Rexroth IndraDyn L Synchronous Linear Motors - Elogia

Industrial 

Hydraulics 

Electric Drives 

and Controls 

exroth IndraControl VCP 20 

Linear Motion and 

Assembly Technologies Pneumatics 

Rexroth IndraDyn L 

Synchronous Linear Motors 

Project Planning Manual 

Service 

Automation 

Mobile 

Hydraulics 

R911293635 

Edition 01

About this documentation Rexroth IndraDyn L 

Title 

Type of Documentation 

Document Typecode 

Internal File Reference 

Purpose of Documentation 

Record of Revisions 

Copyright 

Validity 

Published by 

Note 

Rexroth IndraDyn L 

Synchronous Linear Motors 

Project Planning Manual 

DOK-MOTOR*-MLF********-PR01-EN-P 

• R91129363501_Book.doc 

• Document Number, 120-1500-B319-01-EN 

This documentation .... 

• explains product features and applications, technical data as well as 

conditions and limits for operation 

• provides guidlines for product selection, application, handling and 

operation. 

Description Release 

Date 

Notes 

DOK-MOTOR*-MLF********-PR01-EN-P June04 1 st edition 

© Bosch Rexroth AG, 2004 

Copying this document, giving it to others and the use or communication 

of the contents thereof without express authority, are forbidden. 

Offenders are liable for the payment of damages. All rights are reserved 

in the event of the grand of a patent or the registration of a utility model 

or design (DIN 34-1). 

The specified data is for product description purposes only and may not 

be deemed to be guaranteed unless expressly confirmed in the contract. 

All rights are reserved with respect to the content of this documentation 

and the availability of the product. 

Bosch Rexroth AG 

Bgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main 

Tel +49 (0)93 52 / 40-0 • Tx 68 94 21 • Fax +49 (0)93 52 / 40-48 85 

http://www.boschrexroth.com/ 

Dept. BRC/EDM1 (FS) 

This document has been printed on chlorine-free bleached paper. 

DOK-MOTOR*-MLF********-PR01-EN-P

Rexroth IndraDyn L Contents I 

Contents 

1 Introduction to the Product 1 

1.1 Application range of linear direct drives .......................................................................................1 

1.2 About this Documentation............................................................................................................3 

Additional components ...........................................................................................................4 

Feedback ...............................................................................................................................4 

Standards...............................................................................................................................4 

2 Important directions for use 2-1 

2.1 Appropriate use........................................................................................................................2-1 

Introduction .........................................................................................................................2-1 

Areas of use and application................................................................................................2-2 

2.2 Inappropriate use .....................................................................................................................2-2 

3 Safety Instructions for Electric Drives and Controls 3-1 

3.1 Introduction ..............................................................................................................................3-1 

3.2 Explanations ............................................................................................................................3-1 

3.3 Hazards by Improper Use.........................................................................................................3-2 

3.4 General Information..................................................................................................................3-3 

3.5 Protection Against Contact with Electrical Parts........................................................................3-4 

3.6 Protection Against Electric Shock by Protective Low Voltage (PELV)........................................3-6 

3.7 Protection Against Dangerous Movements ...............................................................................3-7 

3.8 Protection Against Magnetic and Electromagnetic Fields During Operation and 

Mounting..................................................................................................................................3-9 

3.9 Protection Against Contact with Hot Parts...............................................................................3-10 

3.10 Protection During Handling and Mounting...............................................................................3-10 

3.11 Battery Safety.........................................................................................................................3-10 

3.12 Protection Against Pressurized Systems.................................................................................3-11 

4 Technical Data IndraDyn L 1 

4.1 Explanation to technical data.......................................................................................................1 

4.2 Technical data – size 040............................................................................................................4 





4.7 Technical data – size 300..........................................................................................................10 

5 Dimensions, installation dimension and - tolerances 5-1 

5.1 Installation tolerances...............................................................................................................5-1 


II Contents Rexroth IndraDyn L 

5.2 Mounting Sizes.........................................................................................................................5-3 

Size 040, primary in standard encapsulation........................................................................5-3 

Size 040, primary in thermal encapsulation..........................................................................5-4 

Size 040, secondary............................................................................................................5-5 


Size 070, primary in thermal encapsulation..........................................................................5-7 

Size 070, secondary............................................................................................................5-8 


Size 100, primary in thermal encapsulation........................................................................5-10 

Size 100, secondary..........................................................................................................5-11 

Size 140, primary in standard encapsulation......................................................................5-12 









6 Type codes for the IndraDyn L 1 

6.1 Description..................................................................................................................................1 

Type code of the Primary – The MLP......................................................................................2 

Type code of the Secondary – The MLS .................................................................................4 

6.2 Type code for IndraDyn L 040 .....................................................................................................6 

6.3 Type code IndraDyn L 070 ..........................................................................................................8 

6.4 Type code for IndraDyn L 100 ...................................................................................................10 




7 Accessories and Options 7-1 

7.1 Hall sensor box ........................................................................................................................7-1 

Schematic assembly............................................................................................................7-2 

8 Electrical connection 8-1 

8.1 Power connection.....................................................................................................................8-1 

Connection cable on the primary .........................................................................................8-1 

Power Cable Connection .....................................................................................................8-3 

Connection of IndraDrive Drive Controller ............................................................................8-6 

Connection of DIAX04 and EcoDrive Drive-Controllers ........................................................8-8 

8.2 Connection of linear feedback devices....................................................................................8-10 

9 Application and Construction Instructions 9-1 

9.1 Functional principle ..................................................................................................................9-1 

9.2 Motor Design............................................................................................................................9-2 


Rexroth IndraDyn L Inhaltsverzeichnis III 

Primary in standard encapsulation.......................................................................................9-3 

Primary in thermal encapsulation.........................................................................................9-4 

Design secondary part.........................................................................................................9-5 

Motor Sizes .........................................................................................................................9-6 

9.3 Requirements on the Machine Design ......................................................................................9-7 

Mass reduction....................................................................................................................9-7 

Mechanical rigidity...............................................................................................................9-7 

9.4 Arrangement of Motor Components..........................................................................................9-9 

Single arrangement .............................................................................................................9-9 

Several motors per axis.....................................................................................................9-10 

Vertical axes......................................................................................................................9-17 

9.5 Feed and Attractive Forces.....................................................................................................9-18 

Attractive forces between the primary and the secondary...................................................9-18 

Air-gap-related attractive forces between the primary and the secondary ...........................9-19 

Air-gap-related attractive forces vs. power supply ..............................................................9-19 

Air-gap-related feed force ..................................................................................................9-20 

Reduced overlapping between the primary and the secondary...........................................9-20 

9.6 Motor cooling .........................................................................................................................9-22 

Thermal behavior of linear motors......................................................................................9-22 

Cooling concept of IndraDyn L synchronous linear motors .................................................9-24 

Coolant..............................................................................................................................9-26 

Sizing the cooling circuit ....................................................................................................9-29 

Liquid cooling system ........................................................................................................9-33 

9.7 Motor temperature Monitoring Circuit......................................................................................9-38 

9.8 Setup Elevation and Ambient Conditions ................................................................................9-41 

9.9 Protection Class .....................................................................................................................9-42 

9.10 Compatibility ..........................................................................................................................9-42 

9.11 Magnetic Fields ......................................................................................................................9-43 

9.12 Vibration and Shock ...............................................................................................................9-44 

9.13 Enclosure surface ..................................................................................................................9-45 

9.14 Noise emission.......................................................................................................................9-45 

9.15 Length Measuring System ......................................................................................................9-46 

Selection criteria for linear scales.......................................................................................9-46 

Mounting Linear scales......................................................................................................9-52 

9.16 Linear Guides.........................................................................................................................9-53 

9.17 Braking Systems and Holding Devices ...................................................................................9-53 

9.18 End Position shock absorber ..................................................................................................9-54 

9.19 Axis Cover System.................................................................................................................9-55 

9.20 Wipers ...................................................................................................................................9-56 

9.21 Drive and Control of IndraDyn L motors..................................................................................9-57 

Drive controller and power supply modules........................................................................9-57 

Control systems.................................................................................................................9-57 

9.22 Shutdown upon EMERGENCY STOP and in the Event of a Malfunction.................................9-58 

Shutdown by the drive .......................................................................................................9-58 

Shutdown by a master control............................................................................................9-59 

Shutdown via mechanical braking device...........................................................................9-59 


IV Inhaltsverzeichnis Rexroth IndraDyn L 

Response to a mains failure ..............................................................................................9-60 

Short-circuit of DC bus ......................................................................................................9-60 

9.23 Maximum Acceleration Changes (Jerk Limitation)...................................................................9-61 

9.24 Position and Velocity Resolution.............................................................................................9-63 

9.25 Load Rigidity ..........................................................................................................................9-64 

Static load rigidity ..............................................................................................................9-65 

Dynamic load rigidity .........................................................................................................9-65 

10 Motor-Controller-Combinations 10-1 

10.1 General explanation ...............................................................................................................10-1 

Explanation of the variables...............................................................................................10-2 

10.2 Motor/Controller Combinations; one primary per drive ............................................................10-3 

Controlled DC Bus Voltage, mains supply voltage - 3 x 480 VAC.......................................10-3 

10.3 Motor/Controller Combinations; parallel primaries on single drive controllers...........................10-6 

Controlled DC Bus Voltage, mains supply voltage - 3 x 480 VAC.......................................10-6 

11 Motor Sizing 1 

11.1 General Procedure......................................................................................................................1 

11.2 Basic formulae ............................................................................................................................2 

General equations of motion...................................................................................................2 

Feed forces ............................................................................................................................3 

Average velocity.....................................................................................................................5 

Trapezoidal velocity................................................................................................................6 

Triangular velocity ................................................................................................................10 

Sinusoidal velocity................................................................................................................11 

11.3 Duty cycle and Feed Force........................................................................................................13 

Determining the duty cycle....................................................................................................13 

11.4 Determining the Drive Power.....................................................................................................15 

Continuous Output ...............................................................................................................15 

Maximum Output..................................................................................................................16 

Cooling capacity...................................................................................................................17 

Regeneration energy ............................................................................................................17 

11.5 Efficiency ..................................................................................................................................18 

11.6 Sizing Examples........................................................................................................................19 

Handling axis........................................................................................................................19 

Machine tool feed axis; sizing via duty cycle .........................................................................28 

12 Handling, transportion and storage of the units 12-1 

12.1 Identification of the motor components ...................................................................................12-1 

Primary .............................................................................................................................12-1 

Secondary.........................................................................................................................12-1 

12.2 Delivery status and Packaging................................................................................................12-2 

12.3 Transportation and Storage ....................................................................................................12-3 

Specifics for transporting secondaries of synchronous linear motors..................................12-4 

12.4 Checking the motor components ............................................................................................12-5 

Factory checks ..................................................................................................................12-5 


Rexroth IndraDyn L Inhaltsverzeichnis V 

Customer’s receiving inspection ........................................................................................12-5 

13 Mounting Instructions 13-1 

13.1 Basic precondition..................................................................................................................13-1 

13.2 General procedure at mounting of the motor components.......................................................13-1 

Installation at spanned secondary parts over the entire traverse path.................................13-1 

Installation at whole secondary over the entire traverse path .............................................13-3 

13.3 Installation of the secondary segments ...................................................................................13-5 

13.4 Installation of the primary........................................................................................................13-7 

13.5 Connection liquid cooling........................................................................................................13-7 

13.6 Screw locking.........................................................................................................................13-8 

14 Startup, Operation and Maintenance 14-1 

14.1 General information for startup of IndraDyn L motors..............................................................14-1 

14.2 General precondition ..............................................................................................................14-2 

Adherence of all electrically and mechanically components ...............................................14-2 

Implements .......................................................................................................................14-3 

14.3 General start-up procedure.....................................................................................................14-4 

14.4 Parametrization......................................................................................................................14-5 

Entering motor parameters ................................................................................................14-5 

Input of linear scale parameters.........................................................................................14-6 

Input of drive limitations and application-related parameters ..............................................14-6 

14.5 Determining the Polarity of the linear scale .............................................................................14-7 

14.6 Commutation adjustment........................................................................................................14-9 

Method 1: Measuring the reference between the primary and the secondary ...................14-11 

Method 2: Current flow method manually activated..........................................................14-14 

Method 3: Current flow method automatically activated....................................................14-15 

14.7 Setting and Optimizing the Control Loop...............................................................................14-16 

General sequence ...........................................................................................................14-16 

Parameter value assignments and optimization of Gantry axes........................................14-18 

Estimating the moved mass using a velocity ramp ...........................................................14-19 

14.8 Maintenance and check of Motor components ......................................................................14-21 

Check of Motor and Auxiliary Components ......................................................................14-21 

Electrical check of motor components..............................................................................14-21 

15 Service & Support 15-1 

15.1 Helpdesk................................................................................................................................15-1 

15.2 Service-Hotline.......................................................................................................................15-1 

15.3 Internet...................................................................................................................................15-1 

15.4 Vor der Kontaktaufnahme... - Before contacting us... ..............................................................15-1 

15.5 Kundenbetreuungsstellen - Sales & Service Facilities.............................................................15-2 

16 Appendix 16-1 

16.1 Recommended suppliers of additional components ................................................................16-1 

Length Measuring System .................................................................................................16-1 

Linear Guide......................................................................................................................16-1 


VI Inhaltsverzeichnis Rexroth IndraDyn L 

Energy Chains...................................................................................................................16-1 

Heat-exchanger Unit..........................................................................................................16-2 

Coolant Additives ..............................................................................................................16-2 

Coolant Tubes...................................................................................................................16-2 

Axis Cover System ............................................................................................................16-2 

End Position Shock Absorbers...........................................................................................16-3 

Clamping Elements for Linear Guideways..........................................................................16-3 

External Mechanical Brakes ..............................................................................................16-4 

Weight Compensation Systems .........................................................................................16-4 

Wipers...............................................................................................................................16-4 

16.2 Enquiry form for Linear Drives ................................................................................................16-5 

17 Index 17-1 


Rexroth IndraDyn L Introduction to the Product 1 

1 Introduction to the Product 

1.1 Application range of linear direct drives 


New technologies found in high-production equipment, demand more 

and more numerically driven movements with extreme requirements on 

acceleration, speed and exactness. 

Conventional NC-drives consisting of a rotating electrical motor and 

mechanical transmission elements, i.e. gearboxes, belt transmissions or 

gear rack pinions, can only fulfill these demands with great effort. 

In many cases, linear direct drive technology is an optimal alternative 

providing significant benefits including: 

• High velocity and acceleration 

• Excellent control quality and positioning behavior 

• Direct power transfer – no mechanical transmission elements like ball 

srews, toothed belts or gear racks. 

• Maintenance-free drive (no wearing parts on the motor) 

• Simplified machine structure 

• High static and dynamic load rigidity 

Fig. 1-1: Illustration of an IndraDyn L 

IndraDyn_L.jpg 

Due to the direct installation into the machine, there are no wearing 

mechanical components. This produces a power train with no or minimal 

backlash and permits very high control qualities with gains in the position 

control loop (Kv factor) of more than 20 m/min/mm. 

In conventional electromagnetic systems, positioning tasks with high 

feed rates or highly-accelerated, short-stroke movements in quick 

succession lead to premature wear of mechanical parts and thus to 

failures and significant costs. In these applications linear direct drives 

offer decisive advantages.

2 Introduction to the Product Rexroth IndraDyn L 

Performance Overview 

Vorschubkraft in N 

Feed Forces in N 

ORMMM 

OMMMM 

NRMMM 

NMMMM 

RMMM 

M 

21500 

16300 

11000 

300 

Considering the above-mentioned benefits, the following application are 

well-suited for linear synchronous direct drives: 

• High-speed cutting in transfer lines and machining centers 

• Grinding of camshafts and crankshafts 

• Laser machining 

• Precision and ultra-precision machining 

• Sheet-metal working 

• Material handling, textile and packaging machines 

• Free-form surface machining 

• Wood wooking, 

• Machining of printed circuit boards 

• ...... 

Due to a practice-oriented combination of motor technology and 

intelligent digital drive controllers, the linear direct drive technique offers 

new solutions with significantly improved performance. 

The development status of the synchronous linear technique of Bosch 

Rexroth permits a very high force density. 

The spectrum of Bosch Rexroth synchronous linear drive technology, 

which is described below, permits feed drive systems of 250 N up to 

21,000 N per motor and speeds over 600 m/min. 

The following diagram gives an overview of the performance spectrum of 

the Bosch Rexroth motors type IndraDyn L. 

3520 

6720 

5150 

17750 

14250 

10900 

7450 

200 

2415 

5560 

7650 

4460 

3465 

5200 

140 

10000 

1680 

3150 

2415 

7150 

5600 

3750 

100 

1785 

1180 

2310 

Fig. 1-2: Performance spectrum of IndraDyn L motors 

3800 

2600 

2000 

70 

Dauernennkraft FdN 

Continuos Force F dN 

Maximalkraft FMax 

Maximum Force F Max 

1200 

820 

1150 

630 800 250 

40 

370 


A 

D 

C 

B 

Baugröße 

Size KRAFTSPEKTRUM M LF.XLS

Rexroth IndraDyn L Introduction to the Product 3 

1.2 About this Documentation 


Document Structure 

This documentation includes safety instructions, technical data and 

operating instructions. The following setup provides an overview of the 

contents of this documentation. 

Sect. Title Content 

1 Introduction General information 

2 

3 

Important Instructions on Use 

Safety 

Important safety instructions 

4 Technical data 

5 Dimensional Details 

6 Type Code 

7 Accessories 

8 Connection System 

9 

Operating condition and application 

instructions 

10 Motor-Controller-Combinations 

11 Motordimensionierung 

12 Handling, Transport and Storage 

13 Installation 

14 Startup, Operation and 

15 Service & Support 

16 Appendix 

17 Index 

Fig. 1-3: Chapter structure 

Additional documentation 

Product descriptions 

for planners and project 

managers 

Practical information 

Additional information 

for operating and maintenance 

personnel 

To plan your project using an IndraDyn L motor, you may need additional 

documentation depending on the complexity of your system. Bosch 

Rexroth provides all product documentation on CD in a PDF-format. To 

plan your project, you will not necessary use all the documentation 

included on the CD. 

Note: All documentation on the CD are also available in print. You 

can order the required product documentation through your 

Bosch Rexroth sales office. 

Material no.: Title / description 

R911281882 -Produktdokumentation Electric Drives and Controls Version xx 1) 

DOK-GENRL-CONTR*DRIVE-GNxx-DE-D650 

R911281883 -Product documentation Electric Drives and Controls Version xx 1) 

DOK-GENRL-CONTR*DRIVE-GNxx-EN-D650 

1) The index (e.g. ..02-...) identifies the version of the CD. 

Fig. 1-4: Additional documentation

4 Introduction to the Product Rexroth IndraDyn L 

Additional components 

Feedback 

Standards 

Documentation for external systems which are connected to Bosch 

Rexroth components are not included in the scope of delivery and must 

be ordered directly from the particular manufacturers. 

For information about the manufacturers see chapter 16 “Appendix” 

Your experiences are an essential part of the process of improving both 

product and documentation. 

Please do not hesitate to inform us of any mistakes you detect in this 

documentation or of any modifications you might desire. We would 

appreciate your feedback. 

Please send your remarks to: 


Dept. BRC/EDM1 

Bürgermeister-Dr.-Nebel-Strasse 2 

D-97816 Lohr, Germany 

Fax +49 (0) 93 52 / 40-43 80 

This documentation refers to German, European and international 

technical standards. Documents and sheets on standards are subject to 

the protection by copyright and may not be passed on to third parties by 

BOSCH REXROTH AG. If necessary, please address the authorized 

sales outlets or, in Germany, directly to: 

BEUTH Verlag GmbH 

Burggrafenstrasse 6 

10787 Berlin 

Phone +49-(0)30-26 01-22 60, Fax +49-(0)30-26 01-12 60 

Internet: http://www.din.de/beuth postmaster@beuth.de 


Rexroth IndraDyn L Important directions for use 2-1 

2 Important directions for use 

2.1 Appropriate use 

Introduction 


Bosch Rexroth products represent state-of-the-art developments and 

manufacturing. They are tested prior to delivery to ensure operating 

safety and reliability. 

The products may only be used in the manner that is defined as 

appropriate. If they are used in an inappropriate manner, then situations 

can develop that may lead to property damage or injury to personnel. 

Note: Bosch Rexroth, as manufacturer, is not liable for any 

damages resulting from inappropriate use. In such cases, the 

guarantee and the right to payment of damages resulting 

from inappropriate use are forfeited. The user alone carries 

all responsibility of the risks. 

Before using Rexroth products, make sure that all the pre-requisites for 

appropriate use of the products are satisfied: 

• Personnel that in any way, shape or form uses our products must first 

read and understand the relevant safety instructions and be familiar 

with appropriate use. 

• If the product takes the form of hardware, then they must remain in 

their original state, in other words, no structural changes are 

permitted. It is not permitted to decompile software products or alter 

source codes. 

• Do not mount damaged or faulty products or use them in operation. 

• Make sure that the products have been installed in the manner 

described in the relevant documentation.

2-2 Important directions for use Rexroth IndraDyn L 

Areas of use and application 

2.2 Inappropriate use 

Rexroth IndraDyn L motors are designed to be used as linear servo drive 

motors. 

Available for an application-specific use of the motors are unit types with 

differing drive power and different interfaces. 

Control and monitoring of the motors may require additional sensors and 

actors. 

Note: The motors may only be used with the accessories and parts 

specified in this document. If a component has not been 

specifically named, then it may not be either mounted or 

connected. The same applies to cables and lines. 

Operation is only permitted in the specified configurations 

and combinations of components using the software and 

firmware as specified in the relevant function descriptions. 

Every drive controller has to be programmed before starting it up, 

making it possible for the motor to execute the specific functions of an 

application. 

The motors may only be operated under the assembly, installation and 

ambient conditions as described here (temperature, protection 

categories, humidity, EMC requirements, etc.) and in the position 

specified. 

Using the motors outside of the above-referenced areas of application or 

under operating conditions other than described in the document and the 

technical data specified is defined as “inappropriate use". 

IndraDyn L motors may not be used if 

• they are subject to operating conditions that do not meet the above 

specified ambient conditions. This includes, for example, operation 

under water, in the case of extreme temperature fluctuations or 

extremely high maximum temperatures or if 

• Bosch Rexroth has not specifically released them for that intended 

purpose. Please note the specifications outlined in the general 

Safety Instructions! 


Rexroth IndraDyn L Safety Instructions for Electric Drives and Controls 3-1 

3 Safety Instructions for Electric Drives and Controls 

3.1 Introduction 

3.2 Explanations 


Read these instructions before the initial startup of the equipment in 

order to eliminate the risk of bodily harm or material damage. Follow 

these safety instructions at all times. 

Do not attempt to install or start up this equipment without first reading 

all documentation provided with the product. Read and understand these 

safety instructions and all user documentation of the equipment prior to 

working with the equipment at any time. If you do not have the user 

documentation for your equipment, contact your local Bosch Rexroth 

representative to send this documentation immediately to the person or 

persons responsible for the safe operation of this equipment. 

If the equipment is resold, rented or transferred or passed on to others, 

then these safety instructions must be delivered with the equipment. 

WARNING 

Improper use of this equipment, failure to follow 

the safety instructions in this document or 

tampering with the product, including disabling 

of safety devices, may result in material 

damage, bodily harm, electric shock or even 

death! 

The safety instructions describe the following degrees of hazard 

seriousness in compliance with ANSI Z535. The degree of hazard 

seriousness informs about the consequences resulting from noncompliance 

with the safety instructions. 

Warning symbol with signal 

word 

DANGER 

WARNING 

CAUTION 

Degree of hazard seriousness according 

to ANSI 

Death or severe bodily harm will occur. 

Death or severe bodily harm may occur. 

Bodily harm or material damage may occur. 

Fig. 3-1: Hazard classification (according to ANSI Z535)

3-2 Safety Instructions for Electric Drives and Controls Rexroth IndraDyn L 

3.3 Hazards by Improper Use 

DANGER 

DANGER 

WARNING 

WARNING 

CAUTION 

CAUTION 

CAUTION 

High voltage and high discharge current! 

Danger to life or severe bodily harm by electric 

shock! 

Dangerous movements! Danger to life, severe 

bodily harm or material damage by unintentional 

motor movements! 

High electrical voltage due to wrong 

connections! Danger to life or bodily harm by 

electric shock! 

Health hazard for persons with heart 

pacemakers, metal implants and hearing aids in 

proximity to electrical equipment! 

Surface of machine housing could be extremely 

hot! Danger of injury! Danger of burns! 

Risk of injury due to improper handling! Bodily 

harm caused by crushing, shearing, cutting and 

mechanical shock or incorrect handling of 

pressurized systems! 

Risk of injury due to incorrect handling of 

batteries! 



3.4 General Information 


• Bosch Rexroth AG is not liable for damages resulting from failure to 

observe the warnings provided in this documentation. 

• Read the operating, maintenance and safety instructions in your 

language before starting up the machine. If you find that you cannot 

completely understand the documentation for your product, please 

ask your supplier to clarify. 

• Proper and correct transport, storage, assembly and installation as 

well as care in operation and maintenance are prerequisites for 

optimal and safe operation of this equipment. 

• Only persons who are trained and qualified for the use and operation 

of the equipment may work on this equipment or within its proximity. 

• The persons are qualified if they have sufficient knowledge of the 

assembly, installation and operation of the equipment as well as 

an understanding of all warnings and precautionary measures 

noted in these instructions. 

• Furthermore, they must be trained, instructed and qualified to 

switch electrical circuits and equipment on and off in accordance 

with technical safety regulations, to ground them and to mark them 

according to the requirements of safe work practices. They must 

have adequate safety equipment and be trained in first aid. 

• Only use spare parts and accessories approved by the manufacturer. 

• Follow all safety regulations and requirements for the specific 

application as practiced in the country of use. 

• The equipment is designed for installation in industrial machinery. 

• The ambient conditions given in the product documentation must be 

observed. 

• Use only safety features and applications that are clearly and 

explicitly approved in the Project Planning Manual. 

For example, the following areas of use are not permitted: 

construction cranes, elevators used for people or freight, devices and 

vehicles to transport people, medical applications, refinery plants, 

transport of hazardous goods, nuclear applications, applications 

sensitive to high frequency, mining, food processing, control of 

protection equipment (also in a machine). 

• The information given in the documentation of the product with 

regard to the use of the delivered components contains only 

examples of applications and suggestions. 

The machine and installation manufacturer must 

• make sure that the delivered components are suited for his 

individual application and check the information given in this 

documentation with regard to the use of the components, 

• make sure that his application complies with the applicable safety 

regulations and standards and carry out the required measures, 

modifications and complements. 

• Startup of the delivered components is only permitted once it is sure 

that the machine or installation in which they are installed complies 

with the national regulations, safety specifications and standards of 

the application.


• Operation is only permitted if the national EMC regulations for the 

application are met. 

The instructions for installation in accordance with EMC requirements 

can be found in the documentation "EMC in Drive and Control 

Systems". 

The machine or installation manufacturer is responsible for 

compliance with the limiting values as prescribed in the national 

regulations. 

• Technical data, connections and operational conditions are specified 

in the product documentation and must be followed at all times. 

3.5 Protection Against Contact with Electrical Parts 

Note: This section refers to equipment and drive components with 

voltages above 50 Volts. 

Touching live parts with voltages of 50 Volts and more with bare hands 

or conductive tools or touching ungrounded housings can be dangerous 

and cause electric shock. In order to operate electrical equipment, 

certain parts must unavoidably have dangerous voltages applied to 

them. 




DANGER 

High electrical voltage! Danger to life, severe 

bodily harm by electric shock! 

⇒ Only those trained and qualified to work with or on 

electrical equipment are permitted to operate, maintain 

or repair this equipment. 

⇒ Follow general construction and safety regulations 

when working on high voltage installations. 

⇒ Before switching on power the ground wire must be 

permanently connected to all electrical units according 

to the connection diagram. 

⇒ Do not operate electrical equipment at any time, even 

for brief measurements or tests, if the ground wire is 

not permanently connected to the points of the 

components provided for this purpose. 

⇒ Before working with electrical parts with voltage higher 

than 50 V, the equipment must be disconnected from 

the mains voltage or power supply. Make sure the 

equipment cannot be switched on again unintended. 

⇒ The following should be observed with electrical drive 

and filter components: 

⇒ Wait five (5) minutes after switching off power to allow 

capacitors to discharge before beginning to work. 

Measure the voltage on the capacitors before 

beginning to work to make sure that the equipment is 

safe to touch. 

⇒ Never touch the electrical connection points of a 

component while power is turned on. 

⇒ Install the covers and guards provided with the 

equipment properly before switching the equipment on. 

Prevent contact with live parts at any time. 

⇒ A residual-current-operated protective device (RCD) 

must not be used on electric drives! Indirect contact 

must be prevented by other means, for example, by an 

overcurrent protective device. 

⇒ Electrical components with exposed live parts and 

uncovered high voltage terminals must be installed in a 

protective housing, for example, in a control cabinet.


To be observed with electrical drive and filter components: 

DANGER 

High electrical voltage on the housing! 

High leakage current! Danger to life, danger of 

injury by electric shock! 

⇒ Connect the electrical equipment, the housings of all 

electrical units and motors permanently with the 

safety conductor at the ground points before power is 

switched on. Look at the connection diagram. This is 

even necessary for brief tests. 

⇒ Connect the safety conductor of the electrical 

equipment always permanently and firmly to the 

supply mains. Leakage current exceeds 3.5 mA in 

normal operation. 

⇒ Use a copper conductor with at least 10 mm² cross 

section over its entire course for this safety conductor 

connection! 

⇒ Prior to startups, even for brief tests, always connect 

the protective conductor or connect with ground wire. 

Otherwise, high voltages can occur on the housing 

that lead to electric shock. 

3.6 Protection Against Electric Shock by Protective Low 

Voltage (PELV) 

All connections and terminals with voltages between 0 and 50 Volts on 

Rexroth products are protective low voltages designed in accordance 

with international standards on electrical safety. 

WARNING 

High electrical voltage due to wrong 

connections! Danger to life, bodily harm by 

electric shock! 

⇒ Only connect equipment, electrical components and 

cables of the protective low voltage type (PELV = 

Protective Extra Low Voltage) to all terminals and 

clamps with voltages of 0 to 50 Volts. 

⇒ Only electrical circuits may be connected which are 

safely isolated against high voltage circuits. Safe 

isolation is achieved, for example, with an isolating 

transformer, an opto-electronic coupler or when 

battery-operated. 



3.7 Protection Against Dangerous Movements 


Dangerous movements can be caused by faulty control of the connected 

motors. Some common examples are: 

• improper or wrong wiring of cable connections 

• incorrect operation of the equipment components 

• wrong input of parameters before operation 

• malfunction of sensors, encoders and monitoring devices 

• defective components 

• software or firmware errors 

Dangerous movements can occur immediately after equipment is 

switched on or even after an unspecified time of trouble-free operation. 

The monitoring in the drive components will normally be sufficient to 

avoid faulty operation in the connected drives. Regarding personal 

safety, especially the danger of bodily injury and material damage, this 

alone cannot be relied upon to ensure complete safety. Until the 

integrated monitoring functions become effective, it must be assumed in 

any case that faulty drive movements will occur. The extent of faulty 

drive movements depends upon the type of control and the state of 

operation.


DANGER 

Dangerous movements! Danger to life, risk of 

injury, severe bodily harm or material damage! 

⇒ Ensure personal safety by means of qualified and 

tested higher-level monitoring devices or measures 

integrated in the installation. Unintended machine 

motion is possible if monitoring devices are disabled, 

bypassed or not activated. 

⇒ Pay attention to unintended machine motion or other 

malfunction in any mode of operation. 

⇒ Keep free and clear of the machine’s range of motion 

and moving parts. Possible measures to prevent 

people from accidentally entering the machine’s 

range of motion: 

- use safety fences 

- use safety guards 

- use protective coverings 

- install light curtains or light barriers 

⇒ Fences and coverings must be strong enough to 

resist maximum possible momentum, especially if 

there is a possibility of loose parts flying off. 

⇒ Mount the emergency stop switch in the immediate 

reach of the operator. Verify that the emergency stop 

works before startup. Don’t operate the machine if 

the emergency stop is not working. 

⇒ Isolate the drive power connection by means of an 

emergency stop circuit or use a starting lockout to 

prevent unintentional start. 

⇒ Make sure that the drives are brought to a safe 

standstill before accessing or entering the danger 

zone. Safe standstill can be achieved by switching off 

the power supply contactor or by safe mechanical 

locking of moving parts. 

⇒ Secure vertical axes against falling or dropping after 

switching off the motor power by, for example: 

- mechanically securing the vertical axes 

- adding an external braking/ arrester/ clamping 

mechanism 

- ensuring sufficient equilibration of the vertical 

axes 

The standard equipment motor brake or an external 

brake controlled directly by the drive controller are 

not sufficient to guarantee personal safety! 




⇒ Disconnect electrical power to the equipment using a 

master switch and secure the switch against 

reconnection for: 

- maintenance and repair work 

- cleaning of equipment 

- long periods of discontinued equipment use 

⇒ Prevent the operation of high-frequency, remote 

control and radio equipment near electronics circuits 

and supply leads. If the use of such equipment 

cannot be avoided, verify the system and the 

installation for possible malfunctions in all possible 

positions of normal use before initial startup. If 

necessary, perform a special electromagnetic 

compatibility (EMC) test on the installation. 

3.8 Protection Against Magnetic and Electromagnetic Fields 

During Operation and Mounting 

Magnetic and electromagnetic fields generated near current-carrying 

conductors and permanent magnets in motors represent a serious health 

hazard to persons with heart pacemakers, metal implants and hearing 

aids. 

WARNING 

Health hazard for persons with heart 

pacemakers, metal implants and hearing aids in 

proximity to electrical equipment! 

⇒ Persons with heart pacemakers, hearing aids and 

metal implants are not permitted to enter the 

following areas: 

- Areas in which electrical equipment and parts are 

mounted, being operated or started up. 

- Areas in which parts of motors with permanent 

magnets are being stored, operated, repaired or 

mounted. 

⇒ If it is necessary for a person with a heart pacemaker 

to enter such an area, then a doctor must be 

consulted prior to doing so. Heart pacemakers that 

are already implanted or will be implanted in the 

future, have a considerable variation in their electrical 

noise immunity. Therefore there are no rules with 

general validity. 

⇒ Persons with hearing aids, metal implants or metal 

pieces must consult a doctor before they enter the 

areas described above. Otherwise, health hazards 

will occur.


3.9 Protection Against Contact with Hot Parts 

CAUTION 

Housing surfaces could be extremely hot! 

Danger of injury! Danger of burns! 

⇒ Do not touch housing surfaces near sources of heat! 

Danger of burns! 

⇒ After switching the equipment off, wait at least ten 

(10) minutes to allow it to cool down before touching 

it. 

⇒ Do not touch hot parts of the equipment, such as 

housings with integrated heat sinks and resistors. 

Danger of burns! 

3.10 Protection During Handling and Mounting 

3.11 Battery Safety 

Under certain conditions, incorrect handling and mounting of parts and 

components may cause injuries. 

CAUTION 

Risk of injury by incorrect handling! Bodily harm 

caused by crushing, shearing, cutting and 

mechanical shock! 

⇒ Observe general installation and safety instructions 

with regard to handling and mounting. 

⇒ Use appropriate mounting and transport equipment. 

⇒ Take precautions to avoid pinching and crushing. 

⇒ Use only appropriate tools. If specified by the product 

documentation, special tools must be used. 

⇒ Use lifting devices and tools correctly and safely. 

⇒ For safe protection wear appropriate protective 

clothing, e.g. safety glasses, safety shoes and safety 

gloves. 

⇒ Never stand under suspended loads. 

⇒ Clean up liquids from the floor immediately to prevent 

slipping. 

Batteries contain reactive chemicals in a solid housing. Inappropriate 

handling may result in injuries or material damage. 




CAUTION 

Risk of injury by incorrect handling! 

⇒ Do not attempt to reactivate discharged batteries by 

heating or other methods (danger of explosion and 

cauterization). 

⇒ Never charge non-chargeable batteries (danger of 

leakage and explosion). 

⇒ Never throw batteries into a fire. 

⇒ Do not dismantle batteries. 

⇒ Do not damage electrical components installed in the 

equipment. 

Note: Be aware of environmental protection and disposal! The 

batteries contained in the product should be considered as 

hazardous material for land, air and sea transport in the 

sense of the legal requirements (danger of explosion). 

Dispose batteries separately from other waste. Observe the 

legal requirements in the country of installation. 

3.12 Protection Against Pressurized Systems 

Certain motors and drive controllers, corresponding to the information in 

the respective Project Planning Manual, must be provided with 

pressurized media, such as compressed air, hydraulic oil, cooling fluid 

and cooling lubricant supplied by external systems. Incorrect handling of 

the supply and connections of pressurized systems can lead to injuries 

or accidents. In these cases, improper handling of external supply 

systems, supply lines or connections can cause injuries or material 

damage. 

CAUTION 

Danger of injury by incorrect handling of 

pressurized systems ! 

⇒ Do not attempt to disassemble, to open or to cut a 

pressurized system (danger of explosion). 

⇒ Observe the operation instructions of the respective 

manufacturer. 

⇒ Before disassembling pressurized systems, release 

pressure and drain off the fluid or gas. 

⇒ Use suitable protective clothing (for example safety 

glasses, safety shoes and safety gloves) 

⇒ Remove any fluid that has leaked out onto the floor 

immediately. 

Note: Environmental protection and disposal! The media used in 

the operation of the pressurized system equipment may not 

be environmentally compatible. Media that are damaging the 

environment must be disposed separately from normal waste. 

Observe the legal requirements in the country of installation.


Notes 


Rexroth IndraDyn L Technical Data IndraDyn L 1 

4 Technical Data IndraDyn L 

4.1 Explanation to technical data 


All relevant technical motor data as well as the functional principle of 

these motors are given on the following pages in terms of tables and 

characteristic curves. The following parameters will be taken into 

consideration : 

• Size and length of the primary 

• Type of winding of the primary 

• Available power supply or DC link voltage 

Note: Unless otherwise noted, all data and characteristic curves are 

based on the following conditions: 

• Motor-winding temperature of 135°C. 

• Nominal air gap 

• Cooling with water with a supply temperature of 30°C 

Note: Resulting data from certain motor-controller combinations can 

differ from the given data. See Chapter 10 “Motor-controller 

combinations”. 

Characteristic force/speed curve 

The characteristic force vs. speed curve is given shows the limiting 

curve. The shapes of these characteristic curves are defined by the DC 

bus voltage and the relevant motor-specific data, e.g. inductivity, 

resistance and the motor constants. Varying the DC bus voltage (using 

different drives, power supplies or supply voltages) and/or using different 

motor windings will result in different characteristic curves (see Fig. 4-1).

2 Technical Data IndraDyn L Rexroth IndraDyn L 

force 

F max 

F dN 

1 2 3 4 5 

VFMAX V N velocity 

FVKENNLIN-MLF-EN.EPS 

[1]: 3 x 400V providing an unregulated DC bus voltage, UDC = 540V 

(Possible with an HCS compact drive controller or with an HMS or 

HMD drive controller in combination with an HMV power supply) 







[4]: 3 x 480V providing an regulated DC bus voltage, UDC = 650V 

(Possible with an HMS or HMD drive controller in combination with 

an HMV power supply) 

[5]: 3 x 400....480V providing an regulated DC bus voltage, UDC = 750V 

(Possible with an HMS or HMD drive controller in combination with 

an HMV power supply) 

Fig. 4-1: Characteristic force vs. Speed curve 

The maximum force, FMAX, is available up to a limited velocity, vFMAX. 

When the velocity rises, the available DC bus voltage is reduced by the 

velocity-dependent Back EMF of the motor. This leads to a reduction of 

the maximum feed force at higher velocities. The characteristic curves 

are specified up to the continuous nominal force. The velocity that 

belongs to the continuous nominal force is known as nominal velocity, 

vN. 

Note: If the connection voltages or mains voltages are different, the 

specified characteristic curves can be converted linearly 

according to the existing voltages. 

Where power supply modules with unregulated DC bus 

voltage are concerned, voltage drops – from simultaneous 

acceleration of several axes, for example - must be taken into 

consideration. 



Parallel connection of two 

primaries on one drive controller 


The following interrelations exist for the parallel connection of two 

primaries on one drive controller: 

• Doubling of currents and feed forces 

(unless limited by the drive controller) 

• Velocities vFMAX and vNENN as in single arrangement 

• Same motor and voltage constants (kiF, kE) 

• Halved motor resistances and inductances. 

feed force 

F max 

F dN 

parallel arrangement 

F max 

F dN 

single arrangement 

VFMAX 

velocity 

V N 

FVKENNLIN1-MLF-EN.EPS 

Fig. 4-2: Characteristic force vs. Speed curves for single and parallel 

connection of primaries to one drive controller 

Note: To facilitate the commissioning of parallel connection of two 

primaries to one drive controller, this document has 

corresponding selection data for motor – controller 

combinations and the motor parameters (see chapter 10 

“Motor – Controller Combinations” and Chapter 14 

“Commissioning”)


4.2 Technical data – size 040 

Description Symbol Unit MLP040 

Motor data 1 ) 

Frame length A B 

Winding code 0300 0150 0250 0300 

Corresponding secondaries MLS040S-3A-****-NNNN 

Maximum force 2) 

Fmax N 800 1150 

Continuous nominal force FdN N 250 370 

Max. current imax A 20 20 27 35 

Continuous current idN A 4.2 4.2 5.3 6 

Maximum speed with Fmax 3) 

vFmax m/min 300 150 250 300 

Nominal velocity 3) 

vN m/min 500 300 400 500 

Force constant KiFN N/A 60 88 70 62 

Voltage constant 4) 

KEMF Vs/m in preparation 

Winding resistance at 20°C R12 Ohm 8.6 i.p. i.p. 5.1 

Winding inductivety L12 mH 54.2 i.p. i.p. 33.2 

Minimum cross-section of connection cable 5) 

APL mm² 1 

Rated power loss PvN W 400 550 

Nominal air gap δ mm 1.0 ±0.4 

Attractive force 6) 

FATT N 1200 1700 

Mass of primary - standard encapsulation mPS kg 4.7 6.1 

Mass of primary - thermal encapsulation mPT kg 6.1 8.1 

Unit mass if secondary mS kg/m 5.4 

Required coolant flow ∆ϑN 10) 

Qmin l/min 0.57 0.79 

standard encapsulation 

Pressure loss constant 

0.16 0.16 

7) 

thermal encapsulation 

kdp 

0.16 0.16 

Pressure loss at QN 



∆p bar 

0.06 

0.06 

0.10 

0.11 

Coolant inlet temperature 8) 

ϑin °C +15...+40 

Temperature rise at PvN 9) 

∆ϑN K 10 

Thermal time constant Tth min in preparation 

Permissible temperature of secondary TSmax °C 70 

Permissible ambient temperature Tum °C 0...+45 

Permissible storage and transport temperature TL °C -10...+60 

Protection class IP65 

Insulation class acc. to DIN VDE 0530-1 F 

Housing surface of primary 

-FT-: Priming black (RAL 9005) 

-FS-: stainless steel blank / priming black (RAL 9005) 

1 

) 

2 

) 

The measured values are effective values acc. to IEC 60034-1, unless other values are given. Reference value is 540 VDC. 

The maximum obtainable force depends on the drive controller. 

3 

) The obtain velocity depends on the DC bus voltage. 

4 

) 

-1 

EMF=Electromagnetic force. Effective value refer to 1 min . 

5 

) Dimensioned to EN 60204-1(1993), laying system B2 and conversion factor for Bosch Rexroth cable at 40°C environmental 

temperature. When using other cables, other cross-sections may be required. For additional notes to connection and power cables 

see Chapter 8.1. 

6 

) Nominal air gap between primary and secondary, No voltage applied to primary, see Chapter 9.5. 

7 

) Coolant medium is water. Actual pressure loss is dependent on the coolant flow, see Chapter 9.6. 

8 

) The coolant inlet temperature may be max. 5°K under the ambient temperature due to danger of condensation! 

9 

) Operation with liquid cooling using water as coolant with a supply temperature of 30°C. 

10 

) For further notes see Chapter 9.6 “Motor coolant, flow rate“. 

Fig. 4-3: Data sheet motor size 040 




Description 

Motor data 

Symbol Unit MLP070 

1) 

Frame length A B 

Winding code 0150 0220 0300 0100 0120 0150 0250 0300 



Fmax N 2000 2600 

Continuous nominal force FdN N 630 820 

Max. current imax A 27 35 55 28 42 48 55 70 

Continuous current idN A 5.3 6.3 10.5 5.5 5.8 6.2 10 12 


vFmax m/mi 150 220 300 100 120 150 250 300 


vN m/mi 250 360 450 200 220 260 400 450 

Force constant KiFN N/A 119 100 60 149 141 132 82 68 


KEMF Vs/ i.p. i.p. 20 i.p. 80 i.p. i.p. i.p. 

Winding resistance at 20°C R12 Ohm i.p. i.p. 2.8 i.p. 9.2 i.p. i.p. i.p. 

Winding inductivety L12 mH i.p. i.p. 14.3 i.p. 51.6 i.p. i.p. i.p. 


APL mm² 1 

Rated power loss PvN W 780 900 



FATT N 2900 3750 

Mass of primary - standard encapsulation mPS kg 8.4 10.4 

Mass of primary - thermal encapsulation mPT kg 10.9 13.4 



Qmin l/min 1.12 1.29 



0.18 0.18 

7) 


kdp 

0.18 0.18 




∆p bar 

0.22 

0.22 

0.28 

0.29 


ϑin °C +15...+40 


∆ϑN K 10 

Thermal time constant Tth min 6 5.7 







-FT-: 

-FS-: 

Priming black (RAL 9005) 

stainless steel blank / priming black (RAL 9005) 

1 

) 

2 

) 



3 


4 

) 

-1 


5 




6 


7 


8 


9 


10 



Fig. 4-4: Data sheet motor size 070(1/2)



Motor data 1) 

Frame length C 

Winding code 0120 0150 0240 0300 



Fmax N 3800 

Continuous nominal force FdN N 1200 

Max. current imax A 55 62 70 110 

Continuous current idN A 8.9 10 13 19 


vFmax m/min 120 150 240 300 


vN m/min 180 250 350 450 

Force constant KiFN N/A 135 120 92 63 


KEMF Vs/m 78 i.p. i.p. i.p. 

Winding resistance at 20°C R12 Ohm 5.7 i.p. i.p. 1.5 

Winding inductivety L12 mH 33.9 i.p. i.p. 12.3 


APL mm² 1 2.5 

Rated power loss PvN W 1100 



FATT N 5500 

Mass of primary - standard encapsulation mPS kg 14.5 

Mass of primary - thermal encapsulation mPT kg 18.4 



Qmin l/min 1.58 



0.19 

7) 


kdp 

0.19 




∆p bar 

0.43 

0.43 


ϑin °C +15...+40 


∆ϑN K 10 

Thermal time constant Tth min 7.5 







-FT-: 

-FS-: 



1 

) 

2 

) 



3 


4 

) 

-1 


5 




6 


7 


8 


9 


10 


Fig. 4-5: Data sheet motor size 070(2/2) 





Motor data 1) 

Frame length A B C 

Winding code 0090 0120 0150 0190 0120 0250 0090 0120 0190 



Fmax N 3750 5600 7150 

Continuous nominal force FdN N 1180 1785 2310 

Max. current imax A 38 44 55 70 70 130 70 85 140 

Continuous current idN A 6.6 8 10 12 12 22 13 15 23 


vFmax m/mi 90 120 150 190 120 250 90 120 190 


vN m/mi 150 190 220 290 190 350 170 190 290 

Force constant KiFN N/A 169 148 118 98 149 81 178 154 100 


KEMF Vs/ i.p. i.p. i.p. i.p. 87 i.p. i.p. 89 i.p. 

Winding resistance at 20°C R12 Ohm 8.8 8 i.p. i.p. 4.45 i.p. i.p. 3.8 i.p. 

Winding inductivety L12 mH 55 49 i.p. i.p. 25 i.p. i.p. 21.1 i.p. 


APL mm² 1 2.5 1 1.5 4 

Rated power loss PvN W 900 1300 1600 



FATT N 5400 8000 10400 

Mass of primary - standard encapsulation mPS kg 13.5 18.7 24 

Mass of primary - thermal encapsulation mPT kg 17 23.3 29.7 



Qmin l/min 1.29 1.87 2.3 



0.19 0.18 0.19 

7) 


kdp 

0.19 0.18 0.19 




∆p bar 

0.29 

0.3 

0.52 

0.54 

0.8 

0.82 


ϑin °C +15...+40 


∆ϑN K 10 

Thermal time constant Tth min i.p. 7 6.8 







-FT-: 

-FS-: 



1 

) 

2 

) 



3 


4 

) 

-1 


5 




6 


7 


8 


9 


10 



Fig. 4-6: Data sheet size 100




Motor data 1) 


Winding code 0120 0090 0120 0050 0120 0170 



Fmax N 5200 7650 10000 


Max. current imax A 70 70 105 70 125 140 

Continuous current idN A 12 13 18 13 21 29 


vFmax m/min 120 90 120 50 120 170 


vN m/min 190 160 190 110 190 250 

Force constant KiFN N/A 140 186 134 242 150 109 


KEMF Vs/m i.p. i.p. i.p. i.p. i.p. i.p. 

Winding resistance at 20°C R12 Ohm 4 i.p. 2.6 i.p. 2.6 i.p. 

Winding inductivety L12 mH 28.2 i.p. 19.8 i.p. 12.3 i.p. 


APL mm² 1 2.5 1 2.5 4 




FATT N 7500 11000 14400 

Mass of primary - standard encapsulation mPS kg 17 24.5 32 

Mass of primary - thermal encapsulation mPT kg 21.2 30.1 38.9 



Qmin l/min 1.87 2.44 2.87 



0.18 0.18 0.18 

7) 


kdp 

0.19 0.19 0.19 




∆p bar 

0.54 

0.56 

0.87 

0.89 

1.15 

1.18 


ϑin °C +15...+40 


∆ϑN K 10 








-FT-: 

-FS-: 



1 

) 

2 

) 



3 


4 

) 

-1 


5 




6 


7 


8 


9 


10 


Fig. 4-7: Data sheet size 140 





Motor data 1) 

Frame length A B C D 

Winding code 0090 0120 0040 0120 0090 0120 0170 0060 0100 0120 



Fmax N 7450 10900 14250 17750 

Continuous nominal force FdN N 2415 3465 4460 5560 

Max. current imax A 70 88 70 130 140 175 210 140 210 225 

Continuous current idN A 13 16 13 22 29 30 46 28 46 53 


vFmax m/mi 90 120 40 120 90 120 170 60 100 120 


vN m/mi 170 190 100 190 170 190 220 140 180 190 

Force constant KiFN N/A 186 151 267 158 147 142 92 199 121 105 


KEMF Vs/ in preparation 

Winding resistance at 20°C R12 Ohm i.p. 2.3 i.p. 1.7 i.p. 2.7 i.p. i.p. i.p. 1.3 

Winding inductivety L12 mH i.p. 10.9 i.p. 16.4 i.p. 13.1 i.p. i.p. i.p. 12.4 


APL mm² 1 2.5 1 2.5 4 6 10 4 10 10 

Rated power loss PvN W 1700 2200 2700 3000 



FATT N 10700 15600 20500 25400 

Mass of primary - standard encapsulation mPS kg 23 33 42 51 

Mass of primary - thermal encapsulation mPT kg 28.3 40 50.7 61.3 



Qmin l/min 2.44 3.16 3.88 4.31 



0.18 0.18 0.19 0.19 

7) 


kdp 

0.19 0.19 0.19 0.19 




∆p bar 

0.88 

0.9 

1.38 

1.41 

1.99 

2.04 

2.4 

2.45 


ϑin °C +15...+40 


∆ϑN K 10 








-FT-: 

-FS-: 



1 

) 

2 

) 



3 


4 

) 

-1 


5 




6 


7 


8 


9 


10 



Fig. 4-8: Data sheet size 200




Motordaten 1) 


Winding code 0090 0120 0070 0120 0060 0090 



Fmax N 11000 16300 21500 


Max. current imax A 110 138 140 205 140 212 

Continuous current idN A 19 23 28 35 29 37 


vFmax m/min 90 120 70 120 60 90 


vN m/min 160 190 140 190 110 150 

Force constant KiFN N/A 176 146 184 147 232 182 


KEMF Vs/m i.p. i.p. i.p. i.p. i.p. i.p. 

Winding resistance at 20°C R12 Ohm i.p. 2 i.p. 1.3 i.p. 1 

Winding inductivety L12 mH i.p. 20.8 i.p. 13.6 i.p. 9.9 


APL mm² 2.5 4 4 6 4 6 




FATT N 16000 23400 30700 

Mass of primary - standard encapsulation mPS kg 33 48 62 

Mass of primary - thermal encapsulation mPT kg 40.8 58.3 74.9 



Qmin l/min 3.16 4.17 4.6 



0.19 0.19 0.19 

7) 


kdp 

0.19 0.19 0.19 




∆p bar 

1.41 

1.44 

2.29 

2.34 

2.72 

2.78 


ϑin °C +15...+40 


∆ϑN K 10 




Permissible storage and transport temperatur TL °C -10...+60 




-FT-: 

-FS-: 



1 

) 

2 

) 



3 


4 

) 

-1 


5 




6 


7 


8 


9 


10 


Fig. 4-9: Data sheet size 300 


Rexroth IndraDyn L Dimensions, installation dimension and - tolerances 5-1 

5 Dimensions, installation dimension and - 

tolerances 

5.1 Installation tolerances 

L1 


L2 

In order to ensure a constant force along the entire travel length, a 

defined air gap height must be guaranteed. For this purpose, the 

individual parts of the motor (primary and secondary) are tolerated 

accordingly. The distance of the mounting surface, the parallelism and 

the symmetry of the primary and secondary of the linear motor in the 

machine must be within a certain tolerance above the entire travel 

length. Any deformations that result from weight, attractive forces and 

process forces must be taken into account. A deviation of the specified 

nominal air gap may lead 

• to a reduction or modification of the specified performance data, 

• to a contact between the primary and the secondary and thus to 

damaged and destroyed motor components. 

For the installation of the motors into the machine structure, Bosch 

Rexroth specifies a defined installation height including tolerances (see 

installation size L1 in Fig. 5-1). Thus, the specified size and tolerances of 

the air gap are maintained automatically – even if individual motor 

components are replaced. 

Machine 

Primary 

Secondary 

Machine 

Size Primary Design Primary Design 

Secondary 

40, 070, 100, 140, 200 

300 

040, 070, 100, 140, 200 

300 

standard 

encapsulation 

standard 

encapsulation 

thermal 

encapsulation 

thermal 

encapsulation 

MLSxxxS-* 

Fig. 5-1: Mounting Sizes and Tolerances 

Installation 

Height 

L1 

61,4 +0,1 

63,4 +0,1 

73,9 +0,1 

77,9 +0,1 

Measurable 

Air Gap L2 

1,0 ± 0,4

5-2 Dimensions, installation dimension and - tolerances Rexroth IndraDyn L 

Parallelism and symmetry 

between primary and secondary 

Figure 5-2 defines the parallelism and symmetry between primary and 

secondary to be kept. 

Secondary 

0.1/1000 

0.5 

Primary 

Fig. 5-2: Parallelism and symmetry between primary and secondary 

PARALSYSM-MLF-EN.EPS 

Note: The specified installation height with the corresponding 

tolerances has to be observed absolutely. 



5.2 Mounting Sizes 

Size 040, primary in standard encapsulation 


Fig. 5-3: Size 040, primary in standard encapsulation 

mlp040-standard.tif


Size 040, primary in thermal encapsulation 

Fig. 5-4: Size 040, primary in thermal encapsulation 

mlp040-thermo.tif 



Size 040, secondary 


Fig. 5-5: Size 040, secondary 

mls040.tif




mlp070-standard.tif 






mlp070-thermo.tif




mls070.tif 






mlp100-standard.tif




mlp100-thermo.tif 






mls100.tif










mlp140-thermo.tif




mls140.tif 






mlp200-fs.tif




mlp200-ft.tif 






mls200.tif










mlp300-thermo.tif




mls300.tif 


Rexroth IndraDyn L Type codes for the IndraDyn L 1 

6 Type codes for the IndraDyn L 

6.1 Description 


The type code describes the available motor variations. It is the basis for 

selecting and ordering products from BOSCH REXROTH. This applies to 

both new products as well as spare parts and repairs. 

IndraDyn L is the overall product designation for synchronous linear 

motors. This designation describes the whole system, which consists of 

a primary and a secondary. As linear motors are kit motors, the 

primaries and secondaries each have their own additional, unambiguous 

three-letter abbreviations: MLP and MLS, respectively. 

- FS - 


MLP 

primary 

IndraDyn L 

synchronous-linear 

motor 

- FT - 

thermo encapsulation 

Fig. 6-1: Abbreviations for IndraDyn L motor and components 

MLS 

secondary 

IndraDynL_Bausatz_EN.EPS 

The following figures give an example of motor type codes for the 

primary and secondary. The type code allows you to exactly define the 

individual parts, e.g. for orders. 

The following description gives an overview of the separate positions of 

the type code and their meanings. 

Note: When selecting a product, always consider the detailed 

specifications in Chapter 4 “Technical Data” and Chapter 9 

“Notes Regarding Applications”.

2 Type codes for the IndraDyn L Rexroth IndraDyn L 

Type code of the Primary – The MLP 

Abbrev. 

1 

2 

3 

4 

Column 

1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 

Example: M L LPP1 0100A -00 1 2 0 - F S - N 0 C N - NNNN 

0 1 2 3 4 5 6 7 8 9 0 

1. Product 

1.1 MLP . . . . . . . . . . = MLP 

. . . . . = MLP 

2. Motor size 

2.1 100 . . . . . . . . . . . . . . . . . = 100 

3. Motor length 

3.1 Lengths . . . . . . . . . . . . . . . = A, B, C 

4. Windings code 

4.1 MLP100A . . . . . . . . . . . . = 0120, 0150, 0190 

4.2 MLP100B . . . . . . . . . . . . = 0120, 0250 

4.3 MLP100C . . . . . . . . . . . . = 0090, 0120, 0190 

5. Cooling mode 

5.1 Liquid cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = F 

6. Encapsulation 

6.1 Standard encapsulation. . . . . . . . . . . . . . . . . . . . . . . . = S 

6.2 Thermo-encapsulation . . . . . . . . . . . . . . . . . . . . . . . . = T 

7. Motor encoder 

7.1 without encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = N0 

8. Electrical connection 

8.1 Wire conducted through front of primary part . . . . . . . . . . . . . . = CN 

SAMPLE 

9. Other design 

9.1 none. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNNN 

Illustration example: MLP100 

A 

D 

1 2 3 4 5 6 

B 

C 

A 

B 

C 

D 

Secondary part MLS 

Primary part MLP (Standard encapsulation 

or Thermo-encapsulation) 

Electrical connection 

Screw mounting (from above) 

Fig. 6-2: Example of a type code for an MLP100 primary 

INN-41-43-Muster2.EPS 



Positions 1 2 3 


Positions 7 

Positions 9 10 11 12 

Position 14 

Position 15 

Positions 17 18 

Positions 19 20 



Subcomponent MLP 

MLP is the designation of the primary part of an IndraDyn L motor. 

2. Motor Frame Size 

The motor frame size is derived from the active magnet width of the 

secondary and represents different power ranges. 

3. Motor Frame Length 

Within a frame size, the graduation of increasing motor frame length is 

indicated by ID letters in alphabetic order. 

Frame lengths are, for example, A, B, or C. 

4. Winding Code 

The numbers of the winding code describe the obtainable maximum 

speed, Fmax in m/min. 

5. Cooling 

In general, the primary of the IndraDyn L motors are provided with liquid 

cooling for operation and thus only available with liquid cooling. 

6. Encapselation 

• S = standard encapsulation stainless steel encapsulation with the 

liquid cooling integrated into the back of the motor to dissipate the 

lost heat. 

• T = thermal encapsulation: stainless steel encapsulation with 

additional liquid cooling on the back of the motor and additional 

conductive plates for optimal thermal decoupling from the machine 

frame. 


The feedback system is not in the scope of delivery of Bosch Rexroth 

and has to be provided and mounted by the machine manufacturer 

himself. 

8. Electric connection 

The primaries of IndraDyn L synchronous linear motors are fitted with a 

highly-flexible shielded cable. The power cable is brought out through 

the front of the primary and is fixed to it. 

9. Other types 

These fields for future use.


Type code of the Secondary – The MLS 

Abbrev. 

1 

2 

3 

4 

Column 

1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 

xample: Example: MLS100 

MLS100S-3A-0150-NNNN 

5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 

1. Product 

1.1 MLS. . . . . . . . = MLS 

2. Motor size 

2.1 100 . . . . . . . . . . . . . . = 100 

3. Type 

3.1 Secondary part. . . . . . . . . . . = S 

4. Mechanical design 

4.1 Fixing with screws . . . . . . . . . . . . = 3 

5. Mechanical protection 

5.1 with cover sheet . . . . . . . . . . . . . . . = A 

6. Segment length 

6.1 Secondary part length 150 mm . . . . . . . = 0150 



SAMPLE 


7.1 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNNN 

Illustration example: MLS100 

1 

2 

3 

4 

. . . . = MLS 

1 

4 

1 2 3 4 5 6 

2 

3 


Primary part MLP (Standard encapsulation or Thermo-encapsulation) 

Power connection 


Fig. 6-3: Example of a type code for an MLS100 secondary 

RNC-41431-Muster2.EPS 





Position 7 

Position 9 

Position 10 




Subcomponents MLS 

MLS is the designation of the secondary part of an IndraDyn L motor. 

2. Motor Frame Size 

The motor frame size is derived from the active magnet width of the 

secondary and represents different power ranges. 

3. Type 

S = secondary 


The number 3 indicates that the secondary will be bolted along the outer 

edge of the secondary. 


To ensure the utmost operation reliability, the permanent magnets of the 

secondary are protected against corrosion, coolants, oil and mechanical 

damage by an integrated, stainless-steel cover plate. 


Secondary segments are available in 150mm, 450mm and 600mm 

lengths. 

7. Other types 

These fields for future use.


6.2 Type code for IndraDyn L 040 

Abbrev. 

1 

2 

3 

4 

Column 

1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 

Example: M L P 0 4 0 A - 0 3 0 0 - F S - N 0 C N - NNNN 

1. Product 

1.1 MLP . . . . . . . . . . = MLP 

2. Motor size 

2.1 040 . . . . . . . . . . . . . . . . . = 040 


3.1 Lengths . . . . . . . . . . . . . . . . . = A, B 


4.1 MLP040A . . . . . . . . . . . . = 0300 

4.2 MLP040B . . . . . . . . . . . . = 0150, 0250, 0300 




6.1 Standard encapsulation . . . . . . . . . . . . . . . . . . . . . . . = S 






9.1 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNNN 


A 

D 

B 

C 

A 

B 

C 

D 

Fig. 6-4: Type code for primary 040 






INN-41-43-T04-01-M05-MLP2.EPS 



Abbrev. 

1 

2 

3 

Column 

1 2 3 45 6 7 8 9 0 1 2 3 45 6 7 8 9 0 1 2 3 45 6 7 8 9 0 1 2 3 45 6 7 8 9 

Example: MLS040S-3A-0150-NNNN 

1. Product 

1.1 MLS . . . . . . . . = MLS 

2. Motor size 

2.1 040 . . . . . . . . . . . . . . = 040 

3. Type 

3.1 Secondary part . . . . . . . . . . . = S 










7.1 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNNN 


2 

1 

2 

3 

4 





RNC-41430-402_NOR_E_D0_2003-06-162.EPS 


1 

4 

3 

Fig. 6-5: Type code for secondary 040 

4 

0


6.3 Type code IndraDyn L 070 

Abbrev. 

1 

2 

3 

4 

Column 

1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 

Example: M L P 0 7 0 A - 0 3 0 0 - F T - N 0 C N - NNNN 

1. Product 

1.1 MLP . . . . . . . . . . = MLP 

2. Motor size 

2.1 070 . . . . . . . . . . . . . . . . . = 070 


3.1 Lengths . . . . . . . . . . . . . . . = A, B, C 


4.1 MLP070A = 0150, 0220, 0300 

4.2 MLP070B = 0100, 0120, 0150, 0250, 0300 

4.3 MLP070C = 0120, 0150, 0240, 0300 











9.1 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNNN 


A 

D 

B 

C 

A 

B 

C 

D 







INN-41-43-T07-01-M06-MLP2.EPS 



Abbrev. 

1 

2 

3 

Column 

1 2 3 45 6 7 8 9 0 1 2 3 45 6 7 8 9 0 1 2 3 45 6 7 8 9 0 1 2 3 45 6 7 8 9 


1. Product 

1.1 MLS . . . . . . . . = MLS 

2. Motor size 

2.1 070 . . . . . . . . . . . . . . = 070 

3. Type 

3.1 Secondary part . . . . . . . . . . = S 










7.1 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNNN 


1 

2 

3 

4 





RNC-41430-702_NOR_E_D0_2003-06-162.EPS 


1 

4 

2 

3 


4 

0



Abbrev. 

1 

2 

3 

4 

Column 

1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 


1. Product 

1.1 MLP . . . . . . . . . . = MLP 

2. Motor size 

2.1 100 . . . . . . . . . . . . . . . . . = 100 


3.1 Lengths . . . . . . . . . . . . . . . = A, B, C 


4.1 MLP100A . . . . . . . . . . . . = 0120, 0150, 0190 

4.2 MLP100B . . . . . . . . . . . . = 0120, 0250 

4.3 MLP100C . . . . . . . . . . . . = 0090, 0120, 0190 




6.1 Standard encapsulation . . . . . . . . . . . . . . . . . . . . . . . . = S 







9.1 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNNN 


A 

D 

B 

C 

A 

B 

C 

D 







INN-41-43-T10-01-M06-MLP2.EPS 



Abbrev. 

1 

2 

3 

Column 

1 2 3 45 6 7 8 9 0 1 2 3 45 6 7 8 9 0 1 2 3 45 6 7 8 9 0 1 2 3 45 6 7 8 9 


1. Product 

1.1 MLS . . . . . . . . = MLS 

2. Motor size 

2.1 100 . . . . . . . . . . . . . . = 100 

3. Type 

3.1 Secondary part . . . . . . . . . . . = S 










7.1 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNNN 


1 

2 

3 

4 






1 

4 

2 

3 


4 

0 

RNC-41431-002_NOR_E_D0_2003-06-122.EPS



Abbrev. 

1 

2 

3 

4 

Column 

1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 


1. Product 

1.1 MLP . . . . . . . . . . = MLP 

2. Motor size 

2.1 140 . . . . . . . . . . . . . . . . . = 140 


3.1 Lengths . . . . . . . . . . . . . . . = A, B, C 


4.1 MLP140A . . . . . . . . . . . . = 0120 

4.2 MLP140B . . . . . . . . . . . . = 0090, 0120 

4.3 MLP140C . . . . . . . . . . . . = 0050, 0120, 0170 




6.1 Standard encapsulation . . . . . . . . . . . . . . . . . . . . . . . . = S 



7.1 without encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = N0 




9.1 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNNN 


A 

D 

B 

C 

A 

B 

C 

D 







INN-41-43-T14-01-M06-MLP2.EPS 



Abbrev. 

1 

2 

3 

Column 

1 2 3 45 6 7 8 9 0 1 2 3 45 6 7 8 9 0 1 2 3 45 6 7 8 9 0 1 2 3 45 6 7 8 9 


1. Product 

1.1 MLS . . . . . . . . = MLS 

2. Motor size 

2.1 140 . . . . . . . . . . . . . . = 140 

3. Type 











7.1 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNNN 


1 

2 

3 

4 





RNC-41431-402_NOR_E_D0_2003-06-122.EPS 


1 

4 

2 

3 


4 

0



Abbrev. 

1 

2 

3 

4 

Column 

1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 


1. Product 

1.1 MLP . . . . . . . . . . = MLP 

2. Motor size 

2.1 200 . . . . . . . . . . . . . . . . . = 200 


3.1 Lengths . . . . . . . . . . . . . = A, B, C, D 


4.1 MLP200A . . . . . . . . . . . . = 0090, 0120 

4.2 MLP200B . . . . . . . . . . . . = 0040, 0120 

4.3 MLP200C . . . . . . . . . . . . = 0090, 0120, 0170 

4.4 MLP200D . . . . . . . . . . . . = 0060, 0100, 0120 











9.1 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNNN 


A 

D 

B 

C 

A 

B 

C 

D 







INN-41-43-T20-01-M05-MLP2.EPS 



Abbrev. 

1 

2 

3 

Column 

1 2 3 45 6 7 8 9 0 1 2 3 45 6 7 8 9 0 1 2 3 45 6 7 8 9 0 1 2 3 45 6 7 8 9 


1. Product 

1.1 MLS . . . . . . . . = MLS 

2. Motor size 

2.1 200 . . . . . . . . . . . . . . = 200 

3. Type 











7.1 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNNN 


2 

1 

2 

3 

4 






1 

4 

3 


4 

0 

RNC-41432-002_NOR_E_D0_2003-06-122.EPS



Abbrev. 

1 

2 

3 

4 

Column 

1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 

Example: M L P 3 0 0 B - 0 1 2 0 - F T - N 0 C N - NNNN 

1. Product 

1.1 MLP . . . . . . . . . . = MLP 

2. Motor size 

2.1 300 . . . . . . . . . . . . . . . . . = 300 


3.1 Lengths . . . . . . . . . . . . . . . = A, B, C 


4.1 MLP300A . . . . . . . . . . . . . . . . . = 0090, 0120 

4.2 MLP300B . . . . . . . . . . . . . . . . . = 0070, 0120 

4.3 MLP300C . . . . . . . . . . . . . . . . . = 0060, 0090 

5. Cooling 







8.1 Cable conducted through front of the primary part . . . . . . . . . . = CN 


9.1 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNNN 


A 

D 

B 

C 

A 

B 

C 

D 







INN-41-43-T30-01-M03-MLP2.EPS 



Abbrev. 

1 

2 

3 

Column 

1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 


1. Product 

1.1 MLS . . . . . . . . = MLS 

2. Motor size 

2.1 300 . . . . . . . . . . . . . . = 300 

3. Type 



4.1 Fixing per screws . . . . . . . . . . . . = 3 








7.1 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNNN 


1 

2 

3 

4 






1 

4 

2 

3 


4 

0 

RNC-41433-002_NOR_E_D0_2003-06-122.EPS



Rexroth IndraDyn L Accessories and Options 7-1 

7 Accessories and Options 

7.1 Hall sensor box 


The SHL01.1 hall sensor box is an optional component for drive 

controllers with incremental measuring systems and Bosch Rexroth 

IndraDyn L motors. 

When using an incremental measuring system without an SHL box, the 

axis must be commutated every time the drive is powered up. This is 

due to a drive-internal procedure. Without determining the proper 

commutation, the motor cannot be operated. An SHL box eliminates this 

necessity. 

Note: The commutation is determined automatically during the 

phase step up by the SHL-Box. Therefore, no power switchon 

is necessary. 

Possible applications are, for example 

• Commutation of motors on vertically axes, 

• Commutation of motors which should not move for safety reasons 

during the commutation process . 

• Gantry-arrangement of the motors. 

SHL hall-effect-sensor boxes can be delivered 

• ex works, as accessory of an IndraDyn L motor, 

• as a spare part for retrofitting existing machines with IndraDyn L 

motors and IndraDyn or Ecodrive drive controllers. 

Note: With the appropriate firmware, DIAX04-type controllers are 

also compatible with the SHL hall-effect-sensor boxes. 

Fig. 7-1: Accessory SHL01.1 

Hallbox10.EPS

7-2 Accessories and Options Rexroth IndraDyn L 

Schematic assembly 

1 

X4 

H1 

S1 

S3 S2 

0 1 

0 1 

2 

2 

9 

9 

8 

8 

3 

3 

4 

4 

7 

7 

5 5 6 

6 

2 

1 2 3 4 

1 2 3 4 5 6 7 8 9 1 2 3 4 

5 6 7 8 

111213141516 1718 5 6 7 8 

3 ~ 

4 5 6 

IKS4374 

3 

Hallbox1.EPS 

1: Control 4: Secondary 

2: Control unit 5: Primary 

3: Linear scale 6: SHL Hall-effect-sensor box 

with cable 

Fig. 7-2: Schematic assembly of IndraDyn L and SHL box 

Note: Notice the notes within the “SHL01.1, Functional description” 

documentation, part-No. R911292537. 


Rexroth IndraDyn L Electrical connection 8-1 

8 Electrical connection 

8.1 Power connection 

Connection cable on the primary 

Motor Frame 

Size 

primary 

Power cable on 

the primary 


IndraDyn L motor primaries are fitted with a two-meter, flexible, shielded 

power cable. 

screwed conduit entry 

2000 +10 

power cable 

ferrules 

100 +10 

1 - U 

2 - V 

3 - W 

5 - 

PTC SNM.150.DK300 

6 - 

7 - 

PTC KTY84-130 

8 - 

GE/GR 

ANSCHLKAB-MLF-EN.EPS 

Fig. 8-1: Design of power cable for the primary of the IndraDyn L, the MLP 

The following overview gives the technical data of the power cables for 

each motor size. 

Cross-section of 

power 

conductors 


controller 

conductors 


cable 

Bending radius 

of cable 

MLP040x-xxxx INK653 1.0 mm² 0.75 mm² 12 mm 72 mm 

MLP070x-xxxx INK603 4.0 mm² 16.3 mm 100 mm 

MLP100x-xxxx 

MLP140x-xxxx 

MLP200A-xxxx 

MLP200B-xxxx 

MLP200C-0090 

MLP200C-0120 

MLP200D-0060 

MLP200C-0170 

MLP200D-0100 

MLP200D-0120 

MLP300x-xxxx 

INK604 6.0 mm² 18.5 mm 110 mm 

INK605 10.0 mm² 

1.0 or 1.5 mm² 

Fig. 8-2: Power cable data for IndraDyn L primaries 

22.2 mm 130 mm

8-2 Electrical connection Rexroth IndraDyn L 

Laying the primary power cable 

The power cable which is connected to the primary has flying leads 

terminated with ferrules (see Fig. 8-1). This power cable may not be 

exposed to dynamic bending forces (repeated flexing). The power cable 

on the primary should therefore never be laid in a moving cable track. 

We recommend ridgidly laying the cable and terminating it with 

• a flange socket 

• a connection coupling or 

• a terminal box (not in the scope of delivery of Bosch Rexroth) 

From this junction, the main power cable can be laid in a cable track or 

in the machine construction. Ready-made connection cables are 

available from Bosch Rexroth. 

drive controller 

energy chain 

ongoing 

connecting cable 

connection point 

- flange socket 

- coupling 

- terminal box 

primary 

power cable 

motor 

Fig. 8-3: Laying of the connection cable attached to the primary 

WARNING 

MOTORANSCHL-MLF-EN.EPS 

Damage of the connection cable (and, thus, the 

motor) through repeated flexing! 

⇒ Do not lay the power cable of the primary in a cable 

track. 

⇒ Lay the connecting cable, after the junction, in a 

cable track. 

Note: The connection cables of the primaries are designed for the 

highest current of a given motor size, so, in certain 

circumstances, the cross-section of the power cable after the 

junction could be smaller. 



Power Cable Connection 

Connection via flange socket or 

connection coupling 

Terminal box connection 

Parallel motor connection 


The following diagrams show the power cable connection plans for the 

respective connection types. 

M 

3 ~ 

flange socket coupling power connector 

PTC 

J 

PTC 

J 

8 

7 

6 

5 

3 

2 

1 

GNYE 

G 

F 

H 

E 

C 

B 

A 

D 

G 

F 

H 

E 

C 

B 

A 

D 

8 (-) 

7 (+) 

6 

5 

3 

2 

1 

GNYE 

KTY84-130 

SNM.150.DK.*** 

motor temperature 

sensor (connection 

to drive controller) 

ELCON01-MLF-EN.EPS 

Fig. 8-4: Electrical connection when using a flange socket or a connection 

coupling 

M 

3 ~ 

PTC 

PTC 

J 

J 

8 

7 

6 

5 

3 

2 

1 

GNYE 

terminal box 

W 

V 

U 

8 (-) 

7 (+) 

6 

5 

3 

2 

1 

GNYE 

Fig. 8-5: Electric connection when using a terminal box. 

KTY84-130 

SNM.150.DK.*** 


sensor (connection 

to drive controller) 


Laying of cable and cable cross-sectional areas 

When connecting two or more motors parallel onto one drive controller, 

the following connection possibilities exist for connection cable: 

• Lay a common cable with a higher cross-section (Fig. 8-8) 

• Lay two separate parallel cables (Fig. 8-7) 

The latter possibility gives a possible advantage of a lower bending 

radius. The summation of the cross-section of the cables layed in parallel 

must correspond to the increased requirement of the combination of 

motors installed in parallel.


Power connection with a single 

motor arrangement 

Power connection with a parallel 

motor arrangement and separate 

power cables 

Power connection with a parallel 

motor arrangement and a 

common power cable with an 

increased cross-sectional area 


energy chain 


Fig. 8-6: Power connection with a single motor arrangement 


connection 

point 

energy chain 



motor 

MOTORANSCHL01-MLF-EN.EPS 

motor 1 

motor 2 


Fig. 8-7: Power connection with a parallel motor arrangement, and separate 

power cables 


energy chain 

connection 

point 

motor 1 

motor 2 


Fig. 8-8: Power connection with a parallel motor arrangement and a common 

power cable with increased cross-sectional area 



Power Cable (after the junction 

with the primaries connection 

cable) 


The selection of the correct cable cross-sectional area depends on the 

way the cable is laid. The decision should be made according to the 

following table: 


RMS Motor 

Motor Type 

phase-current [A] 

MLP040A-0300 4 

MLP040B-0150 4 

MLP040B-0250 5 

MLP040B-0300 6 

MLP070A-0150 5 

MLP 070A-0220 6 

Power cable arrangement 

acc. to Figs. 8-6 and 8-7 

Power cable arrangement 

according to Fig. 8-8 

1.0 mm² (INK653) 

MLP 070A-0300 10 2.5 mm² (INK602) 

MLP 070B-0100 5.2 

1.0 mm² (INK653) 

MLP 070B-0120 5.8 

1.0 mm² (INK653) 

MLP 070B-0150 6.2 

MLP 070B-0250 10 2.5 mm² (INK602) 

MLP 070B-0300 12 4 mm² (INK603) 

MLP 070C-0120 8.9 

MLP 070C-0150 10 

MLP 070C-0240 13 

2.5 mm² (INK602) 

4 mm² (INK603) 

MLP 070C-0300 19 2.5 mm² (INK602) 6 mm² (INK604) 

MLP 100A-0090 6.6 

MLP 100A-0120 8 

MLP 100A-0150 10 

MLP 100A-0190 12 

MLP100B-0120 12 

1.0 mm² (INK653) 

2.5 mm² (INK602) 

4 mm² (INK603) 

MLP100B-0250 22 2.5 mm² (INK602) 10 mm² (INK605) 

MLP100C-0090 13 1.0 mm² (INK653) 4 mm² (INK603) 


MLP100C-0190 23 4 mm² (INK603) 10 mm² (INK605) 

MLP140A-0120 12 

MLP140B-0090 13 

1.0 mm² (INK653) 4 mm² (INK603) 





MLP200A-0090 13 1.0 mm² (INK653) 4 mm² (INK603) 




MLP200C-0090 29 4 mm² (INK603) 

MLP200C-0120 30 6 mm² (INK604) 

16 mm² (INK606) 


MLP200D-0060 28 4 mm² (INK603) 16 mm² (INK606) 

MLP200D-0100 46 

10 mm² (INK605) 

25 mm² (INK607) 

MLP200D-0120 53 

----- 


MLP300A-0120 23 

4 mm² (INK603) 

10 mm² (INK605) 

MLP300B-0070 28 

MLP300B-0120 35 6 mm² (INK604) 

16 mm² (INK606) 

MLP300C-0060 29 4 mm² (INK603) 


Fig. 8-9: Required cross-sectional areas of the conductors in the power cable 

depending on the motor type, the way the cables are laid and the 

way the motors are arranged


Connection of IndraDrive Drive Controller 

Drive device Terminal block 

power connection 

HMS0x.x 

HMD0x.x 

Separate arrangement 

Note: For additional descriptions of the power cables on the 

primaries and the power connection cables, see the 

documentation entitled “Connection Cable” Selection Data, 

Mat-No.: R911280894. 

The following overview shows the connection and termination 

designations for the motor power conductors and the motor temperature 

sensors. 

Note: For additional information about motor temperature 

monitoring, see Chapter 9-7. 

Termination 

designation of the 


Terminal block 



sensors 

Termination 



sensors 

X5 1, 2, 3 X6 1, 2 

Fig. 8-10: Termination designation at the drive-controller 

X5 

1 

1 2 3 

2 

M 

3 


3 

GNYE 

+24VBr 

motor 

0VBr 

MotTemp+ 

1 

5 

2 

MotTemp- 

6 

7 

PTC 

SNM.150.DK.* 

X6 

motor cable 

screen connection 

8 

PTC 

KTY84-130 

temperature sensors 


Fig. 8-11: Connection to the drive-controller – one primary per drive controller 



Parallel arrangement 

Power cable connection of the 

primary using a parallel 

arrangement of the motors 


X5 

1 

1 2 3 

2 

M 

3 


3 

GNYE 

+24VBr 

motor 

0VBr 

1 MotTemp+ 

2 

MotTemp- 

5 

6 

7 

PTC 

SNM.150.DK.* 

X6 

8 

PTC 

KTY84-130 


motor cable 


1 

2 

M 

3 

3 

GNYE 

motor 

5 

6 

7 

PTC 

SNM.150.DK.* 

8 

PTC 

KTY84-130 



Fig. 8-12: Sample connection to the drive controller – parallel arrangement of 

primaries on one drive controller. 

The way the power conductors are connected to the drive controller 

when you have a parallel arrangement of the primaries depends on the 

direction(s) of the connection cable outputs from the primaries. 

Connection with an arrangement according to Fig. 9-8 

Cable outputs in the same direction 

Drive controller X5 1 2 3 

Primary 1 1 2 3 



Cable outputs in the OPPOSITE direction 

Drive controller X5 1 2 3 



Fig. 8-13: Connection to the drive controller of the power conductors of parallel 

motors to a single drive controller – dependent on layout of 

primaries


Connection of DIAX04 and EcoDrive Drive-Controllers 

Drive device Terminal block 


HDS0x.x 

DKCxx.x 

Single Connection 

The following describes the connection of the power supply and the 

temperature sensors to DIAX04 and EcoDrive (DKCx.3) drivecontrollers. 

The following overview shows the connection and termination 

designations for the power connection and the motor temperature 

sensors. 

Note: For additional information about motor temperature 

monitoring, see Chapter 9-7. 

Termination 


power conductors 

Terminal block 

designation for the 


sensors 

Termination 


motor-temperaturesensor 

conductors 

X5 A1, A2, A3 X6 1, 2 

Fig. 8-14: Termination designations of the drive-controller 


X5 

A1 A2 A3 

1 

2 

M 

3 

3 

GNYE 

4 

BR+ 

motor 

5 

BR- 

1 

TM+ 

5 

2 

TM- 

6 

3 

UB 

6 

0VB 

7 


X6 

SNM.150.DK.* KTY84-130 

XS1 

motor cable 


Fig. 8-15: Connection to the drive-controller – separate primary 





Connection of the power 

conductors of parallel-arranged 

primaries 



X5 

A1 A2 A3 

1 

2 

M 

3 

3 

GNYE 

motor 

5 

4 

BR+ 

6 

5 

BR- 

1 

TM+ 

7 

2 

TM- 

8 

3 

UB 

SNM.150.DK.* KTY84-130 


6 

0VB 

7 

X6 

XS1 

motor cable 


1 

2 

M 

3 

3 

GNYE 

motor 

5 

6 

7 

8 

SNM.150.DK.* KTY84-130 



Fig. 8-16: Connection on the drive-controller – parallel arrangement of 

primaries 

The way the power conductors are connected to the drive controller 

when you have a parallel arrangement of the primaries depends on the 

direction(s) of the connection cable outputs from the primaries. 


Cable outputs in the same direction 

Drive-controller X5 A1 A2 A3 




Cable outputs in the OPPOSITE direction 

Drive-controller X5 A1 A2 A3 



Fig. 8-17: Connection to the drive controller of the power conductors of parallel 

motors to a single drive controller – dependent on layout of primaries


8.2 Connection of linear feedback devices 

The connection of linear feedback devices is made via ready-made 

cables. 


cable assembly 

(available from Bosch Rexroth) 

material measure 

connecting cable for scan head 

(part of the length measuring systems, 

supplied by the measuring system manufacturer) 

connector or 

coupling 

scan head 

Fig. 8-18: Connection example of a linear feedback device 


The following table shows an overview of the ready-made cables for 

linear feedback devices. 

Measuring system type Absolut, ENDAT Incremental 

Output variable Voltage Voltage 

Signal flow line Sine Sine 

Signal amplitude 1Vp-p 1Vp-p 

Position interface DAG DLF 

Bosch Rexroth ready-made cables – designed with 

Connector for DIAX04 

Connector for DKCxx.3 

Connector for 

IndraDrive 

Coupling for DIAX04 

Coupling for DKCxx.3 

RKG 4142 

RKG 4001 

RKG 4038 

RKG 4384 

RKG 4002 

RKG 4041 

Coupling for IndraDrive 

- 

RKG 4040 

Fig. 8-19: Connection components for linear feedback devices 

- 

- 

RKG 4383 

RKG 4389 

Note: For additional descriptions, see documentation “Connection 

Cable” Selection Data, Mat-Nr. R911280894. 


Rexroth IndraDyn L Application and Construction Instructions 9-1 

9 Application and Construction Instructions 

9.1 Functional principle 

Axis installation 


The following figure shows the principal design of IndraDyn L motors. 

N S N S N 

secondary 

with permanent magnets 

primary 

with three-phase winding 

Fig. 9-1: General construction of an IndraDyn L motor 


AUFBAU-MLF-EN.EPS 

The force generation of the IndraDyn L motor, a synchronous-linear 

motor, is the same as the torque generation at rotative synchronous 

motors. The primary (active part) has a three-phase winding; the 

secondary (passive part) has permanent magnets (see Fig. 9-1). 

Both, the primary and the secondary can be moved. 

Realization of any traverse path length can be done by stringing together 

several secondaries. 

The IndraDyn L motor is a kit motor. The components primary and 

secondary are delivered separately and completed by the user via linear 

guide and the linear measuring system. 

The construction of an axis fitted with an IndraDyn L motor (see Fig. 9-2) 

normally consists of 

• Primary with three-phase winding, 

• one or more secondaries with permanent magnets, 

• Linear scale 

• linear guide, 

• energy flow as well as 

• slide or machine construction

9-2 Application and Construction Instructions Rexroth IndraDyn L 

9.2 Motor Design 

secondary 

primary 

cable track 

linear scale 

Fig. 9-2: General construction of an axis with an IndraDyn L 

linear guideways 

slide and/or 

machine 

structure 

ACHSAUFBAU-MLF-EN.EPS 

For force multiplication can be two or more primaries mechanically 

coupled, arranged parallel or in-line. For further information see chapter 

9.4 “Arrangement of Motor Components”. 

Note: Only the primary and the secondary belong to the scope of 

delivery of the motor. 

Linear guide and length scale as well as further additional 

components have to be made available by the user. For 

recommendations to tested additional components see 

chapter 16 “Recommended suppliers of additional 

components” 

IndraDyn L motors of Bosch Rexroth are tested drive components. They 

have the following characters: 

• Modular system with different motor sizes and lengths for feed forces 

up to 21.500 N per motor and speeds over 600 m/min 

• Different winding constructions at any motor size for optimum 

adjustment to different speed demands. 

• All motor components are completely encapsulated, i.e. crack 

initiation within casting compounds, damage or corrosion of magnets 

a.s.o. are excluded. 

• Different designs regarding cooling and encapsulation of the primary 

(see below: “standard and thermal encapsulation”) 

• Protection class IP65 (all motor components) 

• High operation safety for DC-link voltage up to 750V. 

• No mechanical wastage 

• Protection of the motor winding against thermal overstress by 

integrated temperature sensors 

• Flexible, shielded and strain-bearing power lead wire 



Design of cooling and 

encapsulation 

Primary in standard encapsulation 

Main application area 


To make the optimum motor for the different uses, regarding technical 

demands and costs available, are primary parts in different designs in 

cooling and encapsulation available. 

• Standard encapsulation: stainless steel encapsulation with a liquid 

cooling integrated into the back of the motor to dissipate the lost heat. 

• Thermal encapsulation: stainless steel encapsulation with an 

additional liquid cooling on the back of the motor and heat conductive 

plates for optimum thermal decoupling to the machine construction. 

At use with less thermal demands on the exactness of the machine, 

primaries in standard encapsulation present an economy solution. 

Primaries with standard encapsulation are mainly used in the general 

automation sector. There, the electrical motor components are protected 

by a stainless steel encapsulation. The cooling system of this motor 

design is integrated into the motor and can only be used to discharge 

lost heat or keeping the specified continuous feedrate. It offers no 

additional thermal decoupling on the motor side to the machine. 

laminated core 

motor winding 

integrated 

cooling 

fixing thread 

permanent magnets 

primary 

secondary 

cooling connection 

(G 1/4) 

STANDARDKAPSELUNG-MLP-EN.EPS 

Fig. 9-3: Primary with standard encapsulation (see fig. with secondary) 

Note: For further information to liquid cooling see Chapter 9.6 

“Motor cooling”. 

The main application areas of this design of the primary can be found in 

the sectors: 

• General automation 

• Handling


Primary in thermal encapsulation 

Main application area 

Primaries in thermal encapsulation reach an high constant temperature 

on the mounting surface due to an additional – into the encapsulation 

integrated liquid coolant for thermal encapsulation to the machine 

construction. At design “Thermal encapsulation”, a maximum 

temperature rise on the screw-on surface in opposite to the coolant inlet 

temperature of 2 K can be reached. 

integrated 

cooling 

laminated core 

motor winding 

additional cooling 

directions 

fixing thread 

permanent magnets 

primary 

cooling connection 

(G 1/4) 

secondary 

THERMOKAPSELUNG-MLP-EN.EPS 

Fig. 9-4: Primary with thermal encapsulation (see fig. with secondary) 

The primary is not completely connected with the mounting surface on 

the machine side, but only lays on increased bearing points. This offers 

the following advantages: 

• Additional thermal encapsulation and therewith further minimization of 

the possible heat-flow into the machine 

• Processing of the screw-on surface on the machine side makes it 

easier to keep the necessary mounting tolerances. 

Note: For further information to liquid cooling see Chapter 9.6 

“Motor cooling”. 

Main application areas of this primary design are, e.g. 

• Machine tools 

• Precision applications 



Design secondary part 

Available length of the 

secondaries 

Required length of the 

secondary 


The secondary consists of a steel base plate with fitted permanent 

magnets. The fastening holes are located on the outer edge along the 

secondary. 

To ensure the utmost operation reliability, the permanent magnets of the 

secondary are always protected against corrosion, action of outer 

influences (e.g. coolants and oil) and against mechanical damage, due 

to an integrated rustless cover plate. 

It is possible to use a scraper direct on the secondary (see also Chapter 

9.20 “Scraper”). 

Fig. 9-5: MLS-secondary 

MLS.tif 

Note: The design of the secondary is independent from the design 

of the primary. 

Secondaries are available in the following lengths (see also Chapter 5 

“Specification) 

• 150mm 

• 450mm 

• 600mm 

The required length L of the secondary can be defined as follows: 

L ≥ L + L 

Secondary part 

Traverse path 

Fig. 9-6: Defining the required length of the secondary 

Pr imary part


Motor Sizes 

Sizes 

For adjusting on different feed force requirements, Bosch Rexroth offers 

IndraDyn L motors in a modular system with different sizes and lengths. 

The active breadth of the primary and the secondary at linear motors 

serve to define the size. A linear motor with e.g. size 100 has a 

laminated core and magnet breadth of 100 mm. The IndraDyn L modular 

system contains the following motor sizes: 

40 70 100 140 200 300 

Fig. 9-7: Sizes of IndraDyn L synchronous linear motors 

Baugrösse_Breite_MLF.EPS 

Every primary is graduated in different motor lengths. The designation of 

the length of the primary is done by the letters A, B, C, D. 

A B C D 

Fig. 9-8: Different lengths of the primaries 

Baugrösse_Länge_MLF.EPS 

Note: For detailed information to sizes and length see Chapter 5 

“Specification”. 



9.3 Requirements on the Machine Design 

Mass reduction 

Mechanical rigidity 

Natural frequencies 

Mechanically linked axes 


Derived from design and properties of linear direct drives, the machine 

design must meet various requirements. For example, the moved 

masses should be minimized whilst the rigidity is kept at a high level. 

To ensure a high acceleration capability, the mass of the moved 

machine elements must be reduced to a minimum. This can be done by 

using materials of a low specific weight (e.g. aluminum or compound 

materials) and by design measures (e.g. skeleton structures). 

If there are no requirements for extreme acceleration, masses up to 

several tons can be moved without any problems. There is no controlengineering 

correlation between the moved slide mass and the motor´s 

mass, as this is the case with rotary drives. 

Precondition therefore is, a very stiff coupling of the motor to the weight. 

In conjunction with the mass and the resulting resonant frequency, the 

rigidity of the individual mechanical components within a machine chiefly 

determines the quality a machine can reach. The rigidity of a motion axis 

is determined by the overall mechanical structure. The goal of the 

construction must be to obtain an axis structure that is as compact as 

possible. 

The increased loop bandwidth of linear drives required higher 

mechanical natural frequencies of the machine structure in order to 

avoid the excitation of vibrations. 

To ensure an adequate control quality, the lowest natural frequency that 

occurs inside the axis should not be less than approximately 200 Hz. 

The natural frequencies of axes with masses that are not constantly 

moving (e.g. due to workpieces that must be machined differently) 

change, so that the natural frequency is reduced with f ≈ 1/ 

m as the 

mass increases. 

The elasticity´s of the axes (both, the mechanical and the controlengineering 

component) add up. This must be taken into account with 

respect to the rigidity of cinematically coupled axes. 

If several axes must cinematically be coupled in order to produce path 

motions (e.g. cross-table or gantry structure), the mutual effects of the 

individual axes on each other should be minimized. Thus, cinematic 

chains should be avoided in machines with several axes. Axis 

configurations with long projections that change during operation are 

particularly critical.


Reactive forces 

Integrating the linear scale 

Initiated by acceleration, deceleration or process forces of the moved 

axis, reactive forces can deform the stationary machine base or cause it 

to vibrate. 

Ds m 

a 

STEIFIGKEIT01-MLF-EN.EPS 

Fig. 9-9: Deformation of the machine base caused by the reactive force 

during the acceleration process 

m ⋅ a 

∆s 

= 

c 

base plate 

500 kg ⋅10 

m/s² 

= 

= 5 µ m 

1000 N/ µ m 

∆s: Deformation of displacement of the machine base in µm 

m: Mass in kg 

a: Acceleration in m/s² 

c: Rigidity of the machine base in N/µm 

Fig. 9-10: Typical calculation of the machine base deformation 

The rigidity of the length measuring system integration is particularly 

important. Please refer to Chapter 9.15 for explanations. 



9.4 Arrangement of Motor Components 

Single arrangement 


The single arrangement of the primary is the most common 

arrangement. 

Fig. 9-11: Single arrangement of the primaries 

The independent operation of two or more primaries on a secondary is 

possible too (see Fig. 9-11 right-hand sight). In such an arrangement, 

the length measuring system can also be equipped with two or more 

scanning heads. 

Note: Due to the higher sealing lip friction, the number of scanning 

heads in encapsulated linear scales is usually limited to two. 

Please contact the scale manufacturer for details. 

controller drive controller 

3 ~ 

linear scale 

primary secondary 

EINZELANORDNUNG01-MLF-EN.EPS 

Fig. 9-12: Controlling a linear motor with single arrangement of the motor 

components


Several motors per axis 

The arrangement of several motors per axis provides the following 

benefits: 

• Multiplied feed forces 

• With corresponding arrangement, compensation of the attractive 

forces “outwards” 

Fig. 9-13: Arrangement of several motors per axis 

Depending on the application, the motors can be controlled in two 

different ways: 

• Two motors at one drive controller and one linear scale (parallel 

arrangement) 

• Two motors at two drive controllers and two linear scales (Gantry 

arrangement) 


The arrangement of two or more primaries on one drive controller in 

conjunction with a linear scale is known as parallel arrangement. Parallel 

arrangement is possible if the coupling between the motors can be very 

rigid. 

controller drive controller 

3 ~ 

primary 

mechanically 

rigid coupling 

primary 

secondary 

1 linear scale 

secondary 

PARALLELANORDNUNG01-MLF-EN.EPS 

Fig. 9-14: Parallel arrangement of two primaries on one drive controller in 

conjunction with a length measuring system 




To ensure successful operation, the axis must fulfill the following 

requirements in parallel arrangement: 

• Identical primary and secondary parts 

• Very rigid coupling of the motors within the axis 

• Position offset between the primary parts


Cable entry in the same direction 

Parallel arrangement: Arrangement of primaries in 

succession 

In a parallel arrangement – within a Gantry arrangement, too – the 

primaries in feed direction can mechanically be coupled and be arranged 

in succession (see Fig. 9-5 center). 

To ensure successful operation, the primaries must be arranged in a 

specific grid. The determination of the grid sizes that must be adhered to 

depends on the direction of the cable entry and the permissible bending 

radius of the power cable. 

If the primaries are arranged behind each other with the cable entries in 

the same direction (see Fig. 9-9), an integer multiple of twice the 

electrical pole pitch must be adhered to: 

S 

primary 1 

Dxp 

secondary 

xpmin 

Dxp 

primary 2 


Fig. 9-16: Arrangement of the primaries behind each other and cable entry in 

the same direction 

Note: When you determine the correct primary distance with cable 

entries in the same direction acc. to Fig. 9-8, you must 

always use the same reference point for both primaries (e.g. 

the same mounting hole). 

∆x = n ⋅ 2 ⋅τ 

P 

∆xP: Required grid spacing between the primaries in mm 

τP: Electrical pole pitch in IndraDyn L motors in mm (all sizes 37.5 mm) 

n: Integer factor (depends on mounting distance) 

Fig. 9-17: Determining the grid distance between the primaries with cable 

entries in the same direction 

p 


N


Minimum distances between the 

primaries 

Requirement 

Cable entry in opposite direction 


According to Fig. 9-9 and 9-10, the following minimum distances 

between the primaries result at a motor arrangement with the cable 

entries in the same direction: 

Standard encapsulation 

sizes (all) 

Motor version Xpmin in mm 

15 mm + n ⋅ 2 ⋅τ 

Thermal encapsulation 

sizes (all) 65 mm + n ⋅ 2 ⋅τ 

p 

n: The integer factor n must be chosen in that way, so that the following 

conditions can be kept. 


Fig. 9-18: Distance xpmin to be kept between the two primaries with cable 


x p min 

> 

permissible 

bending radius motor cable 



Option 1: 

If the primaries are arranged behind each other and with cable entries in 

opposite directions to Fig. 9-20 a defined distance must be kept between 

the primaries according to Fig. 9-21. 

S 

primary 1 secondary primary 2 N 

xpmin 


Fig. 9-20: Option 1: Arrangement of primaries behind each other with cable 

entries in opposite directions 


entries in opposite directions according to Fig. 9-20, you can 

use the distance between the primary end faces xp as 

reference point. 

x = n ⋅ 2 ⋅τ 

+ x 

P 

p 

pmin 

xP: Required grid spacing between the primaries in mm 





p


Minimum distance between the 

primaries (Option 1) 

Cable entry in opposite direction 

For a motor arrangement with cable entries at opposite directions, the 

following size-related minimum distances between the primaries result 

from: 


sizes (all) 


sizes (all) 


65mm 

59mm 


entries in opposite direction 

Option 2: 

If the primaries are arranged behind each other and with cable entries in 

opposite directions to Fig. 9-20 a defined distance must be kept between 

the primaries according to Fig. 9-21. 

primary 1 

secondary 

S N 

xp 

primary 2 


Fig. 9-23: Option 2: Arrangement of the primaries behind each other with cable 



entries in opposite directions according to Fig. 9-20, you can 

use the distance between the primary end faces xp as 

reference point. 

x = n ⋅ 2 ⋅τ 

+ x 

P 

p 

pmin 

xP: Required grid spacing between the primaries in mm 







Minimum distance between the 

primaries (Option 2) 

Requirement 

Power cable connection 


For a motor arrangement with cable entries at opposite directions, the 

following size-related minimum distances between the primaries result 

from: 



sizes (all) 40mm + n ⋅ 2 ⋅τ 

p 


sizes (all) 71mm + n ⋅ 2 ⋅τ 

p 

n: The integer factor n must be chosen in that way, so that the following 

conditions can be kept. 




x p min 

> 

permissible 

bending radius motor cable 



The connection of the power wires of the connection cable on the drive 

controller at parallel arrangement of the primaries with outgoing cable in 

the cross-direction depend on the direction of the outgoing cable. 

Connection at arrangement acc. to Fig. 9-9 

Outgoing cable in the same direction 

Drive-controller X5 1 2 3 



Connection at arrangement acc. to Fig. 9-20 

Outgoing cable in the same direction 

Drive-controller X5 1 2 3 



Fig. 9-27: Connection of the power wires at parallel arrangement of the 

primaries on a drive-controller 

Note: For detailed information to electrical connection please refer 

to Chapter 8 Connection system. 

Note: The primary 1 according to Fig. 9-20 is always the reference 

motor that is used for determining the sensor polarity and for 

commutation setting. See also Chapter 14 “Commissioning”. 

Ensure that the secondary is correctly aligned.


Gantry Arrangement 

Operation with two linear scales and drive controllers (Gantry 

arrangement) should be planned if there are load conditions that are 

different with respect to place and time, and sufficient rigidity between 

the motors cannot be ensured. This is frequently the case with axis in a 

Gantry structure, for example. 

Note: Parallel motors may also be used with a Gantry arrangement. 

controller 2 drive controllers 

3 ~ 

Fig. 9-28: Gantry arrangement 

length measuring system 


primary 

no mechanically 

rigid coupling 

primary 

secondary 

secondary 

GANTRYANORDNUNG01-MLF-EN.EPS 

With Gantry arrangements it must be remembered that the motors may 

be stressed unsymmetrically, although the position offset is minimized. 

As a consequence, this permanently existing bas load may lead to a 

generally higher stress than in a single arrangement. This must be taken 

into account when the drive is selected. 

Note: The asymmetric stress can be reduced to a minimum by 

exactly aligning the length measuring system and the primary 

and secondary parts to each other, and by a drive-internal 

axis error compensation. 



Vertical axes 

Weight compensation 


WARNING 

Uncontrolled movements 

⇒ When linear motors are used in vertical axes, it 

must be taken into account that the motor is not 

self-locking when power is switched off. Lowering 

the axis can only be secured by an appropriate 

holding brake (see also Chapter 9.17 “Braking 

Systems and Holding Devices”). 

Suitable holding devices must be used for preventing the axis from 

sinking after the power has been switched off. These holding devices 

can be actuated electrically, pneumatically or hydraulically. 

Note: 

• Adequate holding devices are integrated in most of today´s weight 

compensation systems. 

• On vertical axis, the use of an absolute measuring system is 

recommended. Alternatively, also an incremental measuring system, 

in connection with a hall sensor box (see Chapter 7 “Accessories”) 

can be used. 

An additionally used weight compensation ensures that the motor is not 

exposed to an unnecessary thermal stress that is caused by the holding 

forces and the acceleration capability of the axis is independent of the 

motion direction. The weight compensation can be pneumatic or 

hydraulic. 

Weight compensation with a counterweight is not suitable since the 

counterweight must also be accelerated.


9.5 Feed and Attractive Forces 

Attractive forces between the primary and the secondary 

Considering the attractive force 

in motor installation 

When it is installed, a synchronous linear motor has a permanently 

effective attractive force between the primary and the secondary that 

results from its principle. With synchronous linear motors, this attractive 

force also exists when the motor is switched off. 

primary 

F 

secondary 

attractive force 

Fig. 9-29: Attractive force between the primary and the secondary 

ANZKRAFT01-MLF-EN.EPS 

These attractive forced must always be taken into account in the 

mechanical design of the system. 

Depending on the motor arrangement, the attractive forces must be 

accommodated by linear guides and the slide and machine structure. 

With an unfavorable arrangement of the motors, the attractive forces 

can cause deformations (deflection) in the machine structure and 

unacceptable transverse stress on the linear guides. The following points 

should therefore be taken into account during the design integration of 

the motors: 

• Arrange the linear guides as close to the motor as possible. 

• To compensate the attractive forces, you can use the parallel 

arrangement shown at the right-hand side in Fig. 9-13. 

Note: When installed, the attractive force must not reduce the air 

gap between the primary and the secondary. The mechanical 

design must provide sufficient rigidity. 

Note: The attractive forces at the nominal air gap are specified in 

each data sheet of a motor in Chapter 4 “Technical Data”. 



Air-gap-related attractive forces between the primary and the secondary 

attractire force rel. To norminal air gap 

160% 

140% 

120% 

100% 

80% 

60% 

40% 

20% 

nominal air gap 


The attractive force rises as the distance between the primary and the 

secondary is reduce. 

When lowering the primary on the secondary, result by reducing the air 

gap increasing attractive forces. 

The curve in the following diagram shows the attractive force as a 

function of the air gap. 

0% 

0 mm 5 mm 10 mm 15 mm 

measurable air gap 

20 mm 25 mm 30 mm 

ANZIEHUNGSKRAFT.XLS 

Fig. 9-30: Attractive force vs. distance between the primary and the secondary 

Air-gap-related attractive forces vs. power supply 

The attractive force decreases with rising power supply of the primary. 

The curve in the following diagram shows the attractive force vs. the 

power supply. 

FATT 

0 

FATT: Attractive force 

imax: Max. voltage 

Fig. 9-31: Attractive force vs. power supply 

imax 

-6...7% 

ANZIEH_BESTROM-MLF.EPS


Air-gap-related feed force 

feed force, rel. to nominal air gap 

103% 

102% 

101% 

100% 

99% 

98% 

Air gap tolerances 

The feed force detailed in the specifications are related to the specified 

rated air gap. The tolerances permissible for the measurable air gap 

have a slight effect on the feed forces that can be achieved. The 

following diagram shows this relationship: 

nominal air 

gap 

97% 

0,7 mm 0,8 mm 0,9 mm 1,0 mm 1,1 mm 1,2 mm 1,3 mm 

measurable air gap 

LUFTSPALTABHÄNGIGE VORSCHUBKRAFT MLF_EN.XLS 

Fig. 9-32: Feed force within the air gap tolerance of synchronous linear motors 


Note: Sizes in Fig. 9-32 are only valid for IndraDyn L synchronous 

linear motors; there is no general correlation for other motor 

types. 

Reduced overlapping between the primary and the secondary 

Inception of the force reduction 

When moving in the end position range of an axis, it can be necessary 

that the primary moves beyond the end of the secondary. This results in 

a partial coverage between the primary and the secondary. 

If the primary and the secondary are only partially covered, follows a 

reduced feed force and attractive force. 

The force reduction does not start immediately. It differs according to the 

encapsulation types and the installation position of the primary. 

Outside the beginning and end areas, the force is reduced linearly as a 

function of the reduced coverage area. 

The following diagram illustrates the correlation between the coverage 

between the primary and the secondary and the resulting force 

reduction. 



feed and attractive force as a function 

of the coverage factor between 

primary and secondary part 

100 % 

90 % 

80 % 

70 % 

60 % 

50 % 

40 % 

30 % 

20 % 

10 % 

0 % 

SR1 


s R 

overall length of the primary part 

s R 

PRIMPARTOVSEC02-MLF-EN.EPS 

Fig. 9-33: Force reduction with partial coverage of the primary and the 

secondary 

MOUNTING POSITION 1 

SR2 

primary 

secondary 

primary primary 

secondary 

SR1 

MOUNTING POSITION 2 

SR2 

primary 

secondary 

secondary 

PRIMPARTOVSEC04-MLF-EN.EPS 

Fig. 9-34: Presentation of force reduction with regard to Fig. 9-33 

Motor version 

Installation position 1 

SR1 [mm] SR2 [mm] 

Standard encapsulation 30 5 

Thermal encapsulation 52 8 

Installation position 2 

Standard encapsulation 5 30 

Thermal encapsulation 8 52 

Fig. 9-35: Partial coverage vs. installation position 

The partial coverage of the primary and the secondary must not be used 

in continuous operation since there is an increased current consumption 

of the motor. Instabilities in the control loop can be expected from a 

certain reduction of the degree of coverage onwards. 

WARNING 

Malfunctions and uncontrolled motor 

movements due to partial coverage of the 

primary and the secondary! 

⇒ Partial coverage of the primary and the secondary 

only when moving to the end position during a drive 

error 

⇒ Minimum coverage factor 75%


9.6 Motor cooling 

Thermal behavior of linear motors 

Power loss 

Thermal time constant 

The rated feed force of a synchronous linear motor can be achieved is 

mainly determined by the power loss PV that is produced during the 

energy conversion process. The power loss fully dissipates in form of 

heat. Due to the limited permissible winding temperature it must not 

exceed a specific value. 

Note: The maximum winding temperature of IndraDyn L motors is 

155°C. This corresponds to insulation class F. 

The total losses of synchronous linear motors are chiefly determined by 

the direct load loss of the primary due to the low relative velocities 

between the primary and the secondary: 

3 

4 

2 

PV ≈ PVi 

= ⋅i 

⋅R12 

⋅ 

PV: Total loss in W 

PVi: Direct load losses in W 

i: Current in motor cable in A 

R12: Electrical resistance of the motor at 20°C in Ohm 

(see Chapter 5 “Technical Data) 

fT: Factor temperature-related resistance raise 

Fig. 9-36: Power loss of synchronous linear motors 

Note: When you determine the power loss according to Figure 9- 

36, you must take the temperature-related rise of the 

electrical resistance into account. At a temperature rise of 

115 K (from 20°C up to 135°C), for example, the electrical 

resistance goes up by the factor fT = 1.45. 

The temperature variation vs. the time is determined by the produced 

power loss and the heat-dissipation and –storage capability of the motor. 

The heat-dissipation and –storage capability of an electrical machine is 

(combined in one variable) specified as the thermal time constant. 

Note: With liquid cooling systems, the thermal time constant is 

between 5...10 min (depending on size). 

The following Figure 9-37 shows a typical heating and cooling process of 

an electrical machine. The thermal time constant is the period within 

which 63% of the final over temperature is reached. With liquid cooling, 

the cooling time constant corresponds to the heating time constant. 

Thus, the heating process and the cooling process can both be specified 

with the specified thermal time constant (heating time constant) of the 

motor. 

In conjunction with the duty cycle, the correlation to Fig. 9-38 and Fig. 9- 

40 are used for defining the duty type, e.g. acc. to DIN VDE 0530. 

f 

T 



Overtemperature 

63 % 

t th 


heating up with initial overtemperature > 0 

heating up with final 

overtemperature = 0 

Heating up 

Final over temperature 

Cooling 

Time 

final overtemperture 

cooling 

Fig. 9-37: Heating up and cooling down of an electrical machine 

t ⎛ − ⎞ 

tth 

ϑ( 

t) 

= ϑe 

⋅ ⎜1− 

e ⎟ + ϑa 

⋅ e 

⎜ ⎟ 

⎝ ⎠ 

t 

− 

tth 

ERWAERMUNG MLF_EN.XLS 

ϑe: Final over temperature in K 

ϑa: Initial over temperature in K 

t: Time in min 

tth: Thermal time constant in min (see Chapter 4 “Technical Data) 

Fig. 9-38: Heating up (over temperature) of an electrical machine compared 

with coolant 

Since the final over temperature is proportional to the power loss, the 

expected final over temperature ϑe can be estimated according to Fig. 

9-39: 

2 

Pce 

Feff 

ϑe = ⋅ϑe 

max = ⋅ 2 

PvN 

FdN 

ϑ 

emax 

Pce: Permanent power loss or average power loss vs. duty cycle time in 

W (see Chapter 11.4 “Determining the Drive Power) 

Nominal power loss of the motor in W 

PVN: 

ϑemax: Maximum final over temperature of the motor in K 

Feff: Effective force in N (from application) 

FdN: Rated force of the motor in N (see Chapter 4 “Technical data”) 


Fig. 9-39: Expected final over temperature of the motor 

ϑ( 

t) 

= ϑ 

− 

e ⋅ e 

ϑe: Final over temperature or shutdown temperature in K 

t: Time in min 


Fig. 9-40: Cooling down of an electrical machine 

t 

t 

th


Cooling concept of IndraDyn L synchronous linear motors 



The request for highest feed forces and minimum installation volume 

usually requires linear motors to be equipped with a liquid cooling. The 

liquid cooling ensures: 

• that the power loss is removed and, consequently, rated feed forces 

are maintained; 

• that a certain temperature level is maintained at the machine 

The cooling and encapsulation concept of IndraDyn L motors includes 

two different solutions: 

Primaries with standard encapsulation are mainly used in the general 

automation sector. The cooling system of this motor design is integrated 

into the motor and can only be used to discharge lost heat or keeping 

the specified continuous feedrate. It offers no additional thermal 

decoupling on the motor side to the machine. The maximum 

temperature of the contact surface can locally rise up to 60°C. These 

maximum temperature gradients can occur independently of the coolant 

inlet temperature. 

For an optimum thermal decoupling between the motor and the machine 

structure, the primary parts of the thermal encapsulation version have an 

additional liquid cooling system at the back of the motor and at 

longitudinal and frond ends. The constant temperature that can easily be 

attained and the minimum heat transfer into the machine make the 

primary parts of the thermal encapsulation version particularly suitable 

for the utilization in machine tools and in other precision applications. 

Inside the motor there is already an optimum connection between the 

internal cooling circulation used for removing the power loss and the 

cooling ducts of the thermal encapsulation. 

The primary is not completely connected with the mounting surface on 

the machine side, but only lays on increased bearing points. This 

provides an additional thermal decoupling and, consequently, further 

minimization of the possible heat transfer into the machine (see Fig. 9- 

41). 

Note: Using the thermal encapsulation does not provide any 

improved performance date, e.g. for the continuous feed 

force. The power ratings are identical for both versions. 



air gap (1mm) 

(additional thermal 

decoupling) 

2 K 

thermal isolation 

(not a part of the 

secondary) 

Secondaries 


P v 

temperature rise of the attachment surface A 

against the coolant inlet temperature 

machine structure 


cooling at machine side (option) 

Fig. 9-41: Cooling concept for thermal encapsulation 

A 

A 

seating ledges 

THERMOKAPSELUNG02-MLF-EN.EPS 

The secondary version is identical for both primary part versions. The 

secondary does not develop any power loss. With inadvertent conditions 

(extended standstill or slow velocity of the primary together with a 

simultaneously acting high continuous force), there can be a heat 

transfer by the primary due to radiation or convection. 

Note: The secondary does not develop any power loss. The 

maximum heat infiltration possible of the primary at standstill 

and continuous nominal force is approximately 3% of the 

motor´s nominal power loss. 

The heat transfer depends on the ambient temperature and on the 

installation conditions in the machine. 

To maintain a constant temperature level in the machine, cooling can be 

done at the machine side (e.g. via two cooling pipes). See Fig. 9-41.


Coolant 

The specified motor data and the characteristics of the motor cooling 

system (e.g. continuous feed forces, pressure losses, and flow 

characteristics), and all the other specifications in this Chapter are 

related to liquid cooling with coolant water. Most cooling devices use 

water, too. 

The following coolants can be used: 

• Water 

• Oil 

• Air 

Note: The specified motor data and the characteristics of the motor 

cooling system (e.g. continuous feed forces, pressure losses, 

and flow characteristics), and all the other specifications in 

this Chapter are related to liquid cooling with coolant water. 

This data is no longer valid and must again be calculated or determined 

empirically if coolants with different material characteristics are used. 

An impairment of the thermal decoupling may also have to be taken into 

account, if necessary. 

WARNING 

Impairing the cooling effect of damaging the 

cooling system! 

⇒ Adjust coolant and flow to the required motor 

performance data 

⇒ With coolant water use anticorrosion agent and 

observe the specified mixture and the pH-value. 

⇒ Use approved anticorrosion agents, only 

⇒ Do not use cooling lubricants from machining 

process 

⇒ Filter the coolant 

⇒ Do not use flowing water 

⇒ Use a closed cooling circuit 

⇒ Adhere to the specified inlet temperatures 

⇒ Do not exceed the maximum pressure 

⇒ Motor operation not without liquid cooling 

Coolant additives 

Corrosion protection and chemical stabilization required a suitable 

additive to be added to the cooling water. The corrosion protection 

agent must be suitable for a mixed installation (steel or iron, aluminum, 

copper and brass). The required mix (acc. to the manufacturer´s 

specifications) must be adhered to and/or verified. Larger differences 

can lead to changes in the stability of the emulsion, the behavior towards 

sealant, and the corrosion protection capability. 



Watery solutions 

Emulsion with corrosion 

protection oil 

pH-value coolant 


Watery solutions ensure a reliable corrosion protection without 

significant changes of the physical property of the water. The 

recommended additives do not contain any water-endangering 

substances, according to the water endangering classes (WGK). 

Corrosion protection oils for coolant systems contain emulsifiers which 

ensure a fine allocation of the oil in the water. The oily components of 

the emulsion protect the metal surface of the coolant duct against 

corrosion and cavitation. Herewith, an oil content of 0.5 – 2 volume 

percent has proved itself. Does the corrosion protection oil compared 

with the corrosion protection has also the coolant pumping lubricant, 

then the oil content of 5 volume percent is necessary. (observe the 

requirements of the pump manufacturers!) 

Description 

1%...3% emulsions 

Manufacturer 

Aquaplus 22 Petrofer, Hildesheim 

Varidos 1+1 Schilling Chemie, Freiburg 

33%-emulsions 

Glycoshell Deutsche Shell Chemie GmbH, Eschborn 

Tyfocor L Tyforop Chemie GmbH, Hamburg 

OZO Frostschutz Deutsche Total GmbH, Düsseldorf 

Aral Kühler-Frostschutz A ARAL AG, Bochum 

BP antifrost X 2270 A Deutsche BP AG, Hamburg 

Emulsifiable mineral oil concentrate 

Shell Donax CC (WGK: 3) Shell, Hamburg 

Fig. 9-42: Recommended coolant additives 

Note: The specified coolant additives are only a recommendation of 

BOSCH REXROTH. Please contact your responsible sales 

representative when using another coolant additive. 

Not only the mixture, but also the pH-value of the used coolant must be 

checked in suitable distances. The coolant should be chemically neutral. 

Larger differences can lead to changes in the stability of the emulsion, 

the behavior towards sealant, and the corrosion protection capability. 

Note: Keep the pH-value of the used coolant controlled in 6-8 pH!


Temperature range 

Continuous feed force vs. 

coolant temperature 

Coolant temperature 

The recommended temperature range of the coolant is 15...40°C. The 

coolant temperature must never be outside this range. The adjusted 

coolant inlet temperature must be chosen with regard to the actual 

existing environmental temperature and should be max. 5°C lower than 

the measured environmental temperature. 

An overstepping of the recommended temperature range leads to a 

stronger reduction of the continuous feed force. 

Note: The coolant inlet temperature should be maximum 5k lower 

than the actual existing room temperature to avoid 

condensation. 

WARNING 

Reduction of the continuous feed force of 

destruction of the motor! 

⇒ Keep coolant within permissible temperature range 

The specification of the rated feed force in the technical motor 

specifications is related to a coolant inlet temperature of 30°C. 

If the inlet temperature is different, there is a minor change of the 

continuous feed force according to Fig. 9-43: 

Confinuous feed force 

105% 

100% 

95% 

15 °C 20 °C 25 °C 30 °C 35 °C 40 °C 

Cooling water inlet temperature 

KMTEMPERATUR LSF.XLS 

Fig. 9-43: Continuous feed force vs. coolant flow temperature 

Maximum pressure 

With all motor versions, the maximum system pressure via the internal 

system circulation of the motor is 10 bar. 

Pressure fluctuations within the cooling circuit should not exceed ± 1 bar 

during motor operation. Beyond pressure fluctuations or pressure peaks 

are not permitted! 

WARNING 

Motor destruction! 

⇒ Keep coolant within permissible inlet pressure. 

⇒ Incorrect pressure fluctuations and pressure peaks 

have to be excluded via constructive measures. 



Sizing the cooling circuit 

Coolant temperature rise 

Pressure drop 


Operation of IndraDyn L synchronous linear motors 

without liquid cooling 

In certain exceptions it can be necessary or possible, to do without a 

liquid cooling. Depending on the size, this results in a reduction of the 

continuous nominal force to approximately 40...45%. It does not reduce 

the maximum force of the motors. 

Depending on the load, the temperature at the contact surface of the 

primary may rise up to 140%C without liquid cooling. 

WARNING 

Drastic reduction of the rated feed force and 

significant heating and stress of the machine 

structure if synchronous linear motors are used 

without liquid cooling! 

⇒ Provide liquid cooling 

⇒ The reduction of the rated force and the heating of 

the machine structure (stress due to expansion) 

must be included in the sizing and design of axes 

that are used without liquid cooling. 

Q 

T 1, p 1 

Q: Flow quantity 

T1: Coolant inlet temperature 

T2: Coolant outlet temperature 

p1: Inlet pressure 

p2: Outlet pressure 

Fig. 9-44: Liquid-cooled component 

P v 

T T T − = ∆ 

T1: Coolant inlet temperature in K 

T2: Coolant outlet temperature in K 

∆T: Coolant temperature rise in K 

Fig. 9-45: Coolant temperature rise in K 

2 

p p p − = ∆ 

1 

1 

2 

T 2, p 2 

p1: Inlet pressure 

p2: Outlet pressure 

∆p: Pressure drop 

Fig. 9-46: Pressure drop across traversed component 

KUEHLUNG01-MLF-EN.EPS


Design criteria 

Coolant flow to maintain the 

rated feed force 

Maintaining a constant 

temperature level at thermal 

encapsulation 

Related to the motor, two basic application-related requirements must be 

distinguished when the cooling circuit of synchronous linear motors is 

sized. 

1. Liquid cooling is only used for removing the power loss and thus for 

maintaining the specified rated forces (e.g. for standard 

encapsulation motor version) 

2. At the same time, liquid cooling shall ensure a defined temperature 

level at the contact surface (e.g. for the thermal encapsulation motor 

version). 

Flow quantity 

Rexroth recommends to dimension the coolant flow for motors up to size 

070 to ~ 5l/min, for size 100 to ~ 6l/min. 

The minimum coolant flow required to maintain the rated feed force is 

defined in Chapter 4 “Technical Data”. 

The specification of this value is based on a rise of the coolant 

temperature by 10 K. 

Figures 9-47 and 9-48 are used to determine the necessary coolant flow 

at different temperature rises and / or different coolants: 

Pco 

⋅ 60000 

Q = 

c ⋅ ρ ⋅ ∆T 

Q: Rated coolant flow in l/min 

Pro: Removed power loss in W 

c: Specific heat capacity of the coolant in J / kg - K 

ρ: Density of the coolant in kg/m³ 

∆T: Coolant temperature rise in K 

Fig. 9-47: Coolant flow required for removing a given power loss. 

Coolant Specific heat capacity c in J / kg - 

K 

Density ρ in kg/m³ 

Water 4183 998,3 

Thermal oil 

(example) 

1000 887 

Air 1007 1,188 

Fig. 9-48: Substance values of different coolants at 20°C 

If you want to ensure a defined temperature level at the contact surface 

of the primary of the thermal encapsulation motor version, you must use 

the formula acc. to Fig. 9-49 to determine the coolant flow that is 

necessary for maintaining a maximum coolant temperature rise. It is to 

be taken into account that only a part of the power loss remains to be 

removed via the thermal encapsulation. ∆Tm is the temperature at the 

contact surface of the primary. 

Note: A defined temperature level at the contact surface can only 

be maintained with the thermal encapsulation motor version. 



Pressure drop across the motor 

cooling system 


Pco 

⋅ 25200 

Q = 

c ⋅ ρ ⋅ ∆T 

Q: Rated coolant flow in l/min 

Pco: Removed power loss in W 

c: Specific heat capacity of the coolant in J / kg - K 

ρ: Density of the coolant in kg/m³ 

∆Tm: Temperature rise on contact surface in K 

Fig. 9-49: Coolant flow required for maintaining a constant temperature level at 

the motor contact surface in the case of thermal encapsulation 

Prerequisites: Q ≥ Qmin (see chapter 4 “Technical Data”) 

Pressure drop 

The flow resistance at the pipe walls, curves, and changes of the crosssection 

produces a pressure drop along the traversed components (see 

Fig. 9-44). 

The pressure drop ∆p rises as the flow quantity rises (see Fig. 9-50). 

pressure drop Dp 

flow quantity Q 

Fig. 9-50: Pressure drop vs. flow quantity; general representation 

m 

KUEHLUNG02-MLF-EN.EPS 

On the basis of the constant for determining the pressure drop kdp that is 

explained in Chapter 4 “Technical Data”, the pressure drop across the 

internal motor cooling circuit can be determined as follows: 

∆p 

= k ⋅ Q 

m 

dp 

1. 

75 

pm: Pressure drop across the internal motor cooling circuit in bar 

Q: Flow quantity in l/min 

kdp: Constant for determining the pressure drop (see Chapter 4 

“Technical data”) 

Fig. 9-51: Determining the pressure drop vs. the flow quantity


upstream 

coolant 

Overall pressure drop 

heat 

transfer 

The pressure drop across the overall system is determined by the sum 

of a series of partial pressure drop (see Fig. 9-52). Usually, the pressure 

drop across the internal motor cooling system is relatively small. 

heat removal device 

Dp w 

container 

heat exchanger 

Dp p 

coolant 

pump 

Q 

Dp p 

coolant 

lines 

Dp a 

connections 

motor 

Dp m 

heat 

transfer 

KUEHLUNG03-MLF-DE.EPS 

Fig. 9-52: General arrangement of a liquid cooled motor with heat removal 

facility 

Note: The overall pressure drop of the cooling system is determined 

by various partial pressure drops (motor, feeders, connectors, 

etc.). This must be taken into account when the cooling circuit 

is sized. 

Note: With all motor versions, the maximum system pressure via 

the internal system circulation of the motor is 10 bar. 

Cooling capacity 

The specifications that are needed for determining the cooling capacity 

which is required for a synchronous linear motor can be found in Chapter 

11.4 “Determining the Drive Power”. 



Liquid cooling system 

upstream 

coolant 

Heat removal device 


heat 

output 

heat 

output 

Machines and systems can require liquid cooling for one or more 

working components. If several liquid-cooled drive components exist, 

they are connected to the heat removal device via a distribution unit. 



main distributor 

coolant temperature 

controller 

coolant lines 

control 

cabinet 

motor 

motor 1 

motor 2 

motor 3 

motor 4 

control cabinet air 

cooler 

distributor 


Fig. 9-53: General arrangement of cooling systems with one and more drive 

components 

The heat removal device carries off the total heat that was fed into the 

liquid into a higher-level coolant. It provides a temperature-controlled 

coolant and thus maintains a required temperature level at the 

components that are to be cooled. 

There are three different types of heat removal devices (see Fig. 9-54). 

They are identified by the type of the heat exchanger between the 

different media: 

1. Air-to liquid cooling unit 

2. Liquid-to-liquid cooling unit 

3. Cooling unit 

A heat removal device includes a heat exchanger, a coolant pump 

container and a coolant container (see Fig. 9-52).


5 

1 

2 

3 

air-liquid cooling unit liquid-liquid cooling unit 

1 

cooling unit 

Fig. 9-54: Heat removal devices 

Air-to liquid 

cooling unit 

2 

7 

6 

Liquid-to-liquid cooling 

unit 

1 

1 coolant pump 

2 coolant container 

3 air-liquid heat exchanger 

4 liquid-liquid heat exchanger 

5 air-cooled condenser 

6 compressor 

7 vaporizer 

2 

4 


Cooling unit 

Coolant temperature control accuracy Low (±5 K) Low (±5 K) Good (±1 K) 

Upstream coolant circuit required No Yes No 

Heating of ambient air Yes No Yes 

Power loss recovery No Yes No 

Size of the cooling unit Small Small Large 

Dependent of ambient temperature Yes No No 

Environment-damaging coolant No No Yes 

Comments on utilization criteria Particularly 

suitable for 

stand-alone 

machines that 

do not have an 

upstream 

coolant circuit 

available and 

do not have to 

fulfill high 

requirements 

on the stability 

of the coolant 

temperature. 

This cooling type is 

particularly suitable for 

systems with existing 

central feedback cooler. Id 

does fulfill high 

requirements on the 

stability of the coolant 

temperature. 

Particularly suitable for high 

requirements on the thermal 

stability (high-precision 

applications, for example). 

Fig. 9-55: Overview of the heat removal devices according to utilization criteria 

Coolant lines 

The coolant lines are a major part of the cooling system. They have a 

great influence on the system´s operational safety and pressure drop. 

The lines can be made up as hoses or pipes. 



Laying flexible coolant lines 

within the energy chain 

Parallel connection 


The coolant lines of linear motor drives with moved primaries must be 

laid within a flexible energy chain. 

The continuous bending strain of the coolant lines must always be taken 

into account when they are sized and selected. 

Further optional components 

• Distributions 

• Coolant temperature controller 

• Flow monitor 

A message is output when the flow drops below a selectable 

minimum flow quantity. 

• Level monitor 

Chiefly minimum-maximum level monitor to check the coolant level in 

the coolant container 

• Overflow valve 

• Safety valve 

Opens a connection between the coolant inlet and the contained 

when a certain pressure is reached 

• Coolant filter (100 µm) 

• Coolant heatings 

To provide coolant of a correct temperature, in particular for coolant 

temperature control 

• Restrictor and shut-off valves 

Circuit types 

The two possible ways of connecting hydraulic components 

(series/parallel connection) show significant differences with respect to: 

• Pressure drop of the entire cooling system 

• Capacity of the coolant pump 

• Temperature level and controllability of the individual components 

that are to be cooled 

SQ 

J 1 

Q 1 

J 1 

Q2 PV2 J2 SQ 

Q 3 

P V1 

P V3 

Fig. 9-56: Parallel connection of liquid-cooled drive components 

Dp 

J 3 

J 


The parallel connection is characterized by nodes in the hydraulic 

system. The sum of the coolant streams flowing into a node is equal to 

the sum of the coolant streams flowing out of this node. Between two 

nodes, the pressure difference (pressure drop) is the same for all 

intermediate cooling system branches.


Series connection 

Q = Q 

1 

+ Q 

∆ p = ∆p 

= ∆p 

= ∆p 

1 

2 

... + Q 



Fig. 9-57: Pressure drop and flow quantity in the parallel connection of 

hydraulic components 

When several working components are cooled, a parallel connection is 

advantageous for the following reasons: 

• The individual components that are to be cooled can be cooled at the 

individual required flow quantity. This means a high thermal 

operational reliability. 

• Same temperature level at the coolant entry of all components (equal 

machine heating) 

• Same pressure difference between coolant entry and outlet of all 

components (no high overall pressure required) 

Q, J 

J 1 

2 

J < J 1 < J 2 < J 3 

P V1 P V2 P V3 

n 

J 2 

Dp 1 , DJ 1 Dp 2 , DJ 2 Dp 3 , DJ 3 

Dp 

Fig. 9-58: Series connection of liquid-cooled drive components 

n 

J 3 


In series connection, the same coolant stream flows through all 

components that are to be cooled. Each component has a pressure 

drop between coolant inlet and coolant outlet. The individual pressure 

drops add up to the overall pressure drop of the drive components. 

Series connection does not permit any individual selection of the flow 

quantity required for the individual components to be made. It is only 

expedient if the individual components that are to be cooled need 

approximately the same flow quantity and bring about only a small 

pressure drop or if they are installed very far away from the heat removal 

device. 

Q = Q 

1 

= Q 

1 

2 

= Q 

∆ p = ∆p 

+ ∆p 

... + ∆p 



Fig. 9-59: Pressure drop and flow quantity in the parallel connection of 

hydraulic components 

The following disadvantages of series connection must always be taken 

into account: 

2 

n 

n 



Combination of series and 

parallel connection 


• The required system pressure corresponds to the sum of all pressure 

drops of the individual components. This means a reduced hydraulic 

operational safety due to a high system pressure. 

• The temperature level of the coolant rises from one component to the 

next. Each power loss contribution to the coolant rises its temperature 

(inhomogeneous machine heating) 

• Some components may not be cooled as required since the flow 

quantity cannot be selected individually. 

Combining series and parallel connections of the drive components that 

are to be cooled permits the benefits of both connection types to be 

used. 

SQ 

J 0 

Q 1 

Q2 P J V2 

2 

SQ 

Q 3 

P V1 

P V3 

Q4 P J P 4 V5 J P 5 J V4 

V6 6 

Fig. 9-60: Combination of series and parallel connection 

Dp 

J 1 

J 3 

J 

KUEHLUNG08-MLF-EN.EPS


9.7 Motor temperature Monitoring Circuit 

Temperature sensor motor 

protection 

Sensors temperature 

measurement external 

In their standard configuration, the primaries of IndraDyn L motors are 

equipped with built-in motor protection temperature sensors. Every 

motor phase contains of one out of three switched in a row ceramic 

PTC´s, so that a sure thermical control of the motor in every operation 

phase is possible. These thermistors (furthermore: thermistor motor 

protection) have a switching character (see Fig. 9-64) and become 

evaluated on all Bosch Rexroth control devices. 

Furthermore all primaries are fitted with an additional thermistor for 

external temperature measurement. These sensors (furthermore: sensor 

temperature measurement) has nearly a linear characteristic curve (see 

Fig. 9-65). 

PTC 

J 

PTC 

J 

M 

3 ~ 

lead identification 

8 (-) 

7 (+) 

6 

5 

3 

2 

1 

GNYE 

KTY84-130 

sensor external temperature measurement 

no connection to drive controller 

PTC SNM.150.DK.*** 

motor protection temperatute sensor 

connected to drive controller 


Fig. 9-61: Arrangement of temperature sensors at IndraDyn L motors 

Type PTC SNM.150.DK.*** 

Rated response temperature ϑNAT 

150 °C 

Resistor at 25°C ≈ 100...250 Ohm 

Fig. 9-62: Temperature sensor motor protection 

TEMPSENS01-MLF-EN.EPS 

Note: For the parallel arrangement of two or more primary parts, the 

motor protection temperature sensors of all primary parts are 

connected in series. For further details, please see Chapter 8 

“Electrical Connection”. 

Type KTY84-130 

Resistor at 25°C 577 Ohm 

Resistor at 100°C 1000 Ohm 

Continuous current at 100°C 2 mA 

Fig. 9-63: Temperature measurement sensor 

Note: Notice the correct polarity when using the sensor for 

temperature measurement external. 



temperature sensor resistance in ohms 

temperature sensor resistance in ohms 

100000 

10000 

1000 


Motor protection temperature sensors 

connecting cores 5 and 6 

norminal responce temperature 150°C 

=Q=éêáã~êáÉë=áå=ëÉêáÉë= 

O=éêáã~êáÉë=áå=ëÉêáÉë 

N=íÉãéÉê~íìêÉ=ëÉåëçê=EN=éêáã~êóF= 

100 

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 

motor winding temperature in °C 

1500 

1400 

1300 

1200 

1100 

1000 

900 

800 

700 

600 

TEMPERATURSENSOREN LSF.XLS 

Fig. 9-64: Characteristik of temperature sensors motor protection (PTC) 

temperature measuring sensor KTY84-130 

connecting cores 7 (+) und 8 (-) 

500 

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 

motor winding temperature in °C 

Fig. 9-65: Characteristik sensor temperature measurement KTY84-130 (PTC) 

A polynomial of degree 3 proves sufficient for describing the resistance 

characteristic of the sensor used for temperature measurement (KTY84- 

130). Below, this is specified for determining a temperature from a given 

resistance, and vice versa.


Temperature vs. resistance 

Resistance vs. temperature 

3 

Tw = A ⋅R 

KTY + B ⋅RKTY 

+ C ⋅RKTY 

+ D 

Tw: Winding temperature of the motor in °C 

RKTY: Resistance of the temperature sensor in Ohms 

A: 3.039 ·10 -8 

B: -1.44 ·10 -4 

C: 0.358 

D: -143.78 

Fig. 9-66: Polynomial used for determining the temperature with a known 

sensor resistance (KTY84) 

3 

RKTY = A ⋅ Tw 

+ B ⋅ Tw 

+ C ⋅ Tw 

+ D 

Tw: Winding temperature of the motor in °C 

RKTY: Resistance of the temperature sensor in Ohms 

A: 1.065 ·10 -6 

B: 0.011 

C: 3.93 

D: 492.78 

Fig. 9-67: Polynomial used for determining the sensor resistance (KTY84) with 

a known temperature 

2 

2 



9.8 Setup Elevation and Ambient Conditions 


The performance data specified for the motors apply in the following 

conditions: 

• Ambient temperature + 0 bis + 40° C 

• Setup heights of 0 m up to 1000 m above MSL 

Different conditions lead to a departing of the data according to the 

following diagrams. Do occur deviating ambient temperatures and higher 

setup elevations at the same time, both utilization factors must be 

multiplied. 

fT 

1 

0,8 

0,6 

0,4 

4 40 5 50 

tA [°C] 

55 

0,4 

0 

1 

1 2 

(1): Utilization depending on the ambient temperature 

(2): Utilization depending on the site altitude 

fT: Temperature utilization factor 

tA: Ambient temperature in degrees Celsius 

fH: Height utilization factor 

h: Site altitude in meters 

Fig. 9-68: IndraDyn L height utilization 

fH 

0,8 

0,6 

1000 3000 5000 

h [m] 

UMGEBHOE-MLF-DE.EPS 

If either the ambient temperature or the site altitude exceeds the 

nominal data: 

1. Multiply the motor data provided in the selection data with the 

calculated utilization factor. 

2. Ensure that the reduced torque data are not exceeded by your 

application. 

If both the ambient temperature and the site altitude exceed the nominal 

data: 

1. Multiply the determined utilization factors fT and fH by each other. 

2. Multiply the value obtained by the motor data specified in the 

selection data. 

Ensure that the reduced motor data are not exceeded by your 

application. 

Note: The details for the utilization against the site altitude and 

environmental temperature do not apply to the defined liquid 

coolant on the motor, but on the whole drive system, 

consisting of motor, drive controller and mains supply.


9.9 Protection Class 

9.10 Compatibility 

The design of the IndraDyn L synchronous linear motors complies with 

the following degrees of protection according to DIN VDE 0470, Part 1, 

ed. 11/1992 (EN 60 529): 

Motor components Protection class 



IP 65 

Secondary segment 

Fig. 9-69: Protection class of IndraDyn L motors 

The type of protection is defined by the identification symbol IP 

(International Protection) and two code numbers specifying the degree of 

protection. 

The first code number defines the degree of protection against contact 

and penetration of foreign particles. The second code number defines 

the degree of protection against water. 

First figure Degree of protection 

6 

Protection against penetration of dust (dust-proof); 

complete shock protection 

Second figure Degree of protection 

5 

Fig. 9-70: IP degrees of protection 

Protection against a water jet from a nozzle directed 

against the housing from all directions (jet water) 

Note: Tests regarding the second characteristic numeral must be 

performed using fresh water. If cleaning is effected using high 

pressure and/or solvents, coolants, or penetrating oils, it 

might be necessary to select a higher degree of protection. 

WARNING 

Personal injuries, damaging or destroying motor 

components! 

⇒ Use IndraDyn L synchronous linear motors only in 

environments for which the specified class of 

protection proves sufficient. 

All Rexroth controls and drives are developed and tested according to 

the state-of-the-art. 

However, as it is impossible to follow up the permanent new 

development of all material which may come into contact with our 

controllers and drives (e.g. lubricants for machine tools), we cannot 

generally exclude any reaction with the materials used in our systems. 

For this reason, you will have to carry out a test on compatibility among 

new lubricants, detergents, etc. and our housing and device materials. 



9.11 Magnetic Fields 

induction B 

0,8 T 

0,7 T 

0,6 T 

0,5 T 

0,4 T 

0,3 T 

0,2 T 

0,1 T 

0,0 T 


2 

1 

The secondaries of synchronous linear motors are equipped with 

permanent magnets, which are not magnetic shielded. 

To be able to assess EMC problems (e.g. the influence on inductive 

switches or inductive measuring systems), chip attraction, and for 

human protection, the values of the magnetic induction as a function of 

the distance to the secondary are specified below. 

The representation distinguishes between ferromagnetic materials (e.g. 

steel) and non-ferromagnetic materials (e.g. air), and between different 

directions. 

1: direction 1, ferromagnetic material 

2: direction 1, non-ferromagnetic material 

3: direction 2 and 3, areas of both materials 

0 mm 10 mm 20 mm 30 mm 40 mm 50 mm 60 mm 70 mm 80 mm 90 mm 

Chip attraction 

distance to the secondary 

INDUKTIONSVERTEILUNG M 

Fig. 9-71: Magnetic induction in ferromagnetic and non-ferromagnetic materials 

vs. the distance to the secondary 

Note: Secondaries of IndraDyn L motors generate a static magnetic 

field. 

Ferromagnetic chips are not attracted at a distance of approximately 100 

mm from the surface of the secondary. 

Note: It must be ensured that the secondary is not located in the 

immediate chip area of the machine. Suitable covers must be 

provided.


9.12 Vibration and Shock 

According to IEC 721-3-3 Issue 1987 or EN 60721-3-3 Issue 06/1994, 

IndraDyn L motors are approved for the utilization in areas that are 

exposed to vibration and/or shock as given in Fig. 9-72 and 9-73. 

IndraDyn L motors may be used in stationary weather-proof operation 

corresponding to class 3M5. 

Influencing quantity Unit Maximum 

value 

Amplitude of the excursion at 2 to 9 Hz mm 0,3 

Amplitude of the acceleration at 9 to 200 

Hz 

Fig. 9-72: Limit data for sinusoidal vibrations 

m/s² 1 

Influencing quantity Unit Maximum 

value 

Total shock-response spectrum 

(according to IEC721-1, :1990; Table 1, 

Section 6) 

Reference acceleration, 

in IEC 721: Peak acceleration 

Type II 

m/s² 250 

Duration ms 6 

Fig. 9-73: Limits for shock load 

WARNING 

Motor damage and loss of warranty! 

⇒ A motor, used outside of specified operating 

conditions can be damaged. In addition, any 

warranty claim will expire. 

⇒ Ensure that the maximum values specified in Fig. 9- 

72 and Fig. 9-73 for storage, transport, and 

operation of the motors are not exceeded. 



9.13 Enclosure surface 


The following table shows the condition of the enclosure surface when 

delivered. 

Motor component Layout of enclosure / enclosure 

surface 



Secondary 

9.14 Noise emission 

Stainless steel V4A 

black printing (RAL 9005) 

Stainless steel V4A 

black printing (RAL 9005); front side 

aluminium blank 

Cover plate V4A 

magnet base carrier C45, chromatic 

Fig. 9-74: Layout of enclosure surface 

Remarks 

Varnish resistant to weather, 

yellowing, chalking, thinned acids 

and thinned lyes 

Varnish resistant to weather, 

yellowing, chalking, thinned acids 

and thinned lyes 

Note: The surface of the motor components may be painted with 

additional varnish. 

The noise emission of synchronous linear drives can be compared with 

conventional inverter-operated feed drives. 

Experience has shown that the noise generation chiefly depends on 

• the employed linear guides (velocity-related travel noise), 

• The mechanical design (following cover, etc.), and 

• the settings of drive and controller (e.g. switching frequency) 

A generally valid specification is therefore not possible.


9.15 Length Measuring System 

open systems 

model 

ensapsulated 

systems 

Peculiarities of synchronous 

linear motors 

A linear scale is required for measuring the position and the velocity. 

Particularly high requirements are placed upon the linear scale and its 

mechanical connection. The linear scale serves for high-resolution 

position sensing and to determine the current speed. 

Note: The necessary length measuring system is not in the scope 

of delivery of Bosch Rexroth and has to be provided and 

mounted from the machine manufacturer himself. (see Fig. 9- 

80). 

linear scale 

integrated into 

linear guides 

Selection criteria for linear scales 

incremental 

Fig. 9-75: Classification of linear scales 

measuring 

principle 

incremental, 

distance-encoded 

reference marks 

absolute 

It is necessary at synchronous linear motors to receive the position of 

the primary relating on the secondary by return after start or after a 

malfunction (pole position recognition). Using an absolute linear scale is 

the optimum solution here. 

Depending on the operating conditions, open or encapsulated linear 

scales with different measuring principles and signal periods can be 

used. The selection of a suitable linear scales mainly depends on: 

• the maximum feed rate (model, signal period) 

• the maximum travel (measuring length, model) 

• if applicable, utilization of coolant lubricants (model) 

• produced dirt, chips etc. (model) 

• the accuracy requirements (signal period) 




Models 

Open model Encapsulated model Measuring system, 

integrated in rail guides 

Advantages: 

- High traverse rates 

- No friction 

- High accuracy 

Disadvantage: 

- Low protection mode 

- Currently no absolute measurement 

systems available 

- More complicated mounting and 

adjustment 

Open model 

Encapsulated model 

Measuring system, 

integrated in rail guides 

- Easy installation 

- High protection rating 

- Incremental and absolute 

measurement available 

- Maximum velocity 

currently 120m/min 

- Combined guidance and 

measurement 

- No additional installation required 

- Highest protection rating 

- High traverse rates 

- Little space required 

- No absolute measurement systems 

available 

Fig. 9-76: Advantages and disadvantages of different linear scales models 

If there are no dirt, chips, etc. in a machine or system and if coolant 

lubricants will never be used, employing an open linear scale is 

recommended. Thus open linear scale are frequently used for handling 

axes, precision and measuring machines, and in the semiconductor 

industry. 

Encapsulated systems should be employed if chips are produced and/or 

coolant lubricants are used. To achieve highest operational reliability, an 

encapsulated system can have additional sealing air. Encapsulated 

linear scales are chiefly used at chip-producing machine tools. 

The ball and roller rail guides from Rexroth are available with an 

integrated inductive linear scales. The system consists of a separate 

scanner (read head) and a material measure that is integrated into the 

rail. The material measure is accommodated in a groove of the guide 

rail, and is protected by a tightly welded stainless steel type. The read 

head is attached directly to the guide carriage. 

The system is insensitive against soiling (e.g. dust, chips, coolant, etc.) 

and magnetic fields. Due to the little space required, the compact and 

robust device (measuring system and guides) permits simplified 

structures compared with an externally attached measuring system. 

There are no costs for material and installation of external systems.


Absolute scales 

Measuring principle 

The advantages of an absolute linear scale result from the fact that a 

high availability and operational reliability of the axis of motion and, 

consequently, of the entire system is guaranteed. 

Advantage 

• Monitoring and diagnosis functions of the electronic drive system are 

possible without any additional wiring 

• No axis travel limit switches required 

• The maximum available motor force is available at any point of the 

travel immediately after power-up. 

• No referencing required 

• Easy commissioning of horizontal and vertical axes 

• pole position recognition only required for initial commissioning 

Disadvantage: 

• Maximum measuring length is limited (3040mm) 

• Only encapsulated systems available 

Note: An ENDAT interface is required if absolute linear scales are 

used. 

Using an absolute linear scales makes it possible that the pole position 

recognition of the motor need only be performed once for initial 

commissioning. This drive-internal procedure is possible without 

activating the power. This provides advantages when commissioning 

vertical axes, in particular. 

Rexroth recommends the absolute linear scale LS181 and LC481 from 

Heidenhain. Both systems are equipped with an ENDAT interface. 

Fig. 9-77: Absolute encapsulated length measuring system LC181 

LC181_1.TIF 



Incremental scales 

Incremental linear scales with 

distance-encoded reference 

marks 


When an incremental linear scale is used together with a synchronous 

linear motor, the pole position must be measured upon each power-up. 

This is done, using a drive-internal procedure that must be executed 

whenever the axis is switched on. After this, a force processing of the 

motor is possible. 

Note: With incremental linear scales, the drive-internal pole position 

recognition procedure must be executed upon each powerup. 

Pole position recognition required the primary part to be 

moved! 

Advantage 

• Depending on the model, travels up to 30 m (or unlimited distance) 

possible 

• high feed rate possible 

• Different signal periods and, consequently, different position 

resolutions possible. 

Disadvantage: 

• Pole position must be measured upon each power-up. 

• Pole position recognition required the primary part to be moved 

• Pole position recognition is not possible for vertical axes 

• Pole position recognition is not possible for securely braked axes or 

for axes at the hard stop 

• Pole position recognition of Gantry axes may cause problems 

• Reference point interpretation and homing switch are required 

• Safety limit switch is required 

Incremental linear scales with distance-encoded reference marks offer 

the benefit of a simplified and, even more important, shortened 

referencing. With such a system, referencing requires the axis merely to 

be moved by several centimeters (depends on the model). 

Note: Distance-encoded scales do not perform absolute 

measurement. Pole position recognition must also be 

performed upon each power-up (like incremental systems that 

are not distance encoded). 

lida185.tif 

Fig. 9-78: Open incremental linear scales LIDA185C with distance-encoded 

reference marks


Maximum permissible feed rate 

Maximum permissible 

acceleration in the measuring 

direction 

Maximum permissible velocity and acceleration 

One limitation factor of the maximum permissible feed rate of a length 

measuring system are the sealing lips and the guides of the scan 

carriage on the glass rule. Currently, the velocity of an encapsulated 

system is limited to 120 m/min. 

The other limitation factor of the maximum permissible feed rate is the 

frequency limit of the output signals (manufacturer´s specifications) or 

the maximum permissible input frequency of subsequent circuits (drive 

controller). 

v max = fmax 

⋅ Signal period ⋅ 60 

vmax: Maximum feed rate in m/min 

Signal period: Signal period of linear scale in mm 

fMAX: Maximum input frequency of scale interface 

DAG 1 VSS: 500kHz 

DLF 1 VSS: 500kHz 

Fig. 9-79: Maximum traverse rate of linear scale related to the maximum input 

frequency of the scale interface 

The very rigid internal structure of open linear scales permits maximum 

acceleration values in the measuring direction of up to 200m/s². To 

permit relatively high attachment tolerances, the scan carriage of 

encapsulated linear scales cannot rigidly be connected with the mounting 

foot. Encapsulated linear scales systems for linear motors, however, are 

comparatively rigid and may be used for maximum accelerations in the 

measuring direction between 50 m/s² and 100 m/s² (depending on the 

length measuring system employed). 

Note: Please refer to the documents from the corresponding 

manufacturer for detailed and updated information. 

Position resolution and positioning accuracy 

To reach a high resolution of the linear scale, an interpolation of the 

sinusoidal input signal of the linear scale is performed in the drive 

controller (see Fig. 10-9). Depending on the maximum travel range and 

on the signal period, a drive-internal position resolution of less than 1 

mm is possible. (See also Chapter 10.4 Position and Velocity Resolution) 

Note: The drive-internal position resolution does not correspond to 

the positioning accuracy! The absolute positioning accuracy 

is depending on the entire drive system, including mechanical 

systems. 

Measuring system cables 

Ready-made cables of Rexroth are available for the electrical connection 

between the output of the linear scale and the input of the scale 

interface. To ensure maximum transmission and scale interference 

safety, you should preferably use these ready-made cables. 



Manufacturer 

type 

Heidenhain 

LC 181 

Heidenhain 

LC 481 

Heidenhain 

LS 486 

Heidenhain 

LS 486C 

Heidenhain 

LS 186 

Heidenhain 

LS 186C 

Heidenhain 

LB 382 

Heidenhain 

LB 382C 

Heidenhain 

LF 183 

Heidenhain 

LF 183C 

Heidenhain 

LF 481 

Heidenhain 

LF 481C 

Heidenhain 

LIDA 185 

Heidenhain 

LIDA 185C 

Heidenhain 

LIDA 187 

Heidenhain 

LIDA 187C 

Renishaw 

RG 2 

Heidenhain 

LIF 181R 

Heidenhain 

LIF 181C 

Heidenhain LIP 

481R 

Rexroth 

IML 

Signal period 

in mm 

(S-0-0116) 


Recommended linear scales for linear motors 

Model Output 

signals 

0.016 Encapsulated Sine 1 Vss 

0.016 Encapsulated Sine 1 Vss 

Measuring 

principle 

absolute 

ENDAT 

absolute 

ENDAT 

Maximum 

measuring 

length in mm 

Maximum 

velocity in 

m/min 

3040 120 8 

2040 120 8 

0.02 Encapsulated Sine 1 Vss Incremental 2040 120 2 

P-0-0074 Reference marks 

None 

(absolute) 

None 

(absolute) 

one 

(Center meas. 

length) 

0.02 Encapsulated Sine 1 Vss Incremental 2040 120 2 Distance-encoded 


one 

(Center meas. 

length) 



Selectable by 

masks 



Selectable by 

magnets 



one 

(Center meas. 

length) 


0.04 Open Sine 1 Vss Incremental 30040 480 2 

Selectable by 

magnets 

0.04 Open Sine 1 Vss Incremental 30040 480 2 Distance-encoded 


Selectable by 

magnets 




Selectable by 

magnets 

one 

(Center meas. 

length) 



1.000 

Integrated in 

rail guides 

Sine 1 Vss Incremental 4000 600 2 

P-0-0074: Drive parameter “Encoder type 1” 

S-0-0116: Drive parameter “Encoder 1 resolution” 

Fig. 9-80: Recommended linear scales for linear motors 

one 

(Center meas. 

length) 

One 

(Position to 

customer request) 

Note: 

• To ensure maximum interference immunity, Rexroth recommends the 

voltage interface with 1Vpp. 

• Please refer to the documents from the corresponding manufacturer 

for detailed and possibly updated information.


Mounting Linear scales 

Elasticity of the coupling to the 

machine 

Mounting method 

Open linear scales systems 

Encapsulated linear scales 

systems 

Parallel arrangement of motors 

with one linear scale system 

Gantry axes 

With linear drives, the mounting of the measuring system to the machine 

can limit the bandwidth of the position control loop. As a consequence 

for the design, this means that the coupling between the scan unit and 

the rule of an open linear scale, or between the rule enclosure of an 

encapsulated linear scale, and the machine – with respect to the natural 

frequency – must be significantly higher than the one of the linear scale. 

The natural frequencies of today´s encapsulated linear scales are 2kHz 

and higher. 

It must also be ensured that the linear scales is not attached to vibrating 

machine components. In particular, attaching the system in the vicinity of 

vibration maximal must be avoided. 

In order to minimize the moved masses and to obtain the highest rigidity 

in the measuring direction, the scanner unit should always be moved if 

possible. 

The user should provide an encapsulation if an open linear scale is 

employed despite adverse conditions (chips, dust, etc.). It must also be 

noted that the scanning head must be adjusted when the open linear 

scale is installed. Corresponding adjustment possibilities must be 

provided in the design (please heed the specifications of the 

manufacturer). 

To obtain relatively high installation tolerances, the scan carriage of 

encapsulated linear scale is connected with the mounting base via 

coupling that is very rigid in the measuring direction and slightly flexible 

perpendicularly to the measuring direction. If the rigidity of this coupling 

in the measuring direction is too weak, there are low natural frequencies 

in the feedback of the position and velocity control loop that can limit the 

bandwidth. The encapsulated linear scales that are recommended for 

linear motors usually possess a natural frequency in the measuring 

direction that is above 2 kHz. Thus, the natural frequency of the linear 

scale in the measuring direction can be neglected with respect to the 

mechanical natural frequencies of the machine. 

If several motors on an axis are used with a single linear scale, the 

motors should be positioned as symmetrically as possible. 

With a Gantry axis, where each motor of pair of motors is assigned to a 

linear scale system, the distance between motor and linear scale should 

be as small as possible. The accuracy of the linear scale as such and 

with respect to each other should be less than 5 µm/m. Drive-internal 

axis error compensations can minimize remaining misalignments 

between the linear scales. 



9.16 Linear Guides 


Depending on the motor arrangement, the attractive, feed and process 

forces and the velocities of more than 600 m/min that can be reached 

today stress the linear guides. The employed linear guides must the 

able to handle 

• Attractive force between the primary and the secondary and 

• Machining and acceleration forces 

Depending on the application, the following linear guides are employed: 

• Ball or roll rail guides 

• Slideways 

• Hydrostatic guides 

• Aerostatic guides 

The following requirements should be taken into account when a suitable 

linear guide system is selected: 

• High accuracy and no backlash 

• Low friction and no stick-slip effect 

• High rigidity 

• Steady run, even at high velocities 

• Easy mounting and adjustment 

9.17 Braking Systems and Holding Devices 

The following systems can be used as braking systems and/or holding 

devices for linear motors: 

• External braking devices 

• Clamping elements for linear guides 

• Holding brakes integrated in the weight compensation 

See also Chapter 16 “Recommended suppliers of additional 

components”. 

Note: Additional information about stopping linear motors can be 

found in the Chapters 9.18 End Position and 9.21 Stopping at 

EMERGENCY STOP and in the event of malfunction and in 

the appropriate documentation of the used drive-controller.


9.18 End Position shock absorber 

Maximum deceleration when 

driving against end stop 

Braking distance to be kept 

when driving against end stop 

Where linear drives with frequently high traverse rates and accelerations 

are concerned, uncontrolled movements (such as coasting after a mains 

failure) cannot always safely be avoided. 

Suitable energy-absorbing end position shock absorber must be 

provided in order to protect the machine during uncontrolled coasting of 

an axis. 

WARNING 

Damage on machine or motor components 

when driving against hard stop! 

⇒ Use suitable energy-absorbing end position shock 

absorber 

⇒ Adhere to the specified maximum decelerations 

Note: The necessary spring excursion of the shock absorbers must 

be taken into account when the end position shock absorber 

are integrated into the machine (in particular when the total 

travel path is determined). 

Given by the type of attachment and by the type of the primary (number 

of mounting screws, attractive force, mass, etc.), there is a maximum 

deceleration in the movement onto an end stop. 

If this maximum deceleration is exceeded, this can lead to loosening the 

primary and to damaging of motor components. 

The maximum permissible deceleration upon moving against end stop is 

300 m/s². 

Note: Using a suitable end stop shock absorber, the maximum 

permissible deceleration for moving against an end stop must 

be limited to 300 m/s². 

With the known maximum deceleration of 300 m/s² and the maximum 

possible velocity, the minimum spring excursion can be calculated as 

follwos: 

s 

min = 

2 

vmax 

2158 

smin : Minimum braking distance in mm 

vmax: Maximum possible velocity in m/min 

Fig. 9-81: Braking distance to be kept when driving against end stop 



9.19 Axis Cover System 


Depending on the application, design, operational principle and features 

of synchronous linear motors the following requirements on axis cover 

systems apply: 

• High dynamic properties (no overshoot, little masses) 

• Accuracy and smooth run 

• Protection of motor components against chips, dust and 

contamination (in particular ferromagnetic parts), 

• Resistance to oil and coolant lubricants 

• Robustness and wear resistance 

The following axis cover systems can be used: 

• Bellow covers 

• Telescopic covers 

• Roller covers 

A suitable axis cover system should be configured, if possible, during the 

early development process of the machine or system – supportet by the 

corresponding specialized supplier (see Chapter “Recommended 

suppliers of additional components”).


9.20 Wipers 

Secondary part segments 

Ferromagnetic chips 

Temperature produced by 

friction 

Mounting the wiper 

It is generally possible, to use a wiper for removing chips directly from 

the secondary. The following points must be taken into account when a 

suitable wiper system is selected and used. 

If possible, a wiper should be used on a whole secondary. If more than 

one secondary is used, joints between the secondaries must be taken 

into account (destruction of wiper or of secondaries). In these cases, a 

defined distance – smaller than the air gap among the primary and the 

secondary – between wiper and the secondary or a wiper in the form of a 

hard brush can help. 

The secondary attracts ferromagnetic chips at a distance of approx. 100 

mm. These attractive forces must be taken into account when 

ferromagnetic chips are removed. 

If the utilization of the wiper causes a significant rise of the temperature 

on the secondary surface, it must be ensured that this temperature does 

not exceed the limit of 70°C. 

The wiper should be mounted to the superordinated machine 

construction. Mounting the wiper in additional holes directly on the 

primary is not permitted. 

WARNING 

Damage or destruction of motor components by 

inappropriate utilization of a wiper on the 

secondary part! 

⇒ If possible, utilization only on whole secondaries 

⇒ Take slightly height differences of the secondaries 

into account 

⇒ Take temperature rises due to friction into account 

⇒ Mounting the wiper in additional holes directly on 

the primary is not permitted 



9.21 Drive and Control of IndraDyn L motors 


The following figures shows a complete linear direct drive, consisting of a 

synchronous linear motor, length scale system, drive controller and 

superordinate control. 

master control 

act. pos. values, 

communication 

Fig. 9-82: Linear direct drive 

Drive controller and power supply modules 

Control systems 


ðcurrent control 

ðvelocity control 

ðspeed control 

ðfine interpolation 

power, 

sensor signals 

3~ 

motor Motor 

linear scale 

ðabsolute ENDAT 

ðincremental 

ðdistance-encoded 

ANTRSYST01-MLF-EN.EPS 

To control IndraDyn L motors, different digital drive controllers and power 

supply modules are available. These drive systems are configurable and 

of a modular or compact structure. 

Note: The drive controllers and the related firmware for the 

IndraDyn L motors are the same as for the rotary drives from 

Bosch Rexroth. 

A master control is required for generating defined movements. 

Depending on the functionality of the whole machine and the used 

control systems, Bosch Rexroth offers different control systems.


9.22 Shutdown upon EMERGENCY STOP and in the Event of a 

Malfunction 

Shutdown by the drive 

The shutdown of an axis, equipped with an IndraDyn L motor, can be 

initiated by 

• EMERGENCY STOP, 

• drive fault (e.g. response of the encoder monitoring function) or 

• mains failure 

For the options of shutting down an IndraDyn L motor in the event of a 

malfunction, distinction must be made between 

• Shutdown by the drive, 

• Shutdown by a master control and 

• Shutdown by a mechanical braking device. 

As long as there is no fault or malfunction in the drive system, shutdown 

by the drive is possible. The shutdown possibilities depend on the 

occurred drive error and on the selected error response of the drive. 

Certain faults (interface faults or fatal faults) lead to a force 

disconnection of the drive. 

WARNING 

Death, serious injuries or damage to equipment 

may result from an uncontrolled coasting of a 

switched-off linear drive! 

⇒ Construction and design according to the safety 

standards 

⇒ Protection of people by suitable barriers and 

enclosures 

⇒ Using external mechanical braking facilities 

⇒ Use suitable energy-absorbing end position shock 

absorber 

The parameter values of the drive response to interface faults and nonfatal 

faults can be selected. The drive switches off at the end of each 

fault response. 

The following fault responses can be selected: 

0 – Setting velocity command value to zero 

Setting force command value to zero 

Setting velocity command value to zero with command value ramp and 

filter 

3 - Retraction 

Note: Please refer to the corresponding firmware function 

description for additional information about the reaction to 

faults and the related parameter value assignments. 



Shutdown by a master control 


Shutdown by control functions 

Shutdown via mechanical braking device 

Shutdown by the master control should be performed in the following 

steps: 

1. The machine PLC or the machine I/O level reports the fault to the 

CNC control 

2. The CNC control shuts down the drives via a ramp in the fastest 

possible way 

3. The CNC control causes the power at the power supply module to be 

shut down. 

Drive initiated by the control shutdown 

Shutdown by the master control should be performed in the following 

steps: 

1. The machine I/O level reports the fault to the CNC control and SPS 

2. The CNC control or the PLC resets the drive enabling signal of the 

drives. If SERCOS interface is used, it deactivates the “E-STOP” 

input at the SERCOS interface module. 

3. The drive responds with the selected error response. 

4. The power at the power supply module must be switched off 500 ms 

after the drive enabling signal has been reset or the “E-STOP” input 

has been deactivated. 

Note: The delayed power shutdown ensures the safe shutdown of 

the drive by the drive controller. With an undelayed power 

shutdown, the drive coasts in an uncontrolled way once the 

DC bus energy has been used up. 

Shutdown by mechanical braking devices should be activated 

simultaneously with switching off the power at the power supply module. 

Integration into the holding brake control of the drive controllers is 

possible, too. The following must be observed: 

• Braking devices with electrical 24V DC control (electrically un-locking) 

and currents < 2 A can directly be triggered. 

• Braking devices with electrical 24V DC control and currents > 2 A can 

be triggered via a suitable contractor. 

Once the drive enabling signal has been removed, the holding brake 

control has the following effect: 

• Fault reaction “0”, “1” and “3”. 

The holding brake control drops to 0 V once the velocity is less than 

10 mm/min or a time of 400 ms has elapsed. 

• Fault reaction “2” 

The holding brake control drops to 0 V immediately after the drive 

enabling signal has been removed.


Response to a mains failure 

Determining the required 

additional DC bus capacitor 

Short-circuit of DC bus 

In order to be able to shut down the linear drive as fast as possible in the 

event of a mains failure, 

• either an uninterruptible power supply or 

• additional DC bus capacities (condensers), and /or 

• mechanical braking facilities 

must be provided. 

Additional capacities in the DC bus represent an additional energy store 

that can supply the brake energy required in the event of a mains failure. 

Note: Internal control circuits are also supplied by the DC bus; 

external backup is not necessary. 

The additional capacity required for a shutdown upon a mains failure can 

be determined as follows: 

C 

add 

m ⋅ v ⎡ 

⎛ ⎞⎤ 

max 

Fmax 

FR 

= ⋅ ⎢3, 

5 ⋅ ⋅R 

− v ⋅ 

⎜ + 0. 

3 

⎟ 

2 

2 

2 12 max 

⎥ 

U − U ⎢⎣ 

k 

⎝ F 

DCmax 

DCmin 

iF 

max ⎠⎥⎦ 

Cadd: Required additional DC bus capacitor in mF 

m: Moved mass in kg 

vmax: Maximum velocity in m/s 

UDCmax: Maximum DC bus voltage in V 

UDCmin: Minimum DC bus voltage in V 

FMAX: Maximum braking force of the motor in N 

kiF: Motor constant (force constant) in N/A 

R12: Winding resistance at 20°C 

FR: Frictional force in N 

Fig. 9-83: Determining the required additional DC bus capacitor 

Prerequisites: - final velocity = 0- velocity-independent friction – 

constant deceleration – winding temperature 135°C 

Note: The maximum possible DC bus capacity of the employed 

power supply module must be taken into account when 

additional capacities are used in the DC bus. Do not initiate a 

DC voltage short-circuit when additional capacitors are 

employed. 

Most of the power supply modules of Bosch Rexroth permit the DC bus 

to be shortened when the power is switched off, which also establishes a 

short-circuit between the motor phases. When the motor moves, this 

causes a braking effect according to the principle of the induction; 

thereby the motor phases are shorted. The reachable braking force is 

not very high and velocity-dependend. The DC bus short-circuit can 

therefore only be used to support existing mechanical braking devices. 



9.23 Maximum Acceleration Changes (Jerk Limitation) 

Rate of current and force rise 


The maximum rate of current and force rise is determined by the 

available DC bus voltage and the motor inductance. As shown in Fig. 9- 

84, with highly dynamic movements and short strokes, the motor 

inductance should be low and the DC bus voltage as high as possible. 

di 

dt 

dF 

dt 

U 

= 

L 

DC 

12 

U 

= 

L 

DC 

12 

⋅ k 

UDC: DC bus voltage in V 

L12: Winding inductance in H 


i: Current in A 

t: Time in s 

Fig. 9-84: Maximum rate of current and force rise 

The acceleration change per time unit (derivative of the acceleration) is 

known as jerk (see Fig. 9-87). 

da 

= ¥ 

dt 

velocity 

Fig. 9-85: Acceleration and velocity without jerk limitation 

iF 

acceleration 

RUCKBEGR01-MLF-EN.EPS 

Note: The drive controller or the master control must delimit the 

maximum jerk when direct drives are employed. (acceleration 

ramp with da/dt ≠ ∞, Fig. 9-86. 

t


Maximum jerk 

da 

¹ ¥ 

dt 

velocity 

Fig. 9-86: Acceleration and velocity with jerk limitation 

acceleration 

RUCKBEGR02-MLF-EN.EPS 

The maximum jerk is determined by the maximum rate of current rise, by 

the moved mass and by the motor constant: 

r 

max 

da 

dt 

U 

= 

L 

DC 

12 

⋅ k 

⋅ m 


UDC: DC bus voltage in V 


L12: Winding inductance in H 


t: Time in s 

Fig. 9-87: Maximum jerk (acceleration change) 

= 

iF 


t


9.24 Position and Velocity Resolution 


Drive-internal position resolution and positioning 

accuracy 

In linear direct drives, a linear scale is used for measuring the position. 

The linear scale for linear motors supply sinusoidal output signals. The 

length of such a sine signal is known as the signal period. It is mainly 

specified in mm or µm. 

With the drive controllers from Bosch Rexroth, the sine signals are 

amplified again in the drive (see Fig. 9-89). The drive-internal 

amplification also depends on the maximum travel area and the signal 

period of the length measuring system. It always employs 2 n vertices 

(e.g. 2048 or 4096). 

f 

int 

= 2 

31 

s 

⋅ 

x 

p 

max 

rounding to 2 

fint: Multiplication factor (S-0-0256, Multiplication 1) 

sp: Linear scale system signal period in mm (S-0-0116 resolution of 

encoder 1) 

xmax: Maximum travel (S-0-0278, maximum travel) 

Fig. 9-88: Multiplication factor 

Dxd 

signal period 

n 

INTPOLSIN-MLF-EN.EPS 

Fig. 9-89: Drive-internal multiplication and/or interpolation of the measuring 

system signals 

With a known signal period and a drive-internal multiplication, the driveinternal 

position resolution results as: 

s 

∆x 

d = 

f 

∆xd: Drive-internal position resolution 

sp: Linear scale system signal period (S-0-0116 resolution of encoder 1) 

fint: Multiplication factor (S-0-0256, Multiplication 1) 

Fig. 9-90: Drive-internal position resolution 

Note: The drive-internal position resolution is not identical to the 

reachable positioning accuracy. 

p 

int


Reachable positioning accuracy 

9.25 Load Rigidity 

The reachable position accuracy depends on the mechanical and 

control-engineering overall system and is not identical to the driveinternal 

position resolution. . 

The reachable position accuracy can be estimated as follows (using 

empirical values): 

∆xabs 

= ∆xd 

⋅ 30... 

50 

∆xd: Drive-internal position resolution 

∆xabs: Position accuracy 

Fig. 9-91: Estimating the reachable position accuracy 

Prerequisites: Optimum controller setting 

Note: The expected position accuracy cannot be better than the 

smallest position command increment of the master control. 

Velocity resolution 

The resolution of the velocity (velocity quantization) is proportional to the 

position resolution (see Fig. 9-88) and inversely proportional to the 

sample time tAD from: 

∆x 

∆ v d = 

t 

∆vd: Velocity resolution in m/s 

∆xd: Drive-internal position resolution (see Fig. 9-90) 

tAD: Sample time in s (DIAX04: 250µs, ECODRIVE03: 500µs, IndraDrive: 

Standard Performance 250µs / High Performance 125µs) 

Fig. 9-92: Velocity resolution 

The elastic deformability resistance of a structure against an external 

force is known as rigidity (usually specified in N/µm). The reciprocal 

value of the rigidity is known as elasticity. 

Influence of disturbing factors on a controlled electric drive is called load 

rigidity. It is distinguished between static and dynamic load rigidity. 

AD 

d 



Static load rigidity 

Dynamic load rigidity 


The static load rigidity of a linear direct drive only depends on the 

maximum motor force and the drive-internal position resolution: 

c 

stat 

F 

= 

∆x 

cstat: Static load rigidity in N/µm 

FMAX: Maximum force of the motor in N 

∆xD: Drive-internal position resolution in µm (see Fig. 9-90) 

Fig. 9-93: Static load rigidity of linear direct drives 

Note: The rigidity of the machine structure must be taken into 

account when the static load rigidity of a linear direct drive is 

rated. 

d 

stat 

max 

∆x 

= 

F 

dstat: Static elasticity in N/µm 


∆xD: Drive-internal position resolution in µm (see Fig. 9-90) 

Fig. 9-94: Static elasticity of linear direct drives 

Dynamic load rigidity and elasticity are frequency-dependent variables. 

The dynamic load rigidity of a linear direct drive only depends on the 

controller settings (current, velocity and position controller) and on the 

moved masses (see Fig. 9-96). The maximum elasticity (or the minimum 

rigidity) is in the area of the natural frequency of the control loop. 

In a simplified form, the following figure shows a typical elasticity 

frequency response. 

G S( ω ) 

µm 

N 

1.10 3 

0.1 

0.01 

1.10 

4 

D 

D 

max 

. 

1 10 100 1 .10 3 

ω 

2 π . 

Fig. 9-95: Example elasticity frequency response of a linear direct drive


Estimating the dynamic load 

rigidity 

Despite the frequency sensitivity, a sufficiently exact estimate of the 

dynamic rigidity can be made for the area below the natural frequency of 

the control loop: 

c 

dyn 

mit 

1 

D = ⋅ 

2 

m ⋅ 

0. 

06 ⋅k 

p 

( 1+ 

0. 

0167 ⋅k 

⋅ T ) 

0. 

06 ⋅k 

p ⋅k 

iF ⋅ 

= 

π ⎛ −D⋅ 

⎞ 2 ⎜ 

1−D 

e ⎟ 

Tn 

⋅ ⎜1+ 

⎟ 

2 ⎜ 1− 

D ⎟ 

⎝ 

⎠ 

⋅k 

iF 

⋅ T 

( 1+ 

0. 

0167 ⋅k 

⋅ T ) 

cdyn: Dynamic load rigidity in N/µm 

D: Attenuation 


kp: Proportional gain of velocity controller in A min/m 

kv: Proportional gain of position controller (Kv-factor) in m/min mm 

Tn: Integral time of velocity controller in ms 


Fig. 9-96: Estimating the dynamic load rigidity 

d = 

dyn 

1 

c 

dyn 

cdyn: Dynamic load rigidity in N/µm 

ddyn: Dynamic elasticity in N/µm 

Fig. 9-97: Determining of the dynamic elasticity 

1 

ω0 

= ⋅ 

2 ⋅π 

1000 ⋅k 

p 

v 

n 

⋅k 

iF ⋅ 

m ⋅ T 

n 

v 

n 

( 60 + k ⋅ T ) 

ω0: Natural frequency in Hz 


kp: Proportional gain of velocity controller in A min/m 

kv: Proportional gain of position controller (Kv-factor) in m/min mm 

Tn: Integral time of velocity controller in ms 


Fig. 9-98: Determining the controller´s natural frequency 

n 

v 

n 


Rexroth IndraDyn L Motor-Controller-Combinations 10-1 

10 Motor-Controller-Combinations 

10.1 General explanation 

Structure of the selection data 

Sorting of the lists 

Design of the primary 

Parallel motor arrangement 

PWM frequency of the Drive 

Controller 


This chapter contains selection data for different motor/controller 

combinations using the IndraDrive family of motor controllers. 

The structure of the selection data for the IndraDyn L synchronous, 

linear motors depends on: 

• The motor controller used 

• The power supply used and the corresponding supply voltage 

• The physical arrangement of the primaries (individual or parallel) 

The selection data are sorted by the following criteria: 

1. Motor type 

2. Maximum force, FMAX 

3. Maximum speed with maximum force, vFMAX 

Both the standard- and thermally-encapsulated versions of the same 

size motors have identical specifications, so the specifications of the 

motor/controller combinations for both designs have been combined. 

Note: The specifications for motor/controller combinations for 

standard- and thermally-encapsulated motors are identical. 

Motor/controller combinations are also given for motors installed in 

parallel arrangement on one drive controller. 

Note: The specifications for the parallel arrangements of motors 

assume they are being powered by one drive controller. 

Motors mounted parallel in a gantry style and driven by 

separate drive controllers should be considered as individual, 

i.e. non-parrallel, motors. 

The PWM frequency of the drive controller affects the motor data. All 

data in this documentation is based on a 4 kHz PWM frequency.

10-2 Motor-Controller-Combinations Rexroth IndraDyn L 

Explanation of the variables 

FMAX 

vFMAX 

PVMAX 

FdN 

VN 

PvN 

EDFMAX 

FKB 

idN 

imax 

Maximum force of the motor. This is available for up to 400 ms (see Fig. 

4-1). 

Maximum speed with maximum force, FMAX. This is the speed available 

at the maximum force of the motor. (see Fig. 4-1) 

Maximum electrical loss of the motor. This is calculated using the 

maximum current of a motor and a motor winding temperature of 135°C. 

Nominal force of the motor (see Fig. 4-1) assuming: 

- liquid cooling with a coolant inlet temperature of 30°C 

- a motor winding temperature of 135°C, and 

- motor at stand still 

Nominal speed (see Fig. 4-1) 

This is the speed available when the motor is delivering it’s nominal 

force, FdN. 

Nominal power loss of the motor at FdN 

Relative duty cycle in %. This is given with reference to the specified 

maximum and continuous forces. (see Fig. 11-16) 

Intermittent force 

The intermittent force depends on the ratio between motor’s nominal 

current and the nominal current of the drive controller. This intermittent 

force can be used intermittently in S6 operation with a duty cycle of 

EDFKB. The maximum cycle duration corresponds to the thermal time 

constant of the motor (see chapter 4 “Technical Data”). 

ED 

F KB 

⎛ F 

≈ ⎜ 

⎝ F 

dN 

KB 

⎞ 

⎟ 

⎠ 

2 

⋅100% 

FdN: Nominal force of the motor in N 

FKB: Potential intermittent force in N 

Fig. 10-1: Calculation of the potential duty cycle as related to FKB 

An intermittent force higher than the nominal force of the motor is only 

then available when the nominal current of the drive-controller is higher 

than the nominal current of the motor. 

Nominal current of the motor at nominal force, FdN 

Maximum current of the motor at FMAX. 

Note: The specification of the current is always given in peak 

values unless otherwise noted. 



10.2 Motor/Controller Combinations; one primary per drive 

Controlled DC Bus Voltage, mains supply voltage - 3 x 480 VAC 

FMAX 

[N] 

vFmax 

[m/min] 

PVMAX 

[kW] 

FdN 

[N] 

vN 

[m/min] 


PvN 

[kW] 

EDFMAX 

[%] 

FKB 

[N] 

idN 

[A] 

iMAX 

[A] 

Primary MLP... 

Standard- / Thermal encapsulation Controller 

800 360 6,6 250 600 0,33 5 352 5,9 28 040A-0300 HMS01.1N-W0020 

800 360 6,6 250 600 0,33 5 375 5,9 28 040A-0300 HMS01.1N-W0036 

394 537 1,1 127 654 0,08 7 127 3 12 040A-0300 HCS02.1E-W0012 

800 360 6,6 250 600 0,33 5 375 5,9 28 040A-0300 HCS02.1E-W0028 

800 360 6,6 250 600 0,33 5 375 5,9 28 040A-0300 HCS02.1E-W0054 

1150 180 7,8 370 360 0,39 5 515 5,9 28 040B-0150 HMS01.1N-W0020 

1150 180 7,8 370 360 0,39 5 555 5,9 28 040B-0150 HMS01.1N-W0036 

575 313 1,4 188 402 0,1 7 188 3 12 040B-0150 HCS02.1E-W0012 

1150 180 7,8 370 360 0,39 5 555 5,9 28 040B-0150 HCS02.1E-W0028 

1150 180 7,8 370 360 0,39 5 555 5,9 28 040B-0150 HCS02.1E-W0054 

902 357 5,5 370 480 0,43 8 429 7,5 28 040B-0250 HMS01.1N-W0020 

1150 300 10 370 480 0,43 4 555 7,5 38 040B-0250 HMS01.1N-W0036 

477 455 0,9 148 532 0,07 7 148 3 12 040B-0250 HCS02.1E-W0012 

1140 303 9,8 370 480 0,43 4 416 7,5 38 040B-0250 HCS02.1E-W0028 

1150 300 10 370 480 0,43 4 555 7,5 38 040B-0250 HCS02.1E-W0054 

751 483 4 370 600 0,4 10 395 8,5 28 040B-0300 HMS01.1N-W0020 

1150 360 11,9 370 600 0,4 3 555 8,5 49 040B-0300 HMS01.1N-W0036 

1150 360 11,9 370 600 0,4 3 555 8,5 49 040B-0300 HMS01.1N-W0054 

1150 360 11,9 370 600 0,4 3 555 8,5 49 040B-0300 HMS01.1N-W0070 

432 581 0,7 131 674 0,05 7 131 3 12 040B-0300 HCS02.1E-W0012 

930 428 7 370 600 0,4 6 385 8,5 38 040B-0300 HCS02.1E-W0028 

1150 360 11,9 370 600 0,4 3 555 8,5 49 040B-0300 HCS02.1E-W0054 

1150 360 11,9 370 600 0,4 3 555 8,5 49 040B-0300 HCS02.1E-W0070 

1150 360 11,9 370 600 0,4 3 555 8,5 49 040B-0300 HCS03.1E-W0070 

1564 256 4,4 630 420 0,34 8 733 7,5 28 070A-0150 HMS01.1N-W0020 

2000 180 7,9 630 420 0,34 4 945 7,5 38 070A-0150 HMS01.1N-W0036 

819 387 0,7 252 487 0,05 7 252 3 12 070A-0150 HCS02.1E-W0012 

1982 183 7,7 630 420 0,34 4 711 7,5 38 070A-0150 HCS02.1E-W0028 

2000 180 7,9 630 420 0,34 4 945 7,5 38 070A-0150 HCS02.1E-W0054 

1293 351 2,6 630 432 0,28 11 661 8,9 28 070A-0220 HMS01.1N-W0020 

2000 264 7,7 630 432 0,28 4 945 8,9 49 070A-0220 HMS01.1N-W0036 

2000 264 7,7 630 432 0,28 4 945 8,9 49 070A-0220 HMS01.1N-W0054 

2000 264 7,7 630 432 0,28 4 945 8,9 49 070A-0220 HMS01.1N-W0070 

726 421 0,4 212 484 0,03 7 212 3 12 070A-0220 HCS02.1E-W0012 

1611 312 4,5 630 432 0,28 6 644 8,9 38 070A-0220 HCS02.1E-W0028 

2000 264 7,7 630 432 0,28 4 945 8,9 49 070A-0220 HCS02.1E-W0054 

2000 264 7,7 630 432 0,28 4 945 8,9 49 070A-0220 HCS02.1E-W0070 

2000 264 7,7 630 432 0,28 4 945 8,9 49 070A-0220 HCS03.1E-W0070 

1965 365 15,9 630 540 0,67 4 945 14,8 76 070A-0300 HMS01.1N-W0054 

2000 360 16,6 630 540 0,67 4 945 14,8 78 070A-0300 HMS01.1N-W0070 

2000 360 16,6 630 540 0,67 4 757 14,8 78 070A-0300 HCS02.1E-W0070 

2000 360 16,6 630 540 0,67 4 945 14,8 78 070A-0300 HCS03.1E-W0070 

1953 164 8,6 820 240 0,73 8 931 7,8 28 070B-0100 HMS01.1N-W0020 

2600 120 17,2 820 240 0,73 4 1230 7,8 40 070B-0100 HMS01.1N-W0036 

1036 226 1,5 315 274 0,11 7 315 3 12 070B-0100 HCS02.1E-W0012 

2467 129 15,2 820 240 0,73 5 903 7,8 38 070B-0100 HCS02.1E-W0028 

2600 120 17,2 820 240 0,73 4 1230 7,8 40 070B-0100 HCS02.1E-W0054 

1524 217 7,2 820 264 0,67 9 876 8,2 28 070B-0120 HMS01.1N-W0020 

2316 163 23,2 820 264 0,67 3 1170 8,2 51 070B-0120 HMS01.1N-W0036 

2600 144 31,2 820 264 0,67 2 1230 8,2 59 070B-0120 HMS01.1N-W0054 

2600 144 31,2 820 264 0,67 2 1230 8,2 59 070B-0120 HMS01.1N-W0070 

943 256 1,2 300 299 0,09 7 300 3 12 070B-0120 HCS02.1E-W0012 

1850 195 12,7 820 264 0,67 5 859 8,2 38 070B-0120 HCS02.1E-W0028 

2516 150 28,7 820 264 0,67 2 1044 8,2 57 070B-0120 HCS02.1E-W0054 

2600 144 31,2 820 264 0,67 2 1230 8,2 59 070B-0120 HCS02.1E-W0070 

2600 144 31,2 820 264 0,67 2 1230 8,2 59 070B-0120 HCS03.1E-W0070 

Further information – see next page


FMAX 

[N] 

vFmax 

[m/min] 

PVMAX 

[kW] 

FdN 

[N] 

vN 

[m/min] 

PvN 

[kW] 

EDFMAX 

[%] 

FKB 

[N] 

idN 

[A] 

iMAX 

[A] 



1406 269 10,9 820 312 1,18 11 850 8,8 28 070B-0150 HMS01.1N-W0020 

2086 218 35,4 820 312 1,18 3 1103 8,8 51 070B-0150 HMS01.1N-W0036 

2600 180 63,1 820 312 1,18 2 1230 8,8 68 070B-0150 HMS01.1N-W0054 

2600 180 63,1 820 312 1,18 2 1230 8,8 68 070B-0150 HMS01.1N-W0070 

907 306 1,9 280 352 0,14 7 280 3 12 070B-0150 HCS02.1E-W0012 

1686 248 19,3 820 312 1,18 6 835 8,8 38 070B-0150 HCS02.1E-W0028 

2257 206 43,7 820 312 1,18 3 994 8,8 57 070B-0150 HCS02.1E-W0054 

2600 180 63,1 820 312 1,18 2 1230 8,8 68 070B-0150 HCS02.1E-W0070 

2600 180 63,1 820 312 1,18 2 1230 8,8 68 070B-0150 HCS03.1E-W0070 

2555 305 51,2 820 480 1,95 4 1230 14,1 76 070B-0250 HMS01.1N-W0054 

2600 300 53,4 820 480 1,95 4 1230 14,1 78 070B-0250 HMS01.1N-W0070 

2600 300 53,4 820 480 1,95 4 1002 14,1 78 070B-0250 HCS02.1E-W0070 

2600 300 53,4 820 480 1,95 4 1230 14,1 78 070B-0250 HCS03.1E-W0070 

2109 410 39,8 820 540 2,2 6 1230 17 76 070B-0300 HMS01.1N-W0054 

2600 360 66,9 820 540 2,2 3 1193 17 99 070B-0300 HMS01.1N-W0070 

2170 404 42,8 820 540 2,2 5 883 17 79 070B-0300 HCS02.1E-W0070 

2600 360 66,9 820 540 2,2 3 1230 17 99 070B-0300 HCS03.1E-W0070 

3736 146 32,4 1200 216 0,98 3 1800 12,6 76 070C-0120 HMS01.1N-W0054 

3800 144 33,8 1200 216 0,98 3 1800 12,6 78 070C-0120 HMS01.1N-W0070 

3800 144 33,8 1200 216 0,98 3 1520 12,6 78 070C-0120 HCS02.1E-W0070 

3800 144 33,8 1200 216 0,98 3 1800 12,6 78 070C-0120 HCS03.1E-W0070 

3392 199 27,9 1200 300 1,06 4 1800 14,1 76 070C-0150 HMS01.1N-W0054 

3800 180 37 1200 300 1,06 3 1800 14,1 88 070C-0150 HMS01.1N-W0070 

3490 194 30 1200 300 1,06 4 1404 14,1 79 070C-0150 HCS02.1E-W0070 

3800 180 37 1200 300 1,06 3 1800 14,1 88 070C-0150 HCS03.1E-W0070 

3071 325 14,2 1200 420 0,92 6 1797 18,4 76 070C-0240 HMS01.1N-W0054 

3800 288 23,9 1200 420 0,92 4 1710 18,4 99 070C-0240 HMS01.1N-W0070 

3161 321 15,3 1200 420 0,92 6 1248 18,4 79 070C-0240 HCS02.1E-W0070 

3800 288 23,9 1200 420 0,92 4 1800 18,4 99 070C-0240 HCS03.1E-W0070 

3506 381 29,2 1200 540 1,18 4 1800 26,9 141 070C-0300 HCS03.1E-W0100 

2252 150 9,7 1168 180 1,3 13 1168 9,8 28 100A-0090 HMS01.1N-W0020 

3569 113 31,3 1180 180 1,32 4 1664 9,9 51 100A-0090 HMS01.1N-W0036 

3750 108 35,3 1180 180 1,32 4 1770 9,9 54 100A-0090 HMS01.1N-W0054 

3750 108 35,3 1180 180 1,32 4 1770 9,9 54 100A-0090 HMS01.1N-W0070 

1285 177 1,7 358 203 0,12 7 358 3 12 100A-0090 HCS02.1E-W0012 

2794 135 17,1 1108 182 1,17 7 1108 9,3 38 100A-0090 HCS02.1E-W0028 

3750 108 35,3 1180 180 1,32 4 1548 9,9 54 100A-0090 HCS02.1E-W0054 

3750 108 35,3 1180 180 1,32 4 1770 9,9 54 100A-0090 HCS02.1E-W0070 

3750 108 35,3 1180 180 1,32 4 1770 9,9 54 100A-0090 HCS03.1E-W0070 

2042 200 6,2 1023 233 0,84 13 1023 9,8 28 100A-0120 HMS01.1N-W0020 

3187 162 20,2 1180 228 1,11 5 1530 11,3 51 100A-0120 HMS01.1N-W0036 

3750 144 30 1180 228 1,11 4 1770 11,3 62 100A-0120 HMS01.1N-W0054 

3750 144 30 1180 228 1,11 4 1770 11,3 62 100A-0120 HMS01.1N-W0070 

1200 227 1,1 313 256 0,08 7 313 3 12 100A-0120 HCS02.1E-W0012 

2513 185 11 971 235 0,75 7 971 9,3 38 100A-0120 HCS02.1E-W0028 

3476 153 25 1180 228 1,11 4 1347 11,3 57 100A-0120 HCS02.1E-W0054 

3750 144 30 1180 228 1,11 4 1770 11,3 62 100A-0120 HCS02.1E-W0070 

3750 144 30 1180 228 1,11 4 1770 11,3 62 100A-0120 HCS03.1E-W0070 

3686 182 39,3 1180 264 1,49 4 1770 14,1 76 100A-0150 HMS01.1N-W0054 

3750 180 40,9 1180 264 1,49 4 1770 14,1 78 100A-0150 HMS01.1N-W0070 

3750 180 40,9 1180 264 1,49 4 1443 14,1 78 100A-0150 HCS02.1E-W0070 

3750 180 40,9 1180 264 1,49 4 1770 14,1 78 100A-0150 HCS03.1E-W0070 

3042 261 50,7 1180 348 2,8 6 1770 17 76 100A-0190 HMS01.1N-W0054 

3750 228 85 1180 348 2,8 3 1719 17 99 100A-0190 HMS01.1N-W0070 

3129 257 54,4 1180 348 2,8 5 1271 17 79 100A-0190 HCS02.1E-W0070 

3750 228 85 1180 348 2,8 3 1770 17 99 100A-0190 HCS03.1E-W0070 

4549 167 25,3 1785 228 1,4 6 2678 17 76 100B-0120 HMS01.1N-W0054 

5600 144 42,5 1785 228 1,4 3 2585 17 99 100B-0120 HMS01.1N-W0070 

4679 164 27,2 1785 228 1,4 5 1920 17 79 100B-0120 HCS02.1E-W0070 

5600 144 42,5 1785 228 1,4 3 2678 17 99 100B-0120 HCS03.1E-W0070 

4537 334 39 1785 420 2,1 5 2678 31,1 141 100B-0250 HCS03.1E-W0100 

4895 153 29 2310 204 1,88 6 3134 18,4 76 100C-0090 HMS01.1N-W0054 

5902 133 48,7 2310 204 1,88 4 3014 18,4 99 100C-0090 HMS01.1N-W0070 

5020 150 31,2 2310 204 1,88 6 2377 18,4 79 100C-0090 HCS02.1E-W0070 

5902 133 48,7 2310 204 1,88 4 3465 18,4 99 100C-0090 HCS03.1E-W0070 

Further information – see next page 



FMAX 

[N] 

vFmax 

[m/min] 

PVMAX 

[kW] 

FdN 

[N] 

vN 

[m/min] 


PvN 

[kW] 

EDFMAX 

[%] 

FKB 

[N] 

idN 

[A] 

iMAX 

[A] 



5014 181 21,6 2310 228 1,86 9 3079 21,2 76 100C-0120 HMS01.1N-W0054 

6121 162 36,3 2310 228 1,86 5 2947 21,2 99 100C-0120 HMS01.1N-W0070 

5151 179 23,2 2168 231 1,64 7 2168 19,9 79 100C-0120 HCS02.1E-W0070 

6121 162 36,3 2310 228 1,86 5 3465 21,2 99 100C-0120 HCS03.1E-W0070 

5495 269 39 2310 348 2,3 6 3465 32,5 141 100C-0190 HCS03.1E-W0100 

4230 167 22,8 1680 228 1,26 6 2520 17 76 140A-0120 HMS01.1N-W0054 

5200 144 38,2 1680 228 1,26 3 2418 17 99 140A-0120 HMS01.1N-W0070 

4350 164 24,5 1680 228 1,26 5 1804 17 79 140A-0120 HCS02.1E-W0070 

5200 144 38,2 1680 228 1,26 3 2520 17 99 140A-0120 HCS03.1E-W0070 

6182 132 22,8 2415 192 1,47 6 3617 18,4 76 140B-0090 HMS01.1N-W0054 

7650 108 38,2 2415 192 1,47 4 3441 18,4 99 140B-0090 HMS01.1N-W0070 

6364 129 24,5 2415 192 1,47 6 2512 18,4 79 140B-0090 HCS02.1E-W0070 

7650 108 38,2 2415 192 1,47 4 3622 18,4 99 140B-0090 HCS03.1E-W0070 

4590 193 14,8 2415 228 1,84 12 2902 25,5 76 140B-0120 HMS01.1N-W0054 

5556 178 24,8 2415 228 1,84 7 2787 25,5 99 140B-0120 HMS01.1N-W0070 

4710 191 15,9 1885 237 1,12 7 1885 19,9 79 140B-0120 HCS02.1E-W0070 

5556 178 24,8 2415 228 1,84 7 3475 25,5 99 140B-0120 HCS03.1E-W0070 

8079 80 45,5 3150 132 2,95 6 4722 18,4 76 140C-0050 HMS01.1N-W0054 

10000 60 76,4 3150 132 2,95 4 4493 18,4 99 140C-0050 HMS01.1N-W0070 

8317 78 48,9 3150 132 2,95 6 3277 18,4 79 140C-0050 HCS02.1E-W0070 

10000 60 76,4 3150 132 2,95 4 4725 18,4 99 140C-0050 HCS03.1E-W0070 

8344 164 50,7 3150 228 2,49 5 4725 29,7 141 140C-0120 HCS03.1E-W0100 

7531 239 29,2 3150 300 2,74 9 4708 41 141 140C-0170 HCS03.1E-W0100 

6038 135 17,1 2415 204 1,1 6 3571 18,4 76 200A-0090 HMS01.1N-W0054 

7450 108 28,7 2415 204 1,1 4 3402 18,4 99 200A-0090 HMS01.1N-W0070 

6213 132 18,3 2415 204 1,1 6 2509 18,4 79 200A-0090 HCS02.1E-W0070 

7450 108 28,7 2415 204 1,1 4 3622 18,4 99 200A-0090 HCS03.1E-W0070 

5086 184 13,1 2415 228 1,28 10 3125 22,6 76 200A-0120 HMS01.1N-W0054 

6209 165 22 2415 228 1,28 6 2991 22,6 99 200A-0120 HMS01.1N-W0070 

5225 181 14,1 2126 233 0,99 7 2126 19,9 79 200A-0120 HCS02.1E-W0070 

6209 165 22 2415 228 1,28 6 3622 22,6 99 200A-0120 HCS03.1E-W0070 

8815 68 33 3465 120 2,14 6 5172 18,4 76 200B-0040 HMS01.1N-W0054 

10900 48 55,4 3465 120 2,14 4 4922 18,4 99 200B-0040 HMS01.1N-W0070 

9074 66 35,5 3465 120 2,14 6 3603 18,4 79 200B-0040 HCS02.1E-W0070 

10900 48 55,4 3465 120 2,14 4 5198 18,4 99 200B-0040 HCS03.1E-W0070 

8829 168 33,1 3465 228 1,79 5 5198 31,1 141 200B-0120 HCS03.1E-W0100 

10645 143 78 4250 204 7,31 9 6375 41 141 200C-0090 HCS03.1E-W0100 

12544 158 118,4 4250 228 5,28 4 6375 42,4 212 200C-0120 HMS01.1N-W0150 

10589 226 83,3 4250 264 8,76 11 5406 65,1 212 200C-0170 HMS01.1N-W0150 

10589 226 83,3 4250 264 8,76 11 5548 65,1 212 200C-0170 HCS03.1E-W0150 

13394 106 52,6 5560 168 4,6 9 8340 39,6 141 200D-0060 HCS03.1E-W0100 

13287 155 70,2 5560 216 7,37 11 6969 65,1 212 200D-0100 HMS01.1N-W0150 

13287 155 70,2 5560 216 7,37 11 7142 65,1 212 200D-0100 HCS03.1E-W0150 

10135 118 50,7 3350 192 2,05 4 5025 26,9 141 300A-0090 HCS03.1E-W0100 

8477 172 39 3350 228 2,3 6 5025 32,5 141 300A-0120 HCS03.1E-W0100 

12316 114 52,6 5150 168 4,6 9 7725 39,6 141 300B-0070 HCS03.1E-W0100 

12688 171 57 5150 228 3,46 6 7116 49,5 212 300B-0120 HMS01.1N-W0150 

12688 171 57 5150 228 3,46 6 7269 49,5 212 300B-0120 HCS03.1E-W0150 

16172 94 27,3 6720 132 2,56 9 10080 41 141 300C-0060 HCS03.1E-W0100 

16255 134 43,9 6720 180 2,97 7 9083 52,3 212 300C-0090 HMS01.1N-W0150 

16255 134 43,9 6720 180 2,97 7 9280 52,3 212 300C-0090 HCS03.1E-W0150 

Fig. 10-2: Possible combinations of single motors on single controllers


10.3 Motor/Controller Combinations; parallel primaries on 

single drive controllers 

Controlled DC Bus Voltage, mains supply voltage - 3 x 480 VAC 

FMAX 

[N] 

vFmax 

[m/min] 

PVMAX 

[kW] 

FdN 

[N] 

vN 

[m/min] 

PvN 

[kW] 

EDFMAX 

[%] 

FKB 

[N] 

idN 

[A] 

iMAX 

[A] 



911 511 3,4 415 619 0,45 13 415 9,8 28 040A-0300 HMS01.1N-W0020 

1473 388 10,9 500 600 0,65 6 659 11,8 51 040A-0300 HMS01.1N-W0036 

1600 360 13,1 500 600 0,65 5 750 11,8 56 040A-0300 HMS01.1N-W0054 

1600 360 13,1 500 600 0,65 5 750 11,8 56 040A-0300 HMS01.1N-W0070 

1142 460 5,9 394 624 0,4 7 394 9,3 38 040A-0300 HCS02.1E-W0028 

1600 360 13,1 500 600 0,65 5 579 11,8 56 040A-0300 HCS02.1E-W0054 

1600 360 13,1 500 600 0,65 5 750 11,8 56 040A-0300 HCS02.1E-W0070 

1600 360 13,1 500 600 0,65 5 750 11,8 56 040A-0300 HCS03.1E-W0070 

1322 293 4 615 375 0,53 13 615 9,8 28 040B-0150 HMS01.1N-W0020 

2120 201 12,9 740 360 0,77 6 966 11,8 51 040B-0150 HMS01.1N-W0036 

2300 180 15,6 740 360 0,77 5 1110 11,8 56 040B-0150 HMS01.1N-W0054 

2300 180 15,6 740 360 0,77 5 1110 11,8 56 040B-0150 HMS01.1N-W0070 

1651 255 7 583 378 0,48 7 583 9,3 38 040B-0150 HCS02.1E-W0028 

2300 180 15,6 740 360 0,77 5 852 11,8 56 040B-0150 HCS02.1E-W0054 

2300 180 15,6 740 360 0,77 5 1110 11,8 56 040B-0150 HCS02.1E-W0070 

2300 180 15,6 740 360 0,77 5 1110 11,8 56 040B-0150 HCS03.1E-W0070 

2300 300 20 740 480 0,87 4 1110 15 76 040B-0250 HMS01.1N-W0054 

2300 300 20 740 480 0,87 4 1110 15 76 040B-0250 HMS01.1N-W0070 

2300 300 20 740 480 0,87 4 916 15 76 040B-0250 HCS02.1E-W0070 

2300 300 20 740 480 0,87 4 1110 15 76 040B-0250 HCS03.1E-W0070 

1884 424 14,5 740 600 0,8 6 1110 17 76 040B-0300 HMS01.1N-W0054 

2300 360 23,9 740 600 0,8 3 1084 17 98 040B-0300 HMS01.1N-W0070 

1938 416 15,6 740 600 0,8 5 796 17 79 040B-0300 HCS02.1E-W0070 

2300 360 23,9 740 600 0,8 3 1110 17 98 040B-0300 HCS03.1E-W0070 

4000 180 15,8 1260 420 0,69 4 1890 15 76 070A-0150 HMS01.1N-W0054 

4000 180 15,8 1260 420 0,69 4 1890 15 76 070A-0150 HMS01.1N-W0070 

4000 180 15,8 1260 420 0,69 4 1569 15 76 070A-0150 HCS02.1E-W0070 

4000 180 15,8 1260 420 0,69 4 1890 15 76 070A-0150 HCS03.1E-W0070 

3262 309 9,4 1260 432 0,57 6 1890 17,8 76 070A-0220 HMS01.1N-W0054 

4000 264 15,5 1260 432 0,57 4 1843 17,8 98 070A-0220 HMS01.1N-W0070 

3358 304 10,1 1260 432 0,57 6 1332 17,8 79 070A-0220 HCS02.1E-W0070 

4000 264 15,5 1260 432 0,57 4 1890 17,8 98 070A-0220 HCS03.1E-W0070 

3684 381 27,3 1260 540 1,33 5 1890 29,6 141 070A-0300 HCS03.1E-W0100 

5001 127 31,3 1640 240 1,46 5 2460 15,6 76 070B-0100 HMS01.1N-W0054 

5200 120 34,3 1640 240 1,46 4 2460 15,6 80 070B-0100 HMS01.1N-W0070 

5156 122 33,6 1640 240 1,46 4 1878 15,6 79 070B-0100 HCS02.1E-W0070 

5200 120 34,3 1640 240 1,46 4 2460 15,6 80 070B-0100 HCS03.1E-W0070 

3742 193 26,2 1640 264 1,35 5 2358 16,4 76 070B-0120 HMS01.1N-W0054 

4534 167 44 1640 264 1,35 3 2264 16,4 99 070B-0120 HMS01.1N-W0070 

3840 190 28,1 1640 264 1,35 5 1763 16,4 79 070B-0120 HCS02.1E-W0070 

4534 167 44 1640 264 1,35 3 2460 16,4 99 070B-0120 HCS03.1E-W0070 

3408 247 39,8 1640 312 2,36 6 2220 17,6 76 070A-0300 HMS01.1N-W0054 

4088 241 66,9 1640 312 2,36 4 2139 17,6 99 070B-0150 HMS01.1N-W0070 

3492 243 42,8 1640 312 2,36 6 1709 17,6 79 070B-0150 HCS02.1E-W0070 

4088 221 66,9 1640 312 2,36 4 2460 17,6 99 070B-0150 HCS03.1E-W0070 

4793 321 87,7 1640 480 3,89 4 2460 28,2 141 070B-0250 HCS03.1E-W0100 

3971 422 68,2 1640 540 4,4 6 2460 34 141 070B-0300 HCS03.1E-W0100 

6383 208 47,8 2400 300 2,12 4 3600 28,2 141 070C-0150 HCS03.1E-W0100 

5774 335 24,4 2400 420 1,84 8 3600 36,8 141 070C-0240 HCS03.1E-W0100 

5658 134 35,3 2360 180 2,64 7 3357 19,8 76 100A-0090 HMS01.1N-W0054 

6976 115 59,2 2360 180 2,64 4 3199 19,8 99 100A-0090 HMS01.1N-W0070 

5822 132 37,9 2360 180 2,64 7 2366 19,8 79 100A-0090 HCS02.1E-W0070 

6976 115 59,2 2360 180 2,64 4 3540 19,8 99 100A-0090 HCS03.1E-W0070 

5087 184 22,8 2360 228 2,22 10 3085 22,6 76 100A-0120 HMS01.1N-W0054 

6233 165 38,2 2360 228 2,22 6 2984 22,6 99 100A-0120 HMS01.1N-W0070 

Further information – see next page 



FMAX 

[N] 

vFmax 

[m/min] 

PVMAX 

[kW] 

FdN 

[N] 

vN 

[m/min] 


PvN 

[kW] 

EDFMAX 

[%] 

FKB 

[N] 

idN 

[A] 

iMAX 

[A] 



5229 181 24,5 2078 233 1,72 7 2078 19,9 79 100A-0120 HCS02.1E-W0070 

6233 165 38,2 2360 228 2,22 6 3540 22,6 99 100A-0120 HCS03.1E-W0070 

6913 190 67,3 2360 264 2,98 4 3540 28,2 141 100A-0150 HCS03.1E-W0100 

5726 270 86,7 2360 348 5,59 6 3540 34 141 100A-0190 HCS03.1E-W0100 

8567 173 43,4 3570 228 2,8 6 5355 34 141 100B-0120 HCS03.1E-W0100 

12933 156 83,3 4620 228 3,71 4 6930 42,4 212 100C-0120 HMS01.1N-W0150 

7970 173 39 3360 228 2,51 6 5040 34 141 140A-0120 HCS03.1E-W0100 

11624 138 39 4830 192 2,95 8 7245 36,8 68 140B-0090 HCS03.1E-W0100 

11715 173 57 4830 228 3,68 6 6578 51 212 140B-0120 HMS01.1N-W0150 

11715 173 57 4830 228 3,68 6 6719 51 212 140B-0120 HCS03.1E-W0150 

15190 85 78 6300 132 5,89 8 9450 36,8 141 140C-0050 HCS03.1E-W0100 

11364 142 29,2 4830 204 2,21 8 7245 36,8 141 200A-0090 HCS03.1E-W0100 

13117 159 50,4 4830 228 2,56 5 7149 45,2 212 200A-0120 HMS01.1N-W0150 

13117 159 50,4 4830 228 2,56 5 7245 45,2 212 200A-0120 HCS03.1E-W0150 

16579 73 56,5 6930 120 4,27 8 10395 36,8 141 200B-0040 HCS03.1E-W0100 

Fig. 10-3: Possible combinations of parallel motors on single controllers



Rexroth IndraDyn L Motor Sizing 1 

11 Motor Sizing 

11.1 General Procedure 

F 

v 

velocity profile 

application working point 

F = f(v) 


t 

v 

The sizing of linear drives is mainly determined by the application-related 

characteristics of velocity and feed force. The basic sequence of sizing 

linear drives is shown in the figure below. 

+ 

• moved mass 

• friction, machining forces 

• motor mounting position 

• motion path 

• limit values for: 

- maximum velocity 

- maximum acceleration 

• effective force F EFF 

• maximum force F MAX 

• Maximum velocity 

v MAX 

• Maximum velocity 

at maximum force 

v FMAX 

F 

force profile 

bound. conditions 

• Einbauraum 

• motor and axis arrangement 

(single, parallel or Gantry) 

• cooling 

• ambient conditions 

(coolant lubricants,chips, etc.) 

• length measuring ssystem 

• linear guideways 

selection of motor or motor controller combination 

selection criteria: 

· All working points are inside the forcevelocity 

characteristic curve of the motor 

· FMAX £ FMAX,Motor · FEFF £ FdN,Motor · vMAX £ vMAX,Motor · vFMAX £ vFMAX,Motor · Motor version acc. to application 

(cooling, protection rating, etc.) 

drive controller and 

power supply module 

- power 

- connection voltage 

- DC bus voltage 


- moved masses 

- attractive forces 

- mounting space 

- rigidity 

F 

limiting curve motor F = f(v) 

Fig. 11-1: Basic procedure of sizing linear drives 

auxiliary components 

- length measuring system 

- cables 

- linear guideways 

- shock absorbers, brakes, 

weight compensation, etc. 

v 

t 

working pts. 

application 

F = f(v) 

DIMALLGEMEIN-MLF-EN.EPS

2 Motor Sizing Rexroth IndraDyn L 

11.2 Basic formulae 

General equations of motion 

The variables required for sizing and selecting the motor are calculated 

using the equations shown in Figure 11-2. 

Note: When linear direct drives are configured, the process-related 

feed forces and velocities are used directly and without 

conversion for selecting the drive. 

Velocity 

Acceleration 

: 

Force : 

Effective force : 

Average velocity : 

v( 

t) 

a( 

t) 

F( 

t) 

v(t): Velocity profile vs. time in m/s 

s(t): Path profile vs. time in m 

a(t): Acceleration profile vs. time in m/s² 

F(t): Force profile vs. time in N 


F0(t): Base force in N 

FP(t): Process or machining force in N 

Feff: Effective force in N 

vavg: Average velocity in m/s 

t: Time in s 

T: Total time in s 

Fig. 11-2: General equations of motion 

F 

v 

eff 

avg 

s( 

t) 

= 

dt 

v( 

t) 

= 

dt 

= 

= 

= 

a( 

t) 

⋅ m + F ( t) 

+ F ( t) 

1 

T 

1 

T 

⋅ 

⋅ 

T 

∫ 

0 

T 

∫ 

0 

F( 

t 

) 

2 

0 

v( 

t) 

dt 

In most cases the mathematical description of the required positions vs. 

the time is known (NC-program, electronic cam disk). Using the 

preparatory function, velocity, acceleration and forces can be calculated. 

Standard software (such as MS Excel or MathCad) can be used for 

calculating the required variables, even with complex motion profiles. 

Note: The following Chapter provides a more detailed correlation for 

trapezoidal, triangular or sinusoidal velocity characteristics. 

dt 


P


Feed forces 


Acceleration 

force : 

Force due 

Frictional force : 

Maximum force : 

Effective force : 

F 

to weight : 

F 1 

t 1 

F 2 

t 2 

... 

... 

F 

F 

F 

F 

F 

t all 

ACC 

W 

F 

MAX 

EFF 

= m ⋅ a 

fcb 

= m ⋅ g ⋅ sinα 

⋅( 

1− 

) 

100 

= µ ⋅(m 

⋅ g ⋅ sinα 

+ F 

= F 

= 

ACC 

F 

2 

1 

+ F 

⋅ t 

1 

F 

+ F 

+ F 

t 

2 

2 

all 

W 

⋅ t 

2 

ATT 

+ F 

t 

FTRAPEZ01-MLF-EN.FH10 

P 

+ ... 

) + F 

FACC: Acceleration force in N 

FW: Force due to weight in N 

FF: Frictional force in N 

F0: Additional frictional or base force in N (e.g. by seals of linear guides) 

FMAX: Maximum force in N 

FEFF: Effective force in N 

FP: Machining force in N 



g: Gravitational acceleration (9.81 m/s²) 

α: Axis angel in degrees (0°: horizontal axis; 90°C: vertical axis) 

fCB: Weight compensation in % 

tall: Total duty cycle time in s 

FATT: Attractive force between primary and secondary in N 

µ: Friction coefficient 

Fig. 11-3: Determining the feed forces 

Note: For sizing calculations of linear motor drives, the moved 

mass of the motor component must be taken into account (in 

particular, if the slide masses are relatively small). However, 

the moved mass and the attractive force between the primary 

and secondary are only known after the motor has been 

selected. Thus, first make assumptions for these variables 

and verify these values after the motor has been selected. 

0


(1) 

(2) 

(3) 

(4) 

(5) 

(6) 

( 7) 

Acceleration 

(up) : 

Const. velocity (up) : 

Deceleration 

Const. velocity (down) 

Deceleration 

(down) 

Idle time : 

(up) : 

Acceleration 

(down) : 

: 

: 

F = F 

F = F 

F = 

ACC 

F 

F = −F 

F = F 

F = F 

ACC 

F 

F = −F 

F 

+ F 

W 

ACC 

− F 

ACC 

+ F 

W 

W 


F 

+ F 

+ F 

F 

F 

+ F 

+ F 

− F 

‚ ƒ „ … † ‡ 

horizontal 

weight force F W= 0 

velocity 

force 

axis arrangement: 

F 

W 

+ F 

W 

− F 

W 

W 

vertical / slanted 

up 

down 

FVTRAPEZ01-MLF-EN.FH10 


FW: Force due to weight in N 

FF: Frictional force in N 

Fig. 11-4: Determining the resulting feed forces according to motion type and 

direction 

Note: With horizontal axis arrangement, the weight is FW = 0. 

Further directional base and process forces must be taken 

into account.


Average velocity 


The average velocity is required for determining the mechanical 

continuous output of the drive. Figure 11-2 shows the general way of 

determining the average velocity. The following calculation can be used 

for a simple determination in trapezoidal or triangular velocity profiles: 

v 

vavgi 

va 

ti 

vavgi 

ve 

v 

v 

avgi 

avg 

va 

= 

= 

v 

ti 

a 

all 

ve 

− v 

2 

e 

∑ v avg i ⋅ 

t 

t 

i 

va 

ti 

ve 

t 

VAVG01-MLF-EN.FH10 

vavgi 

vavgi: Average velocity for a velocity segment of the duration ti in m/s 

va: Initial velocity of the velocity segment in m/s 

ve: Final velocity of the velocity segment in m/s 

vavg: Average velocity over total duty cycle time in m/s 

ti: Duration of velocity segment in s 

tall: Total duty cycle time, including breaks and/or downtime, in s 

Fig. 11-5: Determining the average velocity with triangular or trapezoidal 

velocity profile


Trapezoidal velocity 

This mode of operation is characteristic for the most applications. An 

acceleration phase is followed by a movement of constant velocity up to 

the deceleration phase. 

va 

vc 

acceleration deceleration 

v = constant 

ta 

Fig. 11-6: Trapezoidal velocity profile 

Acceleration, initial velocity = 0 

• Velocity v ≠ constant 

• Initial velocity va = 0 

• Acceleration a = constant and positive 

Acceleration 

: 

Final velocity 

Travel : 

Time : 

: 

v 

t 

tc 

v 

a = 

t 

= a ⋅ t 

v c 

s = ⋅ t 

2 

a 

c 

c 

a 

v c 2 ⋅ s 

= = = 

a v 

tb 

2 

2 ⋅ s v c = = 2 

t 2 ⋅ s 

a 

a 

= 

a 

2 

v c a ⋅ t 

= = 

2 ⋅ a 2 

c 

ve 

VTRAPEZ01-MLF-EN.EPS 

2 ⋅ s 

2 ⋅ a ⋅ s = 

t 

2 ⋅ s 

a 


vc: Final velocity in m/s 

ta: Acceleration time in s 

s: Travel covered during acceleration in m 

Fig. 11-7: Constantly accelerated movement, initial velocity = 0 (acc. to Fig. 

11-6) 

2 

a 


a 

t



Acceleration, initial velocity ≠ 0 

Acceleration 

: 

Velocity : 

Travel : 

Time : 


• Initial velocity va ≠ 0 

• Acceleration a = constant and positive 

v 

a = 

v 

v 

s = 

t 

a 

c 

c 

= v 

c 

v 

= 

− v 

t 

c 

a 

a 

+ a ⋅ t 

+ v 

2 

a 

a 

− v 

a 

a 

2 ⋅ s 2 ⋅ v 

= − 2 

t t 

a 

⋅ t 

a 

= 

a 

2 

v c − v 

= 

2 ⋅ a 

2 ⋅ s 

= 

v + v 

c 

2 ⋅ a ⋅ s + v 

a 

a 

2 

a 

= 

a 

2 

v c − v 

= 

2 ⋅ s 

= v 

2 

a 

a 

2 ⋅ s 

= − v 

t 

⋅ t 

a 

a ⋅ t 

+ 

2 

2 ⋅ a ⋅ s + v 



va: Initial velocity in m/s 

ta: Acceleration time in s 


Fig. 11-8: Constantly accelerated movement, initial velocity ≠ 0 (acc. to Fig. 

11-6) 

Constant velocity 

• Velocity v = constant 

• Acceleration a = 0 

Acceleration 

: 

Travel : 

Time : 

vc: Average velocity in m/s 

tC: Time during constant velocity in s 

sc: Travel covered constant velocity in m 

Fig. 11-9: Constant velocity (acc. to Fig. 11-6) 

v 

s 

t 

c 

c 

c 

s 

= 

t 

= v 

s 

= 

v 

c 

c 

c 

c 

c 

⋅ t 

c 

a 

2 

a 

a 

2 

a 

2 

a 

a 

− v 

a


Decelerating, Final velocity = 0 


• Final velocity ve = 0 

• Acceleration a = constant and negative 

Acceleration 

: 

Velocity : 

Travel : 

Time : 

v 

a = 

t 

v 

v c 

s = ⋅ t 

2 

t 

c 

b 

c 

b 

= a ⋅ t 

2 

2 ⋅ s v c = = 2 

t 2 ⋅ s 

b 

b 

= 

2 

v c a ⋅ t 

= = 

2 ⋅ a 2 

v c 2 ⋅ s 

= = = 

a v 

b 

2 ⋅ s 

2 ⋅ a ⋅ s = 

t 

c 

2 ⋅ s 

a 



tb: Deceleration time in s 


Fig. 11-10: Constantly decelerated movement, final velocity = 0 (acc. to Fig. 11- 

6) 

2 

b 


b



Decelerating, Final velocity ≠ 0 

Acceleration 

: 

Velocity : 

Travel : 

Time : 


• Final velocity ve ≠ 0 

• Acceleration a = constant and negative 

v 

a = 

v 

v 

s = 

t 

a 

e 

c 

= v 

c 

v 

= 

c 

− v 

t 

c 

b 

− a ⋅ t 

+ v 

2 

e 

e 

− v 

a 

e 

2 ⋅ v 

= 

t 

b 

⋅ t 

b 

= 

v 

2 

v − v c = 

2 ⋅ a 

2 ⋅ s 

= 

v + v 

c 

b 

c 

2 

2 ⋅ s v c − v 

− = 2 

t 2 ⋅ s 

2 

c 

2 ⋅ s 

− 2 ⋅ a ⋅ s = − v 

t 

e 

b 

2 

e 

v 

= 

= v 

c 

c 

− 

⋅ t 

b 

v 

a ⋅ t 

+ 

2 

2 

c 

− 2 ⋅ a ⋅ s 


vc: Initial velocity in m/s 

ve: Final velocity in m/s 



Fig. 16-11: Constantly decelerated movement, final velocity ≠ 0 (acc. to Fig. 11- 

6) 

a 

2 

e 

b 

2 

b 

c


Triangular velocity 

In contrast to the trapezoidal characteristic, this velocity profile does not 

have a phase of constant velocity. The acceleration phase is 

immediately followed by the deceleration phase. This characteristic can 

frequently be found in conjunction with movements of short strokes. 

vmax 

Fig. 11-12: Triangular velocity profile 

Acceleration 

: 

Velocity : 

Travel : 

Time : 


v 

s 

t 

2 ⋅ v 

a = 

t 

max 

all 

2 ⋅ v 

t = 

a 

max 

a ⋅ t 

= = 

2 

4 ⋅ s 

= 2 

t 

a ⋅ s 

4 ⋅ s 

= 

v 


t 

VDREIECK01-MLF-EN.EPS 

2 

v 

= 

s 

2 ⋅ s 

= 

t 

2 

2 

v ⋅ t v 

max 

max a ⋅ t 

= = = 

2 4 ⋅ a 4 

max 

max 

all 

all 

all 

= 

max 

all 

4 ⋅ s 

a 



sall: Total motion travel in m 

t: Positioning time in s 

Fig. 11-13: Calculation of triangular velocity profile (acc. to Fig. 11-12) 

all


Sinusoidal velocity 


This velocity profile results, for example, from the circular interpolation of 

two axes (circular movement) or the oscillating movement of one axis 

(grinding, for example). 

The specified variables are chiefly the motion travel or the circle 

diameter and the period T. 

velocity v 

Travel profile : 

Velocity profile : 

Acceleration 

profile : 

Jerk profile : 

period T 

s( 

t) 

v( 

t) 

a 

= r ⋅ sin( ω ⋅ t) 

= r ⋅ cos( ω ⋅ t) 

⋅ω 

() t = r ⋅ sin( 

ωt) 

() t = r ⋅ cos( 

ωt) 

2 

⋅ω 

3 

r 

⋅ω 

2 ⋅π 

ω = = 2 ⋅π 

⋅ f 

T 

s(t): Travel profile vs. time in m 

v(t): Velocity profile vs. time in m/s 

a(t): Acceleration profile vs. time in m/s 

r(t): Jerk profile over time t m/s³ 

r: Motion travel in one direction (circle radius) in m 

ω: Angular frequency in s -1 

T: Period in s (time for circular motion or complete stroke) 

t: Time in s 

f: Stroke frequency in Hz 

Fig. 11-14: Motion profiles of an axis at sinusoidal velocity. 

time t


The following calculation bases on Fig. 11-14. 

Maximum 

accerlation 

: 

Maximum velocity : 

Average velocity : 

Acceleration 

force : 

Effective 

force : 

Vertical axis arrangement 

Base force up movement 

Base force down 

movement : 

: 

: 

a 

v 

v 

F 

F 

F 

F 

F 

max 

max 

avg 

ACC 

EFF 

EFFv 

0 up 

0 down 

2 ⋅π 

= r ⋅ 

T 

2 ⋅ v 

= 

π 

= a 

max 

F 

2 

= F 

2 

acc 

F 

0 

2 

acc 

0 

max 

⋅ m 

+ F 

w 


w 

= F − F 

2 

⎛ 2 ⋅π 

⎞ 

= r ⋅ ⎜ ⎟ 

⎝ T ⎠ 

= 

= 

4 ⋅r 

= 

T 

+ F 

+ F 

2 

0 

2 

0 up 

2 

+ F 

amax: Maximum acceleration in m/s² 


r: Motion travel in one direction (or circle radius) in m 

T: Period in s 



FEFF: Effective force in N 

FEFFv: Effektive force at vertical or inclined axis arrangement in N 

F0: Base force, e.g. frictional force in N 

FW: Force due to weight in N (acc. to Fig. 11-3) 

Fig. 11-15: Calculation formulae for sinusoidal velocity profile 

2 

0 down 

Note: Further directional base and process forces must additionally 

be taken into account.


11.3 Duty cycle and Feed Force 

Determining the duty cycle 


The relative duty cycle ED specifies the duty cycle percentage of the 

load with respect to a total duty cycle time, including idle time. The 

thermal load capacity of the motor limits the duty cycle. Stressing the 

motor with rated force is possible over the entire duty cycle time. The 

duty cycle must be reduced at F > FdN (see Fig. 11-16) in order to not 

thermally overload the motor at higher feed forces. 

feed force 

in N 

max. motor 

force 

Fmax 

ED Fmax 

Fx 

ED Fx 

contin. nominal 

force of motor 

FdN 

Fig. 11-16: Correlation between duty cycle and feed force 

ED=100% 

ON time 

in % 

EDKENNLIN01-MLF-EN.EPS 

The approximate determination of the relative duty cycle EDideal is 

performed via the correlation: 

⎛ F 

= 

⎜ 

⎝ F 

2 

EFF 

EDideal 2 

MAX 

⎞ 

⎟ ⋅100 

⎠ 

ED: Cyclic duration factor in % 

FEFF: Effective force or rated force in N 

FMAX: Maximum feed force 

Fig. 11-17: Approximate determination of duty cycle ED 

Prerequisites: Linear correlation between feed force and current. 

For IndraDyn L motors to Fig. 11-17, only an approximate duty cycle 

calculation is possible since there is a non-linear correlation between 

force and current. 

This calculation remains valid for a rough determination of possible duty 

cycle at short-time duty forces with FKB ≤ 1.5 FdN. 

Note: You must check with Figure 11-18 or Figure 11-19 to exactly 

determine the relative duty cycle of IndraDyn L linear motors.


ED 

100% 

90% 

80% 

70% 

60% 

50% 

40% 

30% 

20% 

10% 

0% 

1,0 1,2 1,4 

The non-linearity of the characteristic curve force vs. current of 

synchronous linear motor leads to an increased rise of power loss at 

higher feed forces. This increased power loss leads – in particular at a 

high percentage of acceleration and deceleration processes – to a 

possible duty cycle that is reduced with respect to Fig. 11-17. 

Use Fig. 11-18 or Fig. 11-19 to determine exactly the possible relative 

duty cycle. 

ED 

real 

P 

= 

P 

vN 

AVG a 

⋅100 

EDreal: Possible relative duty cycle in % 

PvN 

Maximum removable power loss of the motor in W 

(continuous power loss see Chapter 5 “Technical Data”) 

PAVG a: Average motor power loss in application over a duty cycle time 

including idle time in W 

Fig. 11-18: Determining the duty cycle ED 

Prerequisites: Duty cycle time ≤ Thermal time constant of motor 

ideal 

real 

1,6 1,8 2,0 2,2 2,4 2,6 2,8 3,0 

F / FdN 

NORMIERTE KENNLINIEN MLF.XLS 

Fig. 11-19: Duty cycle vs. force for IndraDyn L synchronous linear motors 



11.4 Determining the Drive Power 

Continuous Output 


To size the power supply module or the mains rating, you must 

determine the rated (continuous) and maximum power of the linear 

drive. 

Note: Take the corresponding simultaneity factor into account when 

determine the total power of several drives that are 

connected to a single power supply module. 

The rated output corresponds to the sum of the mechanical and 

electrical motor power. 

Total rated output 

Mechanical rated output 

Rated electrical output 

: 

: 

: 

P 

c 

P 

cm 

P 

= P 

ce 

cm 

= F 

eff 

⎛ F 

= ⎜ 

⎝ F 

+ P 

⋅ v 

eff 

dn 

ce 

⎞ 

⎟ 

⎠ 

avg 

2 

⋅ P 

vn 

mit 

F 

eff 

≤ F 

Pc: Rated power in W 

Pcm: Mechanical rated output in W 

Pce: Electrical rated power loss of motor in W 

Feff: Effective force in N (from application) 

vavg: Average velocity in m/s 


PvN Rated power loss of the motor in W (see Chapter 4 “Technical data”) 

Fig. 11-20: Rated power of the linear motor 

Note: The rated electrical output (see Fig. 11-20) is reduced when 

the rated force is reduced. 

dn


Maximum Output 

P v / P vmax 

1,0 

0,8 

0,6 

0,4 

0,2 

The maximum output is also the sum of the mechanical and electrical 

maximum output. It must be made available to the drive during 

acceleration and deceleration phase or for very high machining forces, 

for example. 

Total maximum output 

Mechanical maximum output 

: 

: 

P 

max 

P 

maxm 

= P 

maxm 

= F 

Pmax: Total maximum power in W 

Pmaxm: Mechanical maximum power in W 

Pmaxe: Electrical maximum power in W (see Fig. 11-22) 

FMAX: Maximum feed force in N 

vFmax: Maximum velocity with Fmax in N 

Fig. 11-21: Maximum power of the linear motor 

max 

+ P 

Note: When the maximum feed force is reduced against the 

achievable maximum force of the motor, the electrical 

maximum output Pmaxe is reduced too. To determine the 

reduced electrical maximum output Pmaxe use Fig. 11-22. 

0,0 

0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 

F / F max 


F: Maximum force application in N 

Pvmax: Maximum power loss of the motor in W 

PV: Power loss of the motor application in W 

Fig. 11-22: Diagram used for determining the reduced electrical power loss 

Note: The maximum power loss is specified in Chapter 10 “Motor- 

Controller-Combinations”. 

⋅ v 

NORMIERTE KENNLINIEN MLF.XLS 

maxe 

Fmax 




Regeneration energy 


The necessary cooling capacity nearly corresponds to the motor´s 

electrical continuous power loss. 

= 

⎛ F 

= 

⎜ 

⎝ F 

eff 

Cooling capacity : P P ⋅P 

with 

F ≤ 

co ce 

vn 

eff 

Pco: Required cooling capacity in W 

Pce: Electrical power loss of motor in W 

Feff: Effective force in N 


PvN Rated power loss of the motor in W (see Chapter 4 “Technical data”) 

Fig. 11-23: Required cooling capacity of the linear motor 

Compared with rotary servo motors, the energy of a linear motor during 

deceleration is lower. The translatory velocity of a linear motor is usually 

much lower than the circumferential speed of a rotary servo motor. 

The regeneration energy of a synchronous linear drive results from the 

energy balance during the deceleration process. To size additional brake 

resistors or power supply units with feedback capability, it can be 

estimated as follows. 

P 

P 

R 

Ravg 

m ⋅ v 

= 

2 ⋅ t 

= 

1 

T 

b 

⋅ 

2 

T 

∫ 

0 

v ⋅ F 

− 

2 

P 

R 

R 

( t) 

dt 

dn 

⎞ 

⎟ 

⎠ 

2 

− 1, 

5 ⋅ m ⋅ R 

∑PR i ⋅ t 

= 

t 

all 

2 

bi 

12 

⎛a 

⋅ ⎜ 

⎝ k 

PR: Regeneration energy during a deceleration phase in W 

PRavg: Average regeneration energy over total duty cycle time in W 


v: Maximum velocity in m/s 


FR: Frictional force in N 

R12: Winding resistance of the motor at 20°C in ohms 

(see Chapter 4 “Technical Data”) 

amax: Braking deceleration (negative acceleration) in m/s² 

kiFN: Motor constant in N/A 

tall: Total duty cycle time in s 

Fig. 11-24: Regeneration energy of the linear motor 

Prerequisites: Velocity-independent friction 

Constant deceleration 

Final velocity = 0 

Note: If the regeneration energy that is determined according to 

Fig. 11-24 is negative, energy is not fed back. This means 

that energy must be supplied to the motor during the 

deceleration process. 

max 

iFN 

2 

⎞ 

⎟ 

⎠ 

F 

dn


11.5 Efficiency 

1,0 

0,9 

0,8 

0,7 

0,6 

0,5 

0,4 

0,3 

0,2 

0,1 

The efficiency of electrical machines is the ration between the motor 

output and the power fed to the motor. With linear motors, it is 

determined by the application-related traverse rates and forces, and the 

corresponding motor losses. 

Fig. 11-25 and Fig. 11-26 can be used for determining and/or estimating 

the motor efficiency. 

η = 

P 

Pmech 

+ P 

mech 

V el 

F ⋅ v 

= 

( F ⋅ v) 

+ P 

V el 

η: Efficiency 

Pmech: Mechanical output in W 

PVel: Electrical power loss in W 

F: Feed force in N 

v: Velocity in m/s 

Fig. 11-25: Determining the efficiency of linear motors 

effeciency vs. continuous 

norminal force F dN 

1 

= 

Pvel 

1+ 

F ⋅ v 

0,0 

0 m/min 100 m/min 200 m/min 300 m/min 400 m/min 500 m/min 600 m/min 

Velocity 

effeciency vs. 

maximum force F max 

WIRKUNGSGRAD MLF.XLS 

Fig. 11-26: Efficiency vs. velocity for IndraDyn L synchronous linear motors. 



11.6 Sizing Examples 

Handling axis 


The example of a simple handling axis is used for describing the basic 

procedure of sizing a linear drive. 

Specifications 

The following data is specified: 

Slide mass: mS = 65 kg 

Maximum velocity possible: 300 m/min 

Maximum acceleration possible: 50 m/s² 

Axis arrangement: 

Base force through energy chain, 

horizontally, primary moved 

seals, linear guides, etc.: Fzus = 150 N (constant) 

Additional process forces: none 

Friction coefficient of linear guides: µ = 0.005 

Mains connection voltage: 3 x AC 400V 

Coolant temperature (water): ϑcoolant = 25°C 

Required positioning movements: 

No.: Stroke Positioning 

time 

Idle time after stroke Remark 

1 600 mm 0.32 s 0.20 s Moving from start 

position to part 

pickup 

2 -1,300 mm 0.50 s 0.20 s Parts transport and 

deposit 

3 700 mm 0.35 s 0.45 s Moving back to 

start position 

Fig. 11-27: Required positioning movements of the handling axis 

The mass of the primary must be taken into account when the feed 

forces are determined. The attractive force between the primary and 

secondary is required additionally when the frictional force is determined. 

The following assumptions are made to start with: 

Primary mass: mP = 19 kg 

Attractive force: FATT = 8000 N 

Check the calculations again when you have selected the motor.


Moved total mass 

Base force 

Force due to weight 

Acceleration force: 

Maximum force: 

Total time or duty cycle time 

Calculation 

The following velocity and acceleration values are selected in order to 

maintain the required position times and specified limitations. 

No.: Stroke Positioning 

time 

Feed rate Acceleration 

1 600 mm 0.32 s 180 m/min 25 m/s² 

2 -1,300 mm 0.50 s 220 m/min 25 m/s² 

3 700 mm 0.35 s 185 m/min 25 m/s² 

Fig. 11-28: Selected velocities and accelerations of the handling axes 

Note: When you select the position velocity and positioning 

acceleration, you should try to find an optimum ration for the 

motor selection (to reach a minimum effective force, for 

example). 

m 

m 

m 

F 

F 

F 

F 

0 

0 

0 

0 

ges 

ges 

ges 

= m 

= 

= 

= F 

F 

S 

65 kg 

84 kg 

+ F 

= µ ⋅ (m 

= 194 N 

+ m 

zus 

ges 

P 

+ 19 kg 

⋅ g + F 

ATT 

) + F 

zus 

= 0.005 ⋅(84 

kg ⋅ 9.81m/s² 

+ 

FW = 0 N (horizontal axis) 

F 

F 

F 

F 

F 

F 

t 

t 

acc 

acc 

acc 

max 

max 

max 

ges 

ges 

= m 

= 

= 

ges 

⋅ a 

(84 kg) 

2100 N 

= F 

acc 

p 

⋅ 

+ F 

2294 N 

25 

m/s² 

= 2100 N + 194N 

= 

= 2.02 s 

0 

8000 N) 

+ 150 N 

= 0.32 s + 0.2 s + 0.5 s + 0.2 s + 0.35 s + 0.45 s 



Velocity and force profile 

Effective force and average 

velocity 


The selected velocities and the determined forces provide the following 

velocity and force profile: 

velocity v in m/min 

2294 N 2294 N 

2294 N 

0.12 s 

180 m/min 

194 N 0 N 194 N 

0.08 s 

220 m/min 

-1906 N -1906 N -1906 N 

0.12 s 

0.2 s 

0.147 s 

0.206 s 

0.147 s 

time t 

185 m/min 

0 N 194 N 0 N 

0.2 s 

Fig. 11-29: Velocity and force profile of handling axis 

0.123 s 0.123 s 

0.104 s 

0.45 s 

force F in N 

DIMBSPHDL01-MLF-EN.EPS 

The effective force and the average velocity are determined on the basis 

of the force profile: 

No.: Time t 

in s 

Force Fi 

in N 

Average velocity vavg i 

in m/min 

1 0.120 2294 Fi = Facc+F0 90 

2 0.080 194 Fi = F0 180 

3 0.120 -1906 Fi = -Facc+F0 90 

4 0.200 0 0 

5 0.147 2294 Fi = Facc+F0 110 

6 0.206 194 Fi = F0 220 

7 0.147 -1906 Fi = -Facc+F0 110 

8 0.2 0 0 

9 0.123 2294 Fi = Facc+F0 92.5 

10 0.104 194 Fi = F0 185 

11 0.123 -1906 Fi = -Facc+F0 92.5 

12 0.45 0 N 0 

Fig. 11-30: Force profile vs. time to determine the effective force 

F 

F 

eff 

eff 

( Fi 

= 

t 

∑ 

2 

ges 

= 1313 N 

⋅ t ) 

i 

v 

v 

avg 

avg 

v 

= 

t 

∑ 

= 

avg i 

ges 

⋅ t 

77. 

1 m / min 

i


Verification of mass and 

attractive force 

Operation points and 

characteristic curve of the motor 

Selection of motor – controller combination 

Once the application data has been calculated, an appropriate motorcontroller 

combination can be selected. 

The standard encapsulation and the IndraDrive controller family are 

selected. Using the calculated data, the following combination is chosen 

from the selection data for motor-controller combinations (see Chapter 

10 “Motor-Controller Combinations”): 

Motor: MLP140C-0170-FS-xxxx 

Drive device: HMS01.1N-W150 

The mass of the selected primary MLP140C-0170-FS is slightly smaller 

than the previous mass. The same applies to the attractive force. The 

selected motor is retained within the scope of this example. 

Using the profiles of velocity and force (Fig. 11-29), the operating points 

of the required feed forces and the necessary velocities can be 

determined. These operating points and the characteristics are shown in 

the Figure below. 

force in N 

6000 

5250 

4500 

3750 

3000 

2250 

1500 

750 

0 

0 50 100 150 200 250 300 350 400 450 

F-v charact. curve motor 

working pts. application 

velocity in m/min 

Fig. 11-31: Force-velocity diagram of handling axis 

(operating points and motor characteristic) 

DIMBSPHDL02-MLF-EN.EPS 

Note: All operating points that are related to force and velocity of 

the application must be inside the characteristic curve of the 

selected motor – controller combination. 



Required length of the 

secondary parts 

Selecting the secondary part 

segments 


Selecting the secondary segments 

Based on the motion profile, the effective total motion path and, 

consequently, the required number and/or length of the secondary 

segments can be determined. The effective total travel is 1300 mm; the 

length of the selected primary is 510 mm. 

L 

L 

L 

sec ondary 

secondary 

secondary 

≥ L 

total travel 

+ L 

primary 

= 1300 mm + 510 mm 

= 1810 mm 

Secondary segments for IndraDyn L synchronous linear motors are 

available in a length of 150 mm, 450 mm and 600 mm. Three 

secondaries of 600 mm each (total length of 1800 mm) are selected for 

the handling axes.


Rated mechanical power 

Rated electrical power loss 

Total rated power 

Maximum output mechanical 

Maximum output electrical 

Total maximum output 


Power calculation 

P 

P 

P 

P 

P 

P 

P 

P 

P 

P 

P 

P 

cm 

cm 

cm 

ce 

ce 

ce 

c 

c 

c 

= F 

eff 

⋅ v 

avg 

77. 

1 m / min 

= 1313 N ⋅ 

60 

= 1687 W 

⎛ F 

= ⎜ 

⎝ F 

eff 

n_motor 

⎞ 

⎟ 

⎠ 

2 

⎛1313 

N⎞ 

= ⎜ ⎟ 

⎝1785 

N⎠ 

= 703 W 

= P 

cm 

+ P 

ce 

= 2390 W 

2 

⋅P 

vN 

⋅1300 

W 

= 1687 W + 703 W 

maxm 

maxm 

maxm 

= F 

max 

⋅ v 

Fmax 

220 m / min 

= 2294 N⋅ 

60 

= 8412W 

Figure 11-22 is used for determining the maximum electrical power loss. 

The ratio of required maximum force and maximum force of the motor is 

2294 N / 5600 N = 0.41. 

Thus, Figure 11-22 shows a reduction factor of 0.095 for the maximum 

power loss. Together with the specification of the maximum motor power 

loss from the selection charts for the motor-controller combination, the 

maximum electrical power loss results as 

P 

P 

P 

P 

P 

P 

maxe 

maxe 

maxe 

max 

max 

max 

= 0. 

095 ⋅Pmax 

motor 

= 0. 

095 ⋅ 60. 

84 kW 

= 5. 

78 kW 

= P 

maxm 

= 8. 

41kW 

+ 5. 

78 kW 

= 14.19 

+ P 

kW 

maxe 

Pco = Pce 

= 704 W 



Regeneration energy 


Figure 11-24 and the motor data in Chapter 4 “Technical data” are used 

for determining the regeneration energy for all deceleration phases. 

P 

Ri 

m ⋅ v 

= 

2 ⋅ t 

2 

bi 

v ⋅F 

− 

2 

R 

2 

− 1, 

5 ⋅ m ⋅ R 

No.: Deceleration time tbi Feed rate Acceleration Regeneration energy 

12 

⎛a 

⋅⎜ 

⎝ k 

1 0.120 s 180 m/min -25 m/s² 1678 W 

2 0.147 s 220 m/min -25 m/s² 2305 W 

3 0.123 s 185 m/min -25 m/s² 1767 W 

Additional capacities for 

stopping the axis upon a power 

failure 

max 

Fig. 11-32: Regeneration energy during the deceleration phases 

The average regeneration energy over the entire duty cycle time 

amounts to: 

PR 

i ⋅ tbi 

PRavg 

= 

t 

∑ 

P 

Ravg 

= 375 

all 

W 

Additional DC bus capacities (capacitors) shall ensure that the axis is 

safely stopped in the event of a power failure. Figure 9-77 is used for 

determining the required additional capacities in the DC bus. The motor 

decelerates at maximum feed force; the minimum DC bus voltage should 

be 50V. The maximum velocity is 220 m/min is considered as worst 

case. 

C 

C 

C 

add 

add 

add 

= 

U 

= 

= 

m 

ges 

2 

DCmax 

84 kg 

⋅ v 

− U 

⋅ 

2 ( 540 V) 

− ( 50 V) 

0. 

00242F 

max 

2 

DCmin 

m 

4. 

17 

s 

= 

2 

2. 

4 mF 

⎡ F 

⋅ ⎢3, 

5 ⋅ 

⎢⎣ 

k 

max_ motor 

2 

iF 

⋅R 

12 

iFN 

− v 

⎞ 

⎟ 

⎠ 

2 

max 

⎛ 

⋅⎜ 

⎜ 

⎝ F 

F 

R 

max_ motor 

PRi 

⎞⎤ 

+ 0. 

3⎟ 

⎟ 

⎥ 

⎠⎥⎦ 

⎡ 

⎤ 

⎢ 

⎥ 

⎢ 5600 N 

m ⎛ 194 N ⎞ 

⋅ 3, 

5 ⋅ ⋅1. 

2 Ω − 4. 

17 ⋅ 0. 

3 ⎥ 

2 

⎜ + ⎟ 

⎢ 

⎛ N ⎞ 

s ⎝ 5600 N ⎠⎥ 

⎢ ⎜82 

⎟ 

⎥ 

⎢⎣ 

⎝ A ⎠ 

⎥⎦ 

Note: The maximum possible DC bus capacity of the employed 

power supply module must be taken into account when 

additional capacities are used in the DC bus.


Selection of linear scale 

The linear scale can be selected when the effective total travel is known. 

An open incremental linear scale of the LIDA187C type is selected for 

the handling axis. The selected system has distance-encoded reference 

marks. 

Motor efficiency 

The motor efficiency, related on the continuous output, results as follows: 

Pcm 

ηc 

= 

P + P 

η = 

c 

cm 

0. 

706 

ce 

1687 W 

= 

1687 W + 703 W 



Limit overtemperature of the 

motor winding 

Final overtemperature of the 

motor winding 

Absolute final temperature of the 

motor winding 

Reaching the final temperature 


Final overtemperature of the motor 

ϑ 

ϑ 

ϑ 

wg 

wg 

wg 

w 

= ϑ 

w max 

= 155 K − 25 K 

= 130 K 

⎛ F 

ϑ ⎜ 

w = 

⎜ 

⎝ F 

eff 

n_motor 

− ϑ 

⎞ 

⎟ 

⎠ 

2 

coolant 

2 

⋅ϑ 

wg 

⎛1313 

N⎞ 

ϑw 

= ⎜ ⎟ ⋅130K 

⎝1785 

N⎠ 

ϑ = 70 K 

ϑ 

ϑ 

ϑ 

wabs 

wabs 

wabs 

= ϑ + ϑ 

w 

= 70 K + 25 K 

= 95 ° C 

coolant 

The thermal time constant of the selected motor is Tth = 7 min. 98% of 

the final temperature is reached after approximately 4 thermal time 

constants (i.e. after 28 minutes). 

Note: Additional explanations of the thermal behavior of linear 

motors can be found in Chapter 9.4 “Motor Cooling”.


Machine tool feed axis; sizing via duty cycle 

Detailed information of the motion cycle are sometimes not available or 

are not exact. In the case of, e.g. small batch production and frequently 

changing port programs. Sizing of the drives is performed on the basis 

of the relative duty cycle of different operating phases, and based on 

empirical values from machine manufacturers and/or machine users. 

The following example explains this procedure. 

Specifications 

The following data is specified: 

Slide mass including motor: mS = 580 kg 

Velocity rapid travers: 120 m/min 

Velocity machining 15 m/min 

Maximum acceleration possible: 15 m/s² 

Axis arrangement: horizontally, primary moved 

Motion path 0.95 ... 800 mm 

Base force: F0 = 600 N (constant) 

Maximum machining force: FP = 1200 N 

Friction coefficient of linear guides: µ = 0.005 

Mains connection voltage: 3 x AC 400V 

Type of machining/movement Share 

Acceleration and declaration 10 % 

Rapid traverse 20 % 

Machining process 30 % 

Standstill with machining 20 % 

Standstill without machining 20 % 

Total: 

100 % 

Fig. 11-33: Percentage of individual machining processes and movements 

Standstill without 

machining 

20% 

Standstill with 

machining 

20% 

Acceleration/ 

deceleration 

10% 

machining 

30% 

Rapid traverse 

20% 

Fig. 11-34: Graphical presentation of the individual operating phases 



Acceleration force: 

Maximum force: 

Effective force and average 

velocity 


Calculation 

F 

F 

F 

F 

F 

F 

acc 

acc 

acc 

max 

max 

max 

= m 

= 

= 

ges 

⋅ a 

580 kg 

8700 N 

= F 

acc 

⋅ 

+ F 

= 8700 N + 

= 

9300 N 

15 

m/s² 

0 

600 N 

The effective force and the average velocity are determined on the basis 

of the specifications for the individual operating phases. 

Type of machining/movement EDi Force Fi Average 

velocity vavgi 

Acceleration and declaration 10 % 8700 N Fi = Facc ± F0 60 m/min 

Rapid traverse 20 % 600 N Fi = F0 120 m/min 

Machining process 30 % 1800 N Fi = FP + F0 15 m/min 

Standstill with machining 20 % 1200 N Fi = FP 0 m/min 

Standstill without machining 20 % 0 N 0 m/min 

Fig. 11-35: Percentage of individual machining processes and movements 

F 

F 

eff 

eff 

= ∑ ( Fi 

= 

2 

2983 N 

Drive selection 

EDi 

⋅ ) 

100 

v 

v 

avg 

avg 

= ∑( 

v 

= 

34. 

5 

avgi 

EDi 

⋅ ) 

100 

m / min 

The determined data can be used for selecting a motor-controller 

combination. The primary with thermal encapsulation is selected for 

machine tool applications. 

Primary MLP140C-0170-FS-N0CN-NNNN 

Fmax_motor: 10000 N Fn_motor: 3150 N 

vFmax 750V:170 m/min vNENN 750V: 250 m/min 

Secondary segments MLS140A-3A-xxxx-NNNN 

Total travel + Primary ~1,500 mm 

Drive device HMS01.1N-W0150 

Power supply module HMV ( UDC=750V, with feedback capability) 

Linear scale Heidenhain LC481 

encapsulated, absolute, ENDAT interface


Rated electrical power loss 

Required coolant flow 

Determining the cooling capacity 

P 

P 

P 

co 

co 

co 

= P 

ce 

⎛ F 

= ⎜ 

⎝ F 

⎛ 2983 N⎞ 

= ⎜ ⎟ 

⎝ 3150 N⎠ 

= 3050 W 

eff 

n_motor 

2 

⎞ 

⎟ 

⎠ 

2 

⋅P 

⋅ 3400 W 

vN_motor 

The maximum temperature rise at the contact surface of the primary 

should not exceed 3 K. The necessary coolant flow in L/min is 

determined according to Fig. 9-43: 

Pco 

⋅ 25200 

Q = 

c ⋅ ρ ⋅ ∆T 

3050 W ⋅ 25200 

Q = 

J kg 

4183 ⋅ 988, 

3 ⋅ 3 K 3 

kg ⋅K 

m 

Q = 

6. 

2 

l 

min 

m 

Note: The way of determining the drive power and other more 

detailed data are not discussed within the scope of this 

example. 


Rexroth IndraDyn L Handling, transportion and storage of the units 12-1 

12 Handling, transportion and storage of the units 

12.1 Identification of the motor components 

Primary 

Secondary 


A name plate is attached to the front face of the primary where the 

power cable and coolant connections are located. The name plate 

unambiguously identifies the individual primary. An additional name plate 

is attached to the primary. This additional name plate can be attached to 

the machine or can be used otherwise as the customer sees fit. The 

name plate contains the following data: 

Made in Germany 

PRIMARY PART OF MOTOR 7260 

MNR: R911297289 

TYP: MLP070A-0300-FT-N0CN-NNNN 

FD: 03W13 

SN: MLP070-12345 0A01 m 10,9 kg 

F(N) 2000 N 

I(N) 55.0 A 

1 tp 37.5 mm 

2 

5 

I.Cl. F 

IP 65 

3 

4 

Name_Plate_Primary.EPS 

(1): Rated force (N) (2): Rated voltage (A) 

(3): Insulation class (4): Protection class 

(5): Pole pitch (mm) 

Fig. 12-1: Name plate of the primary 

Due to lack of space on the secondary, no name plates are permanently 

attached. Two identical name plates are, however, delivered with the 

secondary. To ensure a safe and permanent identification of the 

secondary in the future, the type designation and the serial numbers are 

stamped directly into the secondary. 

The type designation and serial numbers are located between the first 

two mounting holes starting from the side stamped “S” to signify the 

south pole. 

1 

MLS 

MLS100S-3A-0xxx 

SN:0123456 

2 3 

XX/XX XX 

XXX 

(1): Type designation and serial number 

(2): Manufacturing date (mm/yy) 

(3): Supplier 

(4): Number of test protocol 

(5): Pole designation “S” (for south pole) 

Fig. 12-2: Positions of the identification marks on the secondary 

S 

4 

5 

MLS_KENNZ_EN.EPS

12-2 Handling, transportion and storage of the units Rexroth IndraDyn L 

Name plate 

Note: Independent of the length, each secondary has a magnetic 

north pole on one end and a magnetic south pole on the 

other. To indicate which end is which, the south pole is 

marked with an “S”. 

The type plate of the secondary contains the following data: 

Made in Germany 

SECONDARY PART OF MOTOR 

MNR: R911297292 

TYP: MLS070S-3A-0150-NNNN 

SN: MLS070-12345 0A01 

(1): Protection class (IP rating) 

(2): Mass of the secondary (kg) 

Fig. 12-3: Name plate of the secondary 

12.2 Delivery status and Packaging 

m 2 3.0 kg 

IP 1 65 

7260 

FD: 03W13 

Name_Plate_Secondary.EPS 

Primary 

The primaries are individually packed in wooden boxes which are 

marked with the type designation of the primary contained inside; this 

allows for easy identification of the contents. 

Secondary 

The secondaries are individually packed in cardboard boxes which are 

also marked with the type designation of the secondary inside. 

CAUTION 

Risk of injuries and/or damage when handling 

secondaries of synchronous linear motors! 

⇒ Strictly observe and adhere to the warnings and 

safety instructions 



Warnings on the packaging of 

the secondaries 

12.3 Transportation and Storage 


The boxes containing the secondaries carry the following warnings: 

N 

S 

WARNING 

Health hazard to people with heart pacemakers, 

metal implants and hearing aids when in proximity 

to these parts! 

Strong magnetic fields due to permanent motor 

magnets! 

Anyone with pacemakers, metal implants or 

hearing aids are not permitted to approach or 

to handle these motor parts. 

If you have such conditions, consult with a 

physician prior to handling these parts. 

CAUTION VORSICHT 

Hazardous to sensitive parts! 

Keep watches, credit cards, identification cards 

with magnetic strips, magnetic tape and 

ferromagnetic material (such as iron, nickel, 

and cobalt) away from magnetic parts. 

WARNUNG 

CAUTION VORSICHT 

Hazardous to fingers and hands due to high 

attractive forces of permanent motor magnets! 

Strong magnetic fields due to permanent motor 

magnets! 

Handle only with protective gloves! 

Handle with extreme care. 

Fig. 12-4: Warning label on the MLS secondary boxes 

Gesundheitsgefahr für Personen mit Herzschrittmachern, 

metallischen Implantaten oder Splittern und 

Hörgeräten in unmittelbarer Umgebung dieser Teile! 

Starkes Magnetfeld durch Permanentmagnete 

der Motorteile! 

Personen mit Herzschrittmachern, metallischen 

Implantaten oder Hörgeräten dürfen sich nicht 

diesen Motorteilen nähern oder damit umgehen. 

Besteht die Notwendigkeit für solche Personen, 

sich diesen Teilen zu nähern, so ist das zuvor 

von einem Arzt zu entscheiden. 

Quetschgefahr von Finger und Hand durch starke 

Anziehungskräfte der Magnete! 

Starkes Magnetfeld durch Permanentmagnete 

der Motorteile! 

Nur mit Schutzhandschuhen anfassen. 

Vorsichtig handhaben. 

Zerstörungsgefahr empfindlicher Teile! 

Uhren, Kreditkarten, Scheckkarten und Ausweise 

mit Magnetstreifen sowie alle ferromagnetische 

Metallteile wie Eisen, Nickel und Cobalt von den 

Permanentmagneten der Motorteile fernhalten. 

WARNMAGN_MLF_EN.EPS 

Note: Self-adhesive warning labels, as shown in Fig. 12-4, can be 

ordered from Bosch Rexroth (Mat-Nr. R911278745). The 

approximate size is 110 mm x 150 mm. 

The primaries and secondaries of synchronous linear motors must be 

stored on flat surfaces and supported along the entire bottom – see Fig. 

12-5. This must be ensured even for storage of a short duration. 

The permissible storage and transport temperature is from –10 to +60°C 

(14 - 140°F). Large or periodic temperature variations during transport 

and storage are not permitted. 

+60° C 

-10° C 

Fig. 12-5: Storage of linear motor components 

LAGKOMP_MLF_EN.EPS


CAUTION 

Inappropriate handling during storage or 

transport can damage or destroy the motor 

components! 

⇒ Use the original packaging for permanent storage. 

⇒ Store for short periods according to Fig. 12-5 

⇒ Do not throw parts 

⇒ Adhere to permissible transportation and storage 

temperatures ranges. 

⇒ Remove the transportation and installation 

protection only during or after the installation into 

the machine. 

Specifics for transporting secondaries of synchronous linear motors 

Air freight 

The secondaries of synchronous linear motors have unshielded 

permanent magnets. Strictly adhere to the safety notes in chapter 3! 

CAUTION 

Magnetic fields can influence a plane’s 

electronics! 

⇒ Heed the packaging and transportation instructions 

(IATA 902) 



12.4 Checking the motor components 

Factory checks 

Electrical inspections 

Mechanical inspections 

EMV radia interference 

suppression 

Customer’s receiving inspection 


All Bosch Rexroth linear motors undergo the following electrical checks 

at the factory: 

• High-voltage test acc. to EN 60034-1/2.95 (VDE 0530 Part 1) 

• Insulation resistance test acc. to EN 60204-1 

• Verification of the specified electrical characteristics 

All Bosch Rexroth linear motors undergo the following mechanical tests: 

• Shape and location tolerances acc. to ISO 1101 

• Structure and fits acc. to DIN 7157 

• Surface characteristics acc. to DIN ISO1302 

• Thread test acc. to DIN 13, Part 20 

• Leak tests of the cooling system 

Note: Each motor is accompanied by a corresponding test 

certificate. 

The linear motor components of Bosch Rexroth have been subjected to 

EMV tests and have been certified as compliant to: 

EN 55011 Limit Class B, VDE 0875 Part 11 

If you wish to perform an additional high-voltage receiving inspection, 

you must contact Bosch Rexroth. 

CAUTION 

Destruction of motor components by 

improperly-executed high-voltage inspection! 

⇒ Contact Bosch Rexroth before carrying out such 

tests!



Rexroth IndraDyn L Mounting Instructions 13-1 

13 Mounting Instructions 

13.1 Basic precondition 


Basic precondition for mounting the IndraDyn L components is the 

keeping of the following basic preconditions: 

• Precondition of the necessary installation sizes (Fig. 5-1) 

• Machine construction fulfills the requests for mounting (stiffness, 

attractive force, feed force and acceleration force, etc.) 

• Machine construction is prepared for mounting of all components 

• Mounting is done by trained personal 

• Compliance of danger and safety notes is guaranteed. 

13.2 General procedure at mounting of the motor components 

The installation of the motor into the machine construction depends on 

the arrangement of the secondary and can be done in different ways. 

• Installation at spanned secondaries over the entire traverse path 

• Installation at whole secondary over the entire traverse path 

Note: The described procedures are only suggestions and can be 

done user-specific in other forms. 

Installation at spanned secondary parts over the entire traverse path 

Installation for a spanned secondary can be done, as shown in Fig. 13-1. 

Thereby, only a part of the secondary is installed, so that the primary can 

be laid on the machine bed. 

WARNING 

Do not lay the primary directly on the secondary! 

⇒ Lift-off of the primary from the secondary is difficult 

because of high attractive forces (apparatus 

necessary). 

The assembly of the primary into the installed slide can be done now. 

Afterwards, the slide with installed primary can be pushed over the 

installed secondaries. Then, all the remaining secondaries can be 

installed.

13-2 Mounting Instructions Rexroth IndraDyn L 

STEP 1 

STEP 2 

secondary segment 1 

machine bed 

secondary segment 1 primary 

machine bed 

slide 

total motion path 

slide 


primary 

secondary segment 2 

MOTEINBAU01-MLF-EN.EPS 

Fig. 13-1: Assembly of the components of linear motors at spanned secondary 

part 

CAUTION 

Uncontrolled movement of the slide! 

⇒ Safety against uncontrolled movements by partial 

covering of primary and secondary (force in 

traverse direction). 



Installation at whole secondary over the entire traverse path 

Example 


At whole secondary over the entire traverse path can the primary be 

installed into the prepared slide. After mounting the secondary, the slide 

with prepared primary can be lowered on the machine bed via a suited 

apparatus 

secondary 

machine bed 

primary 


slide 

guide carriage lowering using 

device 

MOTEINBAU02MLF-EN.EPS 

Fig. 13-2: Installation of the linear motor components at whole secondary over 

the entire traverse path 

CAUTION 

When lowering the primary on the secondary, 

result by reducing the air gap increasing 

attractive forces! 

⇒ Heed the specifications in chapter 9.5 feeding and 

attractive forces 

⇒ Do not lower the primary on the secondary with a 

crane (elasticity / attractive force). 

Note: The apparatus for lowering the primary and the slide is not in 

the scope of delivery of Bosch Rexroth. 

Another possibility is, to lay the primary on the installed secondary – with 

a suited apparatus – and to screw it with fastening screws on the slide. 

Thereby, a non-ferromagnetic distance plate (made of plastic or wood) 

has to be laid among the primary and secondary so that the primary 

does not bear on the secondary directly. The thickness of the distance 

plate should be measured according to nominal air gap. After the 

fastening of the primary on the slide a moving of the slide should be 

possible. 

The thickness of the distance plate must be measured in such a way that 

the primary with the fastening screws can preferably not or only 

exiguously be lifted. 

Measurable air gap: 1.0 mm 

Thickness of the distance plate: 0.95 ... 0.99 mm


The tightening of the fastening screws for the primary has to be made as 

described in chapter 13.4 “Mounting of the primary”. 

STEP 1 

STEP 2 

STEP 3 

secondary 

secondary 

secondary 

slide 

machine bed 

slide 

machine bed 

slide 

machine bed 

primary 




primary 

primary 

loweing using 

device 

non-ferromagnetic 

distance plate 

non-ferromagnetic 

distance plate 


Fig. 13-3: Installation of the linear motor components at whole secondary over 

the entire traverse path 

CAUTION 

When lowering the primary on the secondary, 

result by reducing the air gap increasing 

attractive forces! 

⇒ Heed the specifications in chapter 9.5 feeding and 

attractive forces 

⇒ Do not lower the primary on the secondary with a 

crane (elasticity / attractive force). 



13.3 Installation of the secondary segments 

Spanned secondary 


WARNING 

Personal injury and / or damage of motor 

components! 

⇒ Remove the transport and installation protection of 

the secondary only after mounting of the secondary. 

The secondaries have to be bolt together with the machine construction. 

The tightening torque of the fastening screws are given as follows: 

Size secondary 

MLS040 

MLS070 

MLS100 

MLS140 

MLS200 

MLS300 

Bolt size- 

ISO-grade 

Tightening torque 

M6 10 Nm 

Fig. 13-4: Tightening torque for the secondaries fastening screws. 

Using several arranged secondaries over the entire traverse path, the 

pole series must be kept according to the following figure. 

MLS100A-150 

0123456 

correct butt-mounting 

MLS100A-150 

MLS100A-150 

S S 

S 

MLS100A-150 

MLS100A-150 

0123456 S 0123456 S 

incorrect butt-mounting 

S 

MLS100A-150 

0123456 

0123456 

Fig. 13-5: Arrangement of several secondaries 

WARNING 

0123456 


Malefunction and / or uncontrolled movement of 

the motor result in danger of damage or risk of 

injury! 

⇒ Correct arrangement of the secondaries.


WARNING 

Risk of injury or damage by attractive force or 

repulsive force when arranging the secondaries! 

⇒ Safety against uncontrolled movement 

⇒ Remove the transportation and installation 

protection only during or after the installation into 

the machine. 

Attractive or repulsive forces can be approx. 300N differing from the 

size, when arranging the secondaries. 

MLS100A-150 

0123456 S 0123456 S 

attractive force with correct butt-mounting 

F 

S 

MLS100A-150 

0123456 

S 

F 

F F 

MLS100A-150 

0123456 

repulsive force with incorrect butt-mounting 

S 

MLS100A-150 

MLS100A-150 

0123456 

MLS100A-150 

0123456 

S 

F 


Fig. 13-6: Attractive or repulsive force when arranging the secondaries 



13.4 Installation of the primary 


... 

... 

fixing screws 

8 

6 

1 

primary 

3 

4 

2 

slide 

... 

5 

... 

7 

Fig. 13-7: Order of tightening the fixing screws of the primary 

Mounting instructions: 

MOTEINBAU06_MLF_EN.EPS 

1. Prepare the threaded holes acc. to Chapter 13.6. 

2. Fasten the primary with screws 1, 2, 3...n until the primary lais on the 

slide. 

3. Fasten screws 1, 2, 3 ...n with nominal tightening torque: 

Primary size Designs 

MLP040 

MLP070 

MLP100 

MLP140 

MLP200 

MLP300 

13.5 Connection liquid cooling 

Standard and 


Bolt size- 

ISO-grade 

Nominal 

tightening 

torque 

M6 10 Nm 

Fig. 13-8: Nominal tightening torque for the fixing screws of the primaries 

Note: The screw-on surface among the primary and machine 

construction must be oil free and free of grease. 

Connection of the liquid cooling is made by standard threads directly on 

the primary. Fittings and pipes are not in the scope of delivery of the 

linear motor. 

The following connection data have to be kept. Excursion of tightening 

torque or depth of engagement can lead to irreversible machine 

damage. 

Max. tightening Max. depth of 

Primary with... Thread torque engagement 



G1/4 30 Nm 12 mm 

Fig. 13-9: Connection liquid cooling


13.6 Screw locking 

General 

Gluing 

Detach the connection 

LOCTITE is a plastic adhesive, which is applied to the installation parts 

in liquid form. The adhesive remains liquid as long as it is in contact with 

oxygen. Only after the parts have been mounted, it converts from its 

liquid state into hard plastic. This chemical conversion takes place 

under exclusion of air and the produced metallic contact. The result is a 

form-locking connection that is impact- and vibration-resistant. The 

hardening accelerator Activator 7649 reduces the hardening time of the 

adhesive. 

Proceed as follows: 

1. Clean metal chips and coarse dirt from threaded hole and screw or 

grub screw. 

2. Use LOCTITE rapid cleanser 7061 to clean oil, grease and dirt 

particles from threaded hole and screw/grub screw. The threads 

have to be absolutely restless. 

3. Spray LOCTITE activator into the threaded hole and let it dry. 

4. Use LOCTITE adhesive to moisten the same threaded hole in its 

entire thread length thinly and evenly. 

5. Screw in the matching screw/grub screw. 

6. Allow join to harden. Hardening times see Fig. 13-10. 

Securing screwed connections using LOCTITE in tapped 

blind holes 

The adhesive must always be dosed into the tapped hole, never on the 

screw. This prevents that the compressed air extrudes the adhesive 

when the screw or grub screw is screwed in. 

Hardened Hard to the 

touch without 

activator 

Hard to the 

touch with 

activator 7649 

LOCTITE 243 ≈ 12 h 15 to 30 min 10 bis 20 min 

LOCTITE 620 ≈ 24 h 1 to 2 h 15 to 30 min 

NOTE: All values refer to the hardening time at room temperature. The times are shorter 

when heat is added. 

Fig. 13-10: Hardening times LOCTITE adhesive 

Note: LOCTITE 620 is heat-resistant up to 200°C, LOCTITE 243 up 

to 150°C. 

To detach the connection, use a wrench for unscrewing the screw or 

grub screw in the traditional way. The breakaway torque of LOCTITE 

620 is 20-45 Nm, the one of LOCTITE 243 is 14-34 Nm (acc. to DIN 54 

454). Blowing hot air on the screw connection reduces the breakaway 

torque. 

Is the screw/grub screw removed, the residuals of the adhesive must be 

removed from the threaded hole (e.g. re-cutting the thread). 

NOTE: The German version of the chapter was checked by LOCTITE Germany for 

correctness and was approved for publication. 


Rexroth IndraDyn L Startup, Operation and Maintenance 14-1 

14 Startup, Operation and Maintenance 

14.1 General information for startup of IndraDyn L motors 

Parameter 

Controller optimization 

Moving masses 

Encoder polarity 

Commutation adjustment 


The startup of linear motors is different to the rotative servo motors. 

Note: Use the functional description of the drive controller for more 

detailed information. 

The following points have to be especially noticed when startup 

synchronous-linear motors. 

Synchronous-linear motors are kit motors whose single components are 

– completed by an encoder system – directly installed into the machine 

by the manufacturer. As a result of this, kit motors have no data memory 

to supply motor parameters or standard controller adjustment. At startup, 

all parameters have to be manually entered or loaded into the drive. The 

startup-program DriveTop makes all motor parameters of Bosch Rexroth 

available. 

The procedure at controller optimization (voltage, acceleration and 

position controller) of linear direct drives is the same as at rotative servo 

drives. At linear drives are only the adjustment limits higher. At linear 

direct drives compared with rotative servo drives can be, for example, a 

10-fold higher kv-factor adjusted. Precondition therefore is an 

appropriate machine construction (see chapter 9.3 “Request for a 

machine construction”. 

At controlled rotative servo drives are automatic-control engineering 

modifications at the rate of motor-moment of inertia to demand-moment 

of inertia. Such a modification is not available for direct drives with linear 

motors. The moved foreign mass is independent from the motor selfmass. 

The polarity of the actual-speed (length measuring system) must agree 

with the force polarity of the motor. This connection has to be 

established before commutation-adjustment. 

It is necessary at synchronous linear motors to receive the position of 

the primary relating on the secondary by return after start or after a 

malfunction. This is called identification of pole position or commutation 

adjustment. The commutation adjustment-process is the establishment 

of a position reference to the electrical or magnetic model of the motor. 

The commutation adjustment can be done after installation of the motor 

components and length measuring system. The way of doing the 

commutation adjustment complies with the measuring principle of the 

length measuring system.

14-2 Startup, Operation and Maintenance Rexroth IndraDyn L 

14.2 General precondition 

The following preconditions have to be created for a successful start-up. 

• Adherence of the safety instructions and notes. 

• Check of electrical and mechanical components on a safe function. 

• Availability and supply of required implements. 

• Adherence of the following described start-up 

Adherence of all electrically and mechanically components 

Do a check of all electrically and mechanically components before startup. 

Heed the following points in particular: 

• Safety warranty of personnel and machine 

• Proper installation of the motor 

• Correct power connection of the motor 

• Correct connection of the length measuring system 

• Function of available limit switch, door switch, a.s.o. 

• Proper function of the emergency stop circuit and emergency stop. 

• Machine construction (mechanical installation) in proper and 

complete condition. 

• Availability and function of suitable end-of-stroke damper. 

• Correct connection and function of the motor cooling. 

• Proper connection and function of the drive controller unit. 

WARNING 

WARNING 

Danger to life, heavy injury or damage by failure 

or malfunction on mechanical or electrical 

components! 

⇒ Troubleshooting at mechanical or electrical 

components before continue with the start-up. 

Risk of injury or danger to life, as well as 

damage due to non-adherence of warning and 

safety notes! 

⇒ Adherence of the warning and safety notes. 

⇒ Start-up must to be done by skilled personnel 

⇒ Adherence of the following described start-up 



Implements 

Start-up software DriveTop 

PC 

Start-up via NC 

Oscilloscope 

Multimeter 


The start-up can be made directly via a NC-terminal or via a special 

software. The start-up software DriveTop makes a menu-driven, customdesigned 

and motor specific parameterizing and optimization possible. 

For start-up with DriveTop is a usual Windows-PC needed. 

For start-up via NC-control, access to all drive parameters and 

functionalities must be guaranteed. 

An oscilloscope is needed for drive optimization. It serves to display the 

signals, which can be shown via the adjustable analog output of the drive 

controller. Viewable signals are, e.g. nominal and actual values of the 

speed, position or voltage, position lag, intermediate circuit a.s.o. 

At troubleshooting and check of the components can be a multimeter 

with the possibility to voltage metering and resistor measuring helpful.


14.3 General start-up procedure 

Verification: 

In the following flow-chart is the general start-up procedure at 

synchronous linear motors MLF shown. In the following chapters are 

these points explained in detail. 

- power connection - safety end switch 

- measuring system connection - motor cooling 

- mechanical system - controller function 

- end position dampers - drive control function 

- E STOP function 

error ? 

No 

initial 

commissioning 

No 

enter/load motor 

parameters 

enteapplication-related 

parameters 

determine sensor 

polarity 

commutation setting 

set and optimize 

control loop 

Yes 

Yes 

eliminate error 

Yes 

load drive parameter 

default values 

enter parameters for 

length measuring 

system 

enter drive limitation 

polarity 

F soll = v ist ? 

system is operational! 

Necessary information, 

parameters and aids 

- motor parameters 

- constant focommutation 

setting k mx 

parameter value assignments 

No 

position sensor type 

parameter S-0-0277 Bit 3 = 1 

............1001 

Fig. 14-1: General start-up procedure at synchronous linear motors 



14.4 Parametrization 

Entering motor parameters 


With DriveTop, entering or editing certain parameters and executing 

commands during the commissioning process is done inside menudriven 

dialogs or in list representations. Optionally, it can also be 

performed via the control terminal. 

Note: The motor parameters are specified by Rexroth and must not 

be changed by the user. Commissioning is not possible, if 

these parameters are not available. In this case, please get 

into contact with your Rexroth Sales and Service Facility. 

WARNING 

Injuries and mechanical damage, if the motor is 

switched on immediately after the motor 

parameters have been entered! Entering the 

motor parameters does not make the motor 

operational! 

⇒ Do not switch on the motor immediately after the 

motor parameters have been entered. 

⇒ Enter the parameters for the linear scale. 

⇒ Check and adjust the measuring system polarity. 

⇒ Perform commutation setting. 

The motor parameters can be entered in the following way: 

• Use DriveTop to load all the motor parameters. 

• Enter the individual parameters manually via the controller. 

• With series machines, load a complete parameter record 

via the controller or DriveTop.


Input of linear scale parameters 

Encoder type 

Signal period 

The type of the linear scale must be defined. The parameter P-0-0074, 

encoder type 1 (see also Fig. 9-83). 

Encoder type P-0-0074 

Incremental measuring system, e.g. 

LS486 in conjunction with high- 

2 

resolution DLF position interface 

Absolute encoder with ENDAT 

interface, e.g. LC181 in conjunction 

with high-resolution DAG position 

interface 

Fig. 14-2: Encoder type definition 

Linear scale for linear motors generate and interpret sinusoid signals. 

The sine signal period must be entered in the parameter S-0-0116, 

sensor 1 resolution. 

Note: The values that must be enterd for parameter S-0-0116, 

sonsor resolution, are specified in Fig. 9-66. The values for 

linear scale that are not shown in this figure must be obtained 

directly from the manufacturer. 

Input of drive limitations and application-related parameters 

Drive limitations 

Application-related parameters 

The possible selectable drive limitations include: 

• Current limitation 

• Force limitation 

• Velocity limitations 

• Travel range limits 

The application-related drive parameters include, for example, the 

parameters of the drive fault reaction. 

Note: Detailed information can be found in the description of 

function of the employed drive controller and/or Firmware. 

8 



14.5 Determining the Polarity of the linear scale 

Effective direction of motor 

force 


In order to avoid direct feedback in the velocity control loop, the effective 

direction of the motor force and the count direction of the linear scales 

must be the same. 

WARNING 

Different effective directions of motor force and 

count direction of linear scale cause 

uncontrolled movements of the motor upon 

power-up! 

⇒ Safety against uncontrolled movement 

⇒ Adjust effective direction of motor force equal to 

linear scale count direction. 

To set the correct sensor polarity: 

The effective direction of the motor force is always positive in the 

direction of the cable connection of the primary. 

force direction 

+ 

secondary primary 

Fig. 14-3: Effective direction of motor force 


GEBPOL01-MLF-EN.EPS


Effective direction motor force = 

linear scale count direction 

When the primary is moved in the direction of the cable connection, the 

count direction of the linear scale must consequently be positive: 

force direction 

+ 



+ 

count direction 


GEBPOL02-MLF-EN.EPS 

Fig. 14-4: Effective direction motor force = linear scale count direction 

Note: The encoder polarity is selected via the primary (cable 

connection). The installation direction or the pole sequence of 

the secondary does not have any influence on the selection of 

the sensor polarity. 

The encoder polarity is selected via the parameter 

S-0-0277, position encoder type 1 (Bit 3) 

Position, velocity and force data must not be inverted when the linear 

scale count direction is set: 

S-0-0085, Force polarity parameter 0000000000000000 

S-0-0085, Velocity polarity parameter 0000000000000000 

S-0-0085, Position polarities 0000000000000000 

The process-related axis count direction is set as required after sensor 

polarity and commutation have been set. 



14.6 Commutation adjustment 

Adjustment procedure 

absolute 

ENDAT 

Procedure 1 

Measuring the refernece 

between primary and secondary 

part and starting the P-0-0524 

command 

Only for initial 

commissioning and sensor 

replacement 

no controller enabling 

signal 

no axis movment 


Setting the correct commutation angle is a prerequisite for maximum and 

constant force development of the synchronous linear motor. 

This procedure ensures that the angle between the current vector of the 

primary and the flux vector of the secondary is always 90°. The motor 

supplies the maximum force in this state. 

Three different commutation adjustment procedures have been 

implemented in the firmware. The figure below shows the correlation 

between the employed linear scale and the method that is to be use. 

Commutation setting of 

synchronous linear motors 

measuring 

principle of linear scale 

Yes 

Procedure 2 

incremental 

Current flow methode by 

starting the P-0-0524 command 

Only for initial 

commissioning and sensor 

replacement 

with controller 

enabling signal 

axis movement 

initial 

commissioning 

No 

Procedure 3 

Current flow method 

Automatic execution after 

controller enabling signal is set 

always after power-up 

with controller 

anabling signal 

axis movement 

Fig. 14-5: Commutation adjustment method for synchronous linear motors 

Note: The three methods are described subsequently. 

Note: Method 2 and 3 cannot be employed for: 

• vertical axes without weight compensation 

• jammed or blocking axes


Motor connection 

Parameter verification 

DANGER 

WARNING 

Malfunction due to errors in activating motors 

and moving elements! 

Commutation adjustment must always be 

performed in the following cases: 

⇒ Initial commissioning 

⇒ Modification of the mechanical attachment of the 

linear scale 

⇒ Replacement of the linear scale 

⇒ Modification of the mechanical attachment of the 

primary and/or secondary 

Malfunction and/or uncontrolled motor 

movement due to error in commutation 

adjustment! 

⇒ Effective direction motor force = linear scale count 

direction 

⇒ Adhering to the described setting procedures 

⇒ Correct motor and encoder parameterization 

⇒ Expedient parameter values must be assigned for 

current and velocity control loop. 

⇒ Correct connection of motor power cable 

⇒ Protection against uncontrolled movements 

The individual phases of the motor power connection must correctly be 

assigned. See also Chapter 8 “Electrical Connection”. 

To ensure a correct commutation adjustment, the following parameters 

should be checked again and, if necessary, set to the values specified 

below: 

Identity 

number 

Description Value 

S-0-0085 Torque/force polarity parameter 0000000000000000 

S-0-0043 Velocity polarity parameter 0000000000000000 

S-0-0055 Position polarity 0000000000000000 

P-0-4014 Motor type 3 (synchronous linear 

motor) 

P-0-0018 Number of pole pairs/pole pair 

width 

S-0-0116 S-0-0016, Encoder 1 resolution Fig. 9-83 

Fig. 14-6: Parameters that must be checked prior to commutation adjustment 

75 



Method 1: Measuring the reference between the primary and the 

secondary 

Measuring the relative position 

between the primary and the 

secondary 

Calculation of P-0-0523, 

commutation adjustment 

measured value 


If this procedure is used for commutation adjustment, the relative 

position of the primary with respect to the secondary must be 

determined. The benefit of this procedure is that the commuation 

adjustment requires neither the power to be switched on nor the axes to 

be moved. Commutation adjustment need only be performed during the 

first-time commissioning. 

Note: This procedure requires an absolute linear scale with ENDAT 

interface. 

Depending on the accessibility of the primary and the secondary in the 

machine or system, the relative position between primary and secondary 

can be measured in different ways. 

‚ 

e 

d 


lp 

f ƒ 

g 


„ 

KOMMUT01-MLF-EN.EPS 

Fig. 14-7: Measuring the relative position between primary and secondary 

Note: From now on, the position of the primary must not be 

changed until the commutation adjustment procedure is 

terminated! 

The input value for P-0-0523 that is required for calculating the 

commutation offset, is determined from the measured relativce position 

of the primary with respect to the secondary (Fig. 14-10, distance d, e, f 

or g, depending on accessibility), and a motor-related constant kmx (see 

Fig 14-11 and Fig. 14-13).


Motor constant for commutation 

adjustment kmx 

Reference point 1: 

Reference point 



2 : 

3 : 

4 : 

P − 0 − 0523 = d − k 

P − 0 − 0523 = e − k 

mx 

mx 

− 37. 

5 mm 

P − 0 − 0523 = − f − l − k 

P − 0 − 0523 = 37. 

5 

p 

mx 

mm − g − l 

mx 


p 

− k 

P-0-0523: Commutation adjustment measured value in mm 

d: Relative position, reference position 1 in mm (see Fig. 14-7) ) 

e: Relative position, reference position 2 in mm (see Fig. 14-7) f: 

Relative position, reference position 3 in mm (see Fig. 14-7) 

g: Relative position, reference position 4 in mm (see Fig. 14-7) 

kmx: Motor constant for commutation adjustment in mm 

lp: Length of the primary in mm 

Fig. 14-8: Calculation of P-0-0523, commutation adjustment measured value 

Note: Ensure that the sign is correct when you determine P-0-0523, 

commutation adjustment measured value. 

If P-0-0523 is determined with a negative sign, this must be 

entered when the setup procedure is started. 

The motor constants for adjusting the commutation offset kmx depend on 

the orientation of primary and secondary: 

arrangement A 

N 

N 

arrangement B 

N 





N S 

Fig. 14-9: Possible arrangements between primary and secondary 

S 

S 

S 

KOMMUT02-MLF-EN.EPS



Size 040...300 


Size 040 300 

Activation of commutation 

adjustment command 


Arrangement A 

(acc. to Fig. 14-9) 

kmx in mm 

Arrangement B 

(acc. to Fig. 14-9) 

kmx in mm 

68 105.5 

65 102.5 

Fig. 14-10: Motor constants for commutation adjustment kmx 

Example 1, reference point (see Fig. 14-7): 

d = 100 mm , kmx = 38.0 mm 

P-0-0523 = d - kmx = 100 mm - 38.0 mm = 62 mm 


d = 0 mm, kmx = 38.0 mm 

P-0-0523 = d - kmx = 0 mm - 38.0 mm = - 38.0 mm 


g = 180 mm , kmx = 38.0 mm , lp = 540 mm 

P-0-0523 = 37.5 mm - g - lp - kmx = 37.5 mm -180 mm - 540 mm - 38 

mm 

P-0-0523 = 720.5 mm 

Prerequisites: 

1. The drive must be in the A0-13 state during the subsequent 

adjustment procedure (ready for power connection). 

2. The position of the primary part and/or the slide must not have 

changed since the relative position of the primary part with respect to the 

secondary part has been measured. 

Once the determined value P-0-0523, commutation setting measured 

value, has been entered, the command P-0-0524, D300 commutation 

setting command must be started. The commutation offset is calculated 

in this step. The commutation offset is calculated in this step. 

Note: If the drive is in control mode when the command is started, 

the commutation offset is determined using the current flow 

method (see method 2). 

The command must subsequently be cleared.


Method 2: Current flow method manually activated 

This method is used for the following configurations: 

• Synchronous linear motors with absolute linear scale. In 

first-time commissioning, as an alternative of method 1. 

1. Adjust the operation mode “Torque-force control” 

2. Bring the drive into control (AF). 

3. Start the commando via P-0-0524 

WARNING 

Injuries due to errors in activating motors and 

moving elements! 

⇒ Is the drive not accordingly commutated, then the 

drive must only be switched in operation mode 

“Torque-force control” in AF. 

⇒ Is the drive switched in velocity control or in position 

control in AF, an uncontrolled axis movement 

cannot be excepted. 

Note: The parameter P-0-0560, commutation adjustment voltage, 

P-0-0562 and cycle duration can individually be adjusted at 

initial start-up by the user. 



Method 3: Current flow method automatically activated 

Controllers ECODRIVE and 

DIAX04 

Controller IndraDrive 



• Synchronous linear motor with incremental length scale in 

connection with controllers Ecodrive and Diax04 

At initial start-up of the axis, the parameter P-0-0560, 

commutation adjustment voltage, P-0-0562 and 

commutation adjustment are automatically determinated 

and recorded in the drive. 

At every re-start of the axis, the commutation adjustment 

is made new to method 3. The parameter values for P-0- 

0560 and P-0-0562 of the initial start-up serve as initial 

value for the procedure. 

Note: The parameter P-0-0560, commutation adjustment voltage, 

P-0-0562 and cycle duration can individually be adjusted at 

initial start-up by the user. 


• Synchronous linear motors with incremental length scale in 

connection with IndraDrive controllers. 

At initial start-up of the axis, the parameters P-0-0506, 

peak value for angle-survey and P-0-0507, test frequency 

for angle-survey are automatically determinated, if in P-0- 

506 “0” is entered. Subsequently, the determined 

parameters are recorded in the drive-device. 

At every re-start of the axis, the commutation adjustment 

is made new to method 3. The parameter values for P0- 

0506 and P0-0507 of the initial start-up serve as initial 

value for the procedure. 

Note: The parameters P-0-0506, peak value for angle-survey and 

P-0-507, test frequency for angle-survey can individually be 

adjusted at initial start-up by the user.


14.7 Setting and Optimizing the Control Loop 

General sequence 

The control loop settings in a digital drive controller are significant to the 

characteristics of the servo axis. The control loop structure consists of a 

cascaded position, velocity and current controller. The corresponding 

mode defines the active controllers. 

Note: Defining the control loop settings requires the corresponding 

expertise. 

The procedure used for optimizing the control loops (current, velocity 

and position controllers) of linear direct drives corresponds to the one 

used for rotary servo drives. At linear drives are only the adjustment 

limits higher. 

setting and optimizing control loop of 

synchronous linear drives 

set current controller 

(part of motor parameter) 

optimize velocity controller 

filtering mechanical 

resonance vibrations 

no 

optimize position controller 

set and optimize acceleration 

precontrol 

yes 

set rejection frequency 

re-optimize velocity controller 

Fig. 14-11: Setting and optimizing the control loop of synchronous linear drives. 



Automatic control loop setting 

Filtering mechanical resonance 

vibrations 


Note: Use the functional description of the drive controller for more 

detailed information. 

Drive controllers of the EcoDrive03 series are able to perform automatic 

control loop adjustment. 

Digital drives from Rexroth are able to provide a narrow-band 

suppression of vibrations that are produced due to the power train 

between motor and mechanical axis system. This results in increased 

drive dynamic at a good stability. 

The position or velocity feedback in the closed control loop excites the 

mechanical system of the slide that is moved by the linear drive to 

perform mechanical vibrations. This behavior, known as “Two-masses 

vibration”, is mainly in the frequency range between 400 and 800 Hz. It 

depends on the rigidity of the mechanical system and the spatial 

expansion of the system. 

In most cases, this “Two-masses vibration” has a clear resonant 

frequency that can selectively be suppressed by a rejection filter in the 

drive. 

When the mechanical resonant frequency is suppressed, improving the 

dynamic properties of the velocity control loop and of the position control 

loop with may be possible, compared with close-loop operation without 

the rejection filter. 

This leads to an increased profile accuracy and to smaller cycle times for 

positioning processes at a sufficient distance to the stability limit. 

Rejection frequency and bandwidth of the filter can be selected. The 

highest attenuation takes effect on the rejection frequency. The bandwith 

defines the frequency range at which the attenuation is less than –3dB. 

A higher bandwidth leads to less attenuation of the rejection frequency! 

0 

-3 

damping in dB bandwidth 

frequency f 

rejection frequency f sperr 

SPERRFILTER-MLF-EN.EPS 

Fig. 14-12: Amplitude frequency curve rejection filter vs. bandwidth, qualitative


Parameter value assignments and optimization of Gantry axes 

Prerequisites: 

• The parameter settings of the axes are identical 

• Parallelism of the guides of the Gantry axes 

• Parallelism of the linear scale 

• In the controller, the axes are registered as individual axes 

Note: Drive-internal axis error compensation procedures can be 

used for compensating the misalignments between two linear 

scales as or the mechanical system. Please refer to the 

corresponding description of functions of the drive controller 

for a description of the operational principle and the 

parameter settings. 

actual position value 1 actual position value 2 

length meas. system 1 

length meas. system 2 

Dx 

ACHSKOMP-MLF-EN.EPS 

Fig. 14-13: Possible misalignment with the linear scale of a Gantry axes 

Parameter settings 

When using Gantry axes, your must ensure that the parameter settings 

of the following parameters are identical: 

• Motor parameters 

• Polarity parameters for force, velocity and position 

• Control loop parameters 

We have: 

k 

k 

v1 

p1 

= k 

= k 

kv: Position controller kv-factor S-0-0104 

kp: Velocity controller proportional gain S-0-0100 

Fig. 14-14: Proportional gains in the position and velocity control loop of both 

axes. 

v2 

p2 



Velocity controller integral time 

(integral part) 

Alignment of length 

linear scale and 

guides 


The following possibilities must be taken into account for the velocity 

controller integral time (integral part): 

Possibility 1 Possibility 2 Possibility 3 Possibility 4 

ideal not ideal not ideal not ideal 

Integral Part in both axes in both axes in one axis only in no axis 

Behaviour of the axes Since both motors 

follow the position 

command value 

ideally, there will not 

be a distortion of the 

mechanical system 

Optimization 

Both axes work 

against each other 

until there is an 

equalization via the 

mechanical coupling 

or until the maximum 

current of one or both 

drive controller(s) has 

been reached and a 

control effect is no 

longer possible. 

The axis without 

integral-part permits a 

continuous position 

offset. The magnitude 

of the position offset 

depends on the 

rigidity of the 

mechanical coupling 

of both axes and of 

the proportional gains 

in the position and 

velocity control loop. 

Both axes permit a 

continuous position 

offset. The magnitude 

of the position offset 

depends on the 

proportional gains in 

the position and 

velocity control loop. 

Fig. 14-15: Parameterization of the velocity controller integral time S-0-0101 for 

Gantry-axes. 

The previously described procedure must be followed for optimizing the 

position and velocity loop. 

Note: Any parameter modifications that are made during the 

optimization of Gantry axes must always be made in both 

axes simultaneously. If this is not possible, the parameter 

changes should be made during optimization in smaller 

subsequent steps in both axes. 

Estimating the moved mass using a velocity ramp 

Preparation 

Often, the exact moving mass of the machine slide is not known. 

Determining this mass can be made difficult by moving parts, additionally 

mounted parts, etc. 

The procedure explained below permits the moving axes mass to be 

estimated on the basis of a recorded velocity ramp. This permits, for 

example, the acceleration capability of the axis to be estimated. 

This procedure requires the oscillographic recording of the following 

parameters: 

• S-0-0040, actual velocity value 

• S-0-0080, torque/force command value 

You can either use an oscilloscope or the oscilloscope function of the 

drive in conjunction with DriveTop or NC.


F acc 

F dec 

dt 

dv 

S-0-0040, 

actual velocity value 


Fig. 14-16: Oscillogram of velocity and force 

m = 30 ⋅F 

dN 

⎛ FACC 

+ F 

⋅ ⎜ 

⎝ 100% 

S-0-0080, 

force command value 

DEC 

t 

ERMITTLGMASSE-MLF-EN.EPS 

⎞ ∆t 

⎟ ⋅ 

⎠ ∆v 

m: Moved axis mass in kg 

FdN: Continuous nominal force of the motor in N 

FACC: Force command value during acceleration in % 

FDEC: Force command value during braking in % 

v: Velocity change during constant acceleration in m/min 

t: Time change during constant acceleration in s 

Fig. 14-17: Determining the moved axis mass on the basis of a recorded velocity 

ramp 

Prerequisites: 1. Correct parameter settings of the rated motor 

current (basis of representation S-0-0080) 

2. Frictional force not directional 

3. Recording of v and t at constant acceleration 

4. Do not perform at maximum motor force to avoid 

non-linearities 

Note: Due to possible direction-related force variations, this 

procedure cannot or only conditionally be used for vertical 

axes. 



14.8 Maintenance and check of Motor components 

Check of Motor and Auxiliary Components 

Electrical check of motor components 

Resistance and inductance 

Insulation resistance 


The motor components of IndraDyn L do not need any maintenance. 

Due to external influence, the motor components can be damaged 

during operation. There should be a preventive maintenance of the 

linear motor components within the service intervals of the machine or 

system. 

The following points should be observed during the preventive check of 

motor and auxiliary components: 

• Scratches on primary and secondary 

• Chips in the air gap between primary and secondary 

• Tightness of liquid cooling, hoses and connections 

• State of power and encoder cables in a drag chain. 

• State of linear scale (e.g. soiled) 

• State of guides (e.g. wear of linear guides) 

The electrical defect of a primary can be checked by measuring electrical 

characteristics. The following variables are relevant: 

• Resistance between motor connecting wires 1-2, 2-3 and 1-3 

• Inductance between motor connecting wires 1-2, 2-3 and 1-3 

• Insulation resistance between motor connecting wired and guides 

The measured values of resistance and inductance can be compared 

with the values specified in Chapter 5 “Technical Data”. The individual 

values of resistance and inductance measured between the connections 

1-2, 2-3 and 1-3 should be identical – within a tolerance of ± 5 %. There 

can be a phase short circuit, a fault between windings, or a short circuit 

to ground if one or more values differ significantly. 

The insulation resistance – measured between the motor connecting 

leads and ground – should be at least 1 MΩ. The primary must be 

replaced in this case. 

Note: If there are and doubts during the electrical verification, 

please consult your Rexroth Service.

Rexroth IndraDyn L Service & Support 15-1 

15 Service & Support 

15.1 Helpdesk 

Unser Kundendienst-Helpdesk im Hauptwerk Lohr 

am Main steht Ihnen mit Rat und Tat zur Seite. 

Sie erreichen uns 

15.2 Service-Hotline 


Our service helpdesk at our headquarters in Lohr am 

Main, Germany can assist you in all kinds of inquiries. 

Contact us 

- telefonisch - by phone: 49 (0) 9352 40 50 60 

über Service Call Entry Center Mo-Fr 07:00-18:00 

- via Service Call Entry Center Mo-Fr 7:00 am - 6:00 pm 

- per Fax - by fax: +49 (0) 9352 40 49 41 

- per e-Mail - by e-mail: service.svc@boschrexroth.de 

Außerhalb der Helpdesk-Zeiten ist der Service 

direkt ansprechbar unter 

15.3 Internet 

+49 (0) 171 333 88 26 

oder - or +49 (0) 172 660 04 06 

Unter www.boschrexroth.com finden Sie 

ergänzende Hinweise zu Service, Reparatur und 

Training sowie die aktuellen Adressen *) unserer 

auf den folgenden Seiten aufgeführten Vertriebsund 

Servicebüros. 

Verkaufsniederlassungen 

Niederlassungen mit Kundendienst 

Außerhalb Deutschlands nehmen Sie bitte zuerst Kontakt mit 

unserem für Sie nächstgelegenen Ansprechpartner auf. 

*) Die Angaben in der vorliegenden Dokumentation können 

seit Drucklegung überholt sein. 

After helpdesk hours, contact our service 

department directly at 

At www.boschrexroth.com you may find 

additional notes about service, repairs and training 

in the Internet, as well as the actual addresses *) 

of our sales- and service facilities figuring on the 

following pages. 

sales agencies 

offices providing service 

Please contact our sales / service office in your area first. 

*) Data in the present documentation may have become 

obsolete since printing. 

15.4 Vor der Kontaktaufnahme... - Before contacting us... 

Wir können Ihnen schnell und effizient helfen wenn 

Sie folgende Informationen bereithalten: 

1. detaillierte Beschreibung der Störung und der 

Umstände. 

2. Angaben auf dem Typenschild der 

betreffenden Produkte, insbesondere 

Typenschlüssel und Seriennummern. 

3. Tel.-/Faxnummern und e-Mail-Adresse, unter 

denen Sie für Rückfragen zu erreichen sind. 

For quick and efficient help, please have the 

following information ready: 

1. Detailed description of the failure and 

circumstances. 

2. Information on the type plate of the affected 

products, especially type codes and serial 

numbers. 

3. Your phone/fax numbers and e-mail address, 

so we can contact you in case of questions.

15-2 Service & Support Rexroth IndraDyn L 

15.5 Kundenbetreuungsstellen - Sales & Service Facilities 

Deutschland – Germany vom Ausland: (0) nach Landeskennziffer weglassen! 

from abroad: don’t dial (0) after country code! 

Vertriebsgebiet Mitte 

Germany Centre 

Rexroth Indramat GmbH 

Bgm.-Dr.-Nebel-Str. 2 / Postf. 1357 

97816 Lohr am Main / 97803 Lohr 

Kompetenz-Zentrum Europa 

Tel.: +49 (0)9352 40-0 

Fax: +49 (0)9352 40-4885 

Vertriebsgebiet Süd 

Germany South 


Landshuter Allee 8-10 

80637 München 

Tel.: +49 (0)89 127 14-0 

Fax: +49 (0)89 127 14-490 

Vertriebsgebiet Nord 

Germany North 


Walsroder Str. 93 

30853 Langenhagen 

Tel.: +49 (0) 511 72 66 57-0 

Service: +49 (0) 511 72 66 57-256 

Fax: +49 (0) 511 72 66 57-93 

Service: +49 (0) 511 72 66 57-783 

SERVICE 

CALL ENTRY CENTER 

MO – FR 

von 07:00 - 18:00 Uhr 

from 7 am – 6 pm 

Tel. +49 (0) 9352 40 50 60 

service.svc@boschrexroth.de 

Vertriebsgebiet West 

Germany West 


Regionalzentrum West 

Borsigstrasse 15 

40880 Ratingen 

Tel.: +49 (0)2102 409-0 

Fax: +49 (0)2102 409-406 

+49 (0)2102 409-430 

Vertriebsgebiet Mitte 

Germany Centre 


Regionalzentrum Mitte 

Waldecker Straße 13 

64546 Mörfelden-Walldorf 

Tel.: +49 (0) 61 05 702-3 

Fax: +49 (0) 61 05 702-444 

SERVICE 

HOTLINE 

MO – FR 

von 17:00 - 07:00 Uhr 

from 5 pm - 7 am 

+ SA / SO 

Tel.: +49 (0)172 660 04 06 

oder / or 

Tel.: +49 (0)171 333 88 26 

Gebiet Südwest 

Germany South-West 


Service-Regionalzentrum Süd-West 

Siemensstr.1 

70736 Fellbach 

Tel.: +49 (0)711 51046–0 

Fax: +49 (0)711 51046–248 

Vertriebsgebiet Ost 

Germany East 


Beckerstraße 31 

09120 Chemnitz 

Tel.: +49 (0)371 35 55-0 

Fax: +49 (0)371 35 55-333 

SERVICE 

ERSATZTEILE / SPARES 

verlängerte Ansprechzeit 

- extended office time - 

♦ nur an Werktagen 

- only on working days - 

♦ von 07:00 - 18:00 Uhr 

- from 7 am - 6 pm - 

Tel. +49 (0) 9352 40 42 22 

Vertriebsgebiet Ost 

Germany East 


Regionalzentrum Ost 

Walter-Köhn-Str. 4d 

04356 Leipzig 

Tel.: +49 (0)341 25 61-0 

Fax: +49 (0)341 25 61-111 



Europa (West) - Europe (West) 

Austria - Österreich 

Bosch Rexroth GmbH 

Electric Drives & Controls 

Stachegasse 13 

1120 Wien 

Tel.: +43 (0)1 985 25 40 

Fax: +43 (0)1 985 25 40-93 

Great Britain – Großbritannien 

Bosch Rexroth Ltd. 


Broadway Lane, South Cerney 

Cirencester, Glos GL7 5UH 

Tel.: +44 (0)1285 863000 

Fax: +44 (0)1285 863030 

sales@boschrexroth.co.uk 

service@boschrexroth.co.uk 

France – Frankreich 

Bosch Rexroth SAS 


91, Bd. Irène Joliot-Curie 

69634 Vénissieux – Cedex 

Tel.: +33 (0)4 78 78 53 65 

Fax: +33 (0)4 78 78 53 62 

Italy - Italien 

Bosch Rexroth S.p.A. 

Via del Progresso, 16 (Zona Ind.) 

35020 Padova 

Tel.: +39 049 8 70 13 70 

Fax: +39 049 8 70 13 77 

Norway - Norwegen 

Bosch Rexroth AS 


Berghagan 1 or: Box 3007 

1405 Ski-Langhus 1402 Ski 

Tel.: +47 (0) 64 86 41 00 

Fax: +47 (0) 64 86 90 62 

Hotline: +47 (0)64 86 94 82 

jul.ruud@rexroth.no 

Sweden - Schweden 

Bosch Rexroth AB 


Ekvändan 7 

254 67 Helsingborg 

Tel.: +46 (0) 42 38 88 -50 

Fax: +46 (0) 42 38 88 -74 


vom Ausland: (0) nach Landeskennziffer weglassen, Italien: 0 nach Landeskennziffer mitwählen 

from abroad: don’t dial (0) after country code, Italy: dial 0 after country code 

Austria – Österreich 

Bosch Rexroth GmbH 


Industriepark 18 

4061 Pasching 

Tel.: +43 (0)7221 605-0 

Fax: +43 (0)7221 605-21 

Finland - Finnland 

Bosch Rexroth Oy 


Ansatie 6 

017 40 Vantaa 

Tel.: +358 (0)9 84 91-11 

Fax: +358 (0)9 84 91-13 60 



Via G. Di Vittorio, 1 

20063 Cernusco S/N.MI 

Hotline: +39 02 92 365 563 

Tel.: +39 02 92 365 1 

Service: +39 02 92 365 326 

Fax: +39 02 92 365 500 

Service: +39 02 92 365 503 



Via Isonzo, 61 

40033 Casalecchio di Reno (Bo) 

Tel.: +39 051 29 86 430 

Fax: +39 051 29 86 490 

Spain - Spanien 

Bosch Rexroth S.A. 


Centro Industrial Santiga 

Obradors s/n 

08130 Santa Perpetua de Mogoda 

Barcelona 

Tel.: +34 9 37 47 94 00 

Fax: +34 9 37 47 94 01 

Switzerland East - Schweiz Ost 

Bosch Rexroth Schweiz AG 


Hemrietstrasse 2 

8863 Buttikon 

Tel. +41 (0) 55 46 46 111 

Fax +41 (0) 55 46 46 222 

Belgium - Belgien 

Bosch Rexroth NV/SA 

Henri Genessestraat 1 

1070 Bruxelles 

Tel: +32 (0) 2 582 31 80 

Fax: +32 (0) 2 582 43 10 

info@boschrexroth.be 

service@boschrexroth.be 

France - Frankreich 



Avenue de la Trentaine 

(BP. 74) 

77503 Chelles Cedex 

Tel.: +33 (0)164 72-70 00 

Fax: +33 (0)164 72-63 00 

Hotline: +33 (0)608 33 43 28 



Via Paolo Veronesi, 250 

10148 Torino 

Tel.: +39 011 224 88 11 

Fax: +39 011 224 88 30 

Netherlands - Niederlande/Holland 

Bosch Rexroth Services B.V. 

Technical Services 

Kruisbroeksestraat 1 

(P.O. Box 32) 

5281 RV Boxtel 

Tel.: +31 (0) 411 65 16 40 

+31 (0) 411 65 17 27 

Fax: +31 (0) 411 67 78 14 

+31 (0) 411 68 28 60 

services@boschrexroth.nl 

Spain – Spanien 

Goimendi S.A. 


Parque Empresarial Zuatzu 

C/ Francisco Grandmontagne no.2 

20018 San Sebastian 

Tel.: +34 9 43 31 84 21 

- service: +34 9 43 31 84 56 

Fax: +34 9 43 31 84 27 

- service: +34 9 43 31 84 60 

sat.indramat@goimendi.es 

Switzerland West - Schweiz West 

Bosch Rexroth Suisse SA 

Av. Général Guisan 26 

1800 Vevey 1 

Tel.: +41 (0)21 632 84 20 

Fax: +41 (0)21 632 84 21 

Denmark - Dänemark 

BEC A/S 

Zinkvej 6 

8900 Randers 

Tel.: +45 (0)87 11 90 60 

Fax: +45 (0)87 11 90 61 

France - Frankreich 



ZI de Thibaud, 20 bd. Thibaud 

(BP. 1751) 

31084 Toulouse 

Tel.: +33 (0)5 61 43 61 87 

Fax: +33 (0)5 61 43 94 12 



Via Mascia, 1 

80053 Castellamare di Stabia NA 

Tel.: +39 081 8 71 57 00 

Fax: +39 081 8 71 68 85 

Netherlands – Niederlande/Holland 

Bosch Rexroth B.V. 

Kruisbroeksestraat 1 

(P.O. Box 32) 

5281 RV Boxtel 

Tel.: +31 (0) 411 65 19 51 

Fax: +31 (0) 411 65 14 83 

www.boschrexroth.nl 

Sweden - Schweden 

Bosch Rexroth AB 


- Varuvägen 7 

(Service: Konsumentvägen 4, Älfsjö) 

125 81 Stockholm 

Tel.: +46 (0)8 727 92 00 

Fax: +46 (0)8 647 32 77


Europa (Ost) - Europe (East) 

Czech Republic - Tschechien 

Bosch -Rexroth, spol.s.r.o. 

Hviezdoslavova 5 

627 00 Brno 

Tel.: +420 (0)5 48 126 358 

Fax: +420 (0)5 48 126 112 

Poland – Polen 

Bosch Rexroth Sp.zo.o. 

Biuro Poznan 

ul. Dabrowskiego 81/85 

60-529 Poznan 

Tel.: +48 061 847 64 62 /-63 

Fax: +48 061 847 64 02 

Russia - Russland 

ELMIS 

10, Internationalnaya 

246640 Gomel, Belarus 

Tel.: +375/ 232 53 42 70 

+375/ 232 53 21 69 

Fax: +375/ 232 53 37 69 

elmis_ltd@yahoo.com 

Czech Republic - Tschechien 

DEL a.s. 

Strojírenská 38 

591 01 Zdar nad Sázavou 

Tel.: +420 566 64 3144 

Fax: +420 566 62 1657 

Romania - Rumänien 

East Electric S.R.L. 

Bdul Basarabia no.250, sector 3 

73429 Bucuresti 

Tel./Fax:: +40 (0)21 255 35 07 

+40 (0)21 255 77 13 

Fax: +40 (0)21 725 61 21 

eastel@rdsnet.ro 

Turkey - Türkei 

Bosch Rexroth Otomasyon 

San & Tic. A..S. 

Fevzi Cakmak Cad No. 3 

34630 Sefaköy Istanbul 

Tel.: +90 212 413 34 00 

Fax: +90 212 413 34 17 

www.boschrexroth.com.tr 

vom Ausland: (0) nach Landeskennziffer weglassen 

from abroad: don’t dial (0) after country code 

Hungary - Ungarn 

Bosch Rexroth Kft. 

Angol utca 34 

1149 Budapest 

Tel.: +36 (1) 422 3200 

Fax: +36 (1) 422 3201 

Romania - Rumänien 


Str. Drobety nr. 4-10, app. 14 

70258 Bucuresti, Sector 2 

Tel.: +40 (0)1 210 48 25 

+40 (0)1 210 29 50 

Fax: +40 (0)1 210 29 52 

Turkey - Türkei 

Servo Kontrol Ltd. Sti. 

Perpa Ticaret Merkezi B Blok 

Kat: 11 No: 1609 

80270 Okmeydani-Istanbul 

Tel: +90 212 320 30 80 

Fax: +90 212 320 30 81 

remzi.sali@servokontrol.com 

www.servokontrol.com 

Poland – Polen 


ul. Staszica 1 

05-800 Pruszków 

Tel.: +48 22 738 18 00 

– service: +48 22 738 18 46 

Fax: +48 22 758 87 35 

– service: +48 22 738 18 42 

Russia - Russland 

Bosch Rexroth OOO 

Wjatskaja ul. 27/15 

127015 Moskau 

Tel.: +7-095-785 74 78 

+7-095 785 74 79 

Fax: +7 095 785 74 77 

laura.kanina@boschrexroth.ru 

Slowenia - Slowenien