixtures Recommended quantity of clamping fixtures: with 1 hole, 6 pieces per meter on each sidewith 4 holes, 3 pieces per meter on each side

Tightening Torque forMounting Screws

For Friction Factor 0.125Tensile Class 8.8

0375-310-00

NoteThe Compact Module is mounted usingclamping fixtures.

Do not secure or support CompactModules on the drive or idler end blocks.The aluminum profile base is the weight-bearing section.

When mounting Compact Modules, pleasenote the maximum tightening torqueslisted in the table.

8.8 M4 M5 M6

Nm 2.7 5.5 9.5

Size 15-110Size 20-145

Size 12-90

Mounting with Clamping Fixtures

Size A B

(mm) (mm)

12-90 102 112

15-110 126 140

20-145 161 175

0375-310-02

Part Numbers0375-310-03 0375-510-000375-410-02

Part Numbers0375-510-02

Countersink for M6ISO 4762

Countersink for M4ISO 4762 Countersink for M5

ISO 4762

BA +– 0.1

35 RE 82 615/2003-04

ØA

ØB

C

ØY

ØY

X

ØY

ØY

Lubrication access points for short carriage

Lubrication access points for long carriage

O-Ring

Carriage

Customer-installed plate

Size X Y

(mm) (mm)

CKR 12-90 0 8

CKR 15-110 41.5 10

CKR 20-145 50 10

Size A ± 0.1 BH13 C-0.2

(mm) (mm) (mm)

CKR 12-90 10 4 1.7

CKR 15-110 10 5 1.2

CKR 20-145 10 5 1.2

Center of carriage

Center of main body

Drive

Centrallubricationpointsfor grease

DriveFor short-stroke units, please contact usfor lubrication information:

CKR 12-90: Stroke< 70 mmCKR 15-110: Stroke< 120 mmCKR 20-145: Stroke< 150 mm

Central lubrication pointsfor grease

Main Body

Lubrication Access PortsThe Compact Module with toothed-beltdrive is designed for single point greaselubrication via one of three access ports.

The schematic at right indicates all availableaccess ports for lubrication. Grease appliedat any of these ports will travel through themanifold and lubricate all runner blocks.This central lubrication system allows foreasy maintenance of the module.

When using the lube port in the carriage,the set-screw must be removed. To preventany grease leakage, an O-ring must be usedas a seal between the carriage and thecustomer installed plate as shown in theschematic at the bottom right.

The table below locates the position of thelubrication ports:

Central LubricationVia carriage:• Each unit is shipped with an M6 set-screw

sealing the access the port (size 12-90uses an M4 set-screw).

Via side of extrusion ØY:• Each unit uses a funnel-shaped grease

nipple according to DIN 3405-AM6 (size12-90 per DIN 3405-D4).

O-Ring DesignFor customer installed connection plates,we recommend the seat of the O-ring to beaccording to the following table (referenceschematic bottom right):

Module size Part Number O-Ring Desc.

CKR 12-90 8411-119-01 Ø4 x 2.5

CKR 15-110 8411-109-01 Ø5 x 2.0

CKR 20-145 8411-109-01 Ø5 x 2.0

O-Ring according to DIN 3771:

CKR Compact Modules

36RE 82 615/2003-04

DocumentationThe standard report serves as confirmationthat the listed inspection items have beenchecked, and the the measured values fallwithin the permitted tolerance range.

Inspection items included in thestandard report :

– Functional test of mechanicalcomponents

– Functional test of electricalcomponents

– Unit matches order confirmation

Forward Reverse

Standard reportOption 01

Frictional Torque Measurementsfor the Complete SystemOption 02

The frictional torque is measured along theentire travel path. Due to friction, thetorque moment is measured along theentire travel range.

3.2

2.41.60.800.81.62.43.2

M (Nm)

M (Nm)

t (ms)

37 RE 82 615/2003-04

Positioning Accuracy

per VDI/DGQ 3441Option 05

Measurement points are selected atirregular intervals along the travel path.These points allow the capture of periodicpositioning deviations.

Each measurement point is approachedseveral times, from both directions.

From this, the following values can becalculated.

Position Accuracy P The position accuracy is determinedby the total deviation. It includes allsystematic and random deviationsin positioning.

Position Deviation Pa The position deviation is determined by themaximum occurring difference betweenthe mean values of all measurementpoints. It describes systematic deviations.

Reversal Range U The reversal range is determined by thedifference in the mean values from bothdirections of approach. The reversal rangeis calculated at each measurement point.It describes systematic deviations.

Variation Range Ps The variation range shows the effects ofrandom deviations. It is calculated at eachmeasurement point.

Dev

iatio

n (µ

m)

The position accuracy takes the followingvalues under consideration:

– Position deviation– Reversal range– Variation range

Example

Measurement path (mm)

P

U

P a

P S/2

P S/2

0 400 800 1200 1600 2000 2400

300

150

0

-150

CKR Compact Modules

38RE 82 615/2003-04

Ordering Example

L = (Stroke + 2 · excess travel) + LT + 25 mm

Stroke = Maximum distance of the carriagecenter to the outermost switchactivation points.

Stroke = 1500 mmLT = 156

Description

Compact ModuleCKR 12-90, length = 2250 mm

With gear reducer per illustration MG01 (gear reducer on right)

Ball rail guideDrive end for use with gear reducerCarriage with length LT = 156 mmFor motor MKD 25 B, i = 5Motor MKD 25 BHALL Sensor, PNP NCREED SwitchHALL Sensor, PNP NCCable duct shipped uninstalledSocket/plug shipped uninstalledMeasurement report: Moment of friction

The excess travel must be greater than thebraking distance. As a guideline for thebraking distance, refer to the accelerationdistance "s" in the performance valuestables.Example CKR 12-90:Horizontal operation with Motor MKD 25 B,i = 5, m = 4 kg: s = 82 mmExcess travel > 82 (90 mm assumed)

Ordering Code

Compact Module(Part Number): 0364-300-00, 2250 mm

Version = MG01

Guideway = 01Drive = 10Carriage = 02Motor Mount = 11Motor = 501st Switch = 222nd Switch = 213rd Switch = 22Cable Duct = 10Socket/Plug = 17Documentation = 02

Please check to ensure that the selected combination is permitted (load capacity, torque, maximum RPMs, motor data, etc.)!

Calculate the length of theCompact Module (all sizes):

A cable duct is required for switchinstallation.

Switch installation is permitted on only oneside of the Compact Module (left or right).

For further information on switch installationand switch types, see "Switch Installation".

Switch Installation

Example L = [(1500 + 2 · 90) + 156 + 25] mm

L = 1861 mm

39 RE 82 615/2003-04

Inquiry/Order Form

Rexroth Compact Module CKR

To be completed by customer: Inquiry / OrderCompact Module CKR _________________________________

(Part Number): ______-______-______, Length__________mm

Type =

Guideway =Drive =Carriage =Motor Mount =Motor =1st Switch =2nd Switch =3rd Switch =Cable Duct = , mmSocket/Plug =Documentation =

Quantity Order of:____ pcs., _____ per month, ______ per year, per order, or ____________________

Comments:

From:Company: _________________________________________ Name: _________________________________________

Address: _________________________________________ Department: _________________________________________

_________________________________________ Telephone: _________________________________________

_________________________________________ Fax: _________________________________________

E-mail: _________________________________________

Telephone +49-97 21 9 37-0

Fax +49-97 21 9 37-350

Individual Parts:

(Part Number): _______-_______-_______

_______-_______-_______

_______-_______-_______

_______-_______-_______

Bosch Rexroth AGLinear Motion and Assembly TechnologiesErnst-Sachs-Straße 100D-97424 Schweinfurt

Great care been taken during thecompilation of this publication to ensureall the information contained is accurate.We accept no responsibility however forany damage resulting from incorrect orincomplete information contained.

For deliveries and other services in thecourse of commercial business, thegeneral terms and conditions in the validprice lists and the confirmations of orderapply.

As our products are constantly in theprocess of further development, they aresubject to alteration without notice.

Bosch Rexroth AGLinear Motion and Assembly TechnologiesErnst-Sachs-Straße 100D-97424 Schweinfurt

Telephone +49 97 21 9 37-0

Telefax +49 97 21 9 37-2 75(general)

Telefax +49 97 21 9 37-3 50(direct)

Internet www.boschrexroth.com/brle-mail info.brl@boschrexroth.de

Compact Modules CKRwith Ball Rail Systemsand Toothed Belt DriveRE 82 615/2003-04

Printed in Germany - p 2003/08/3/S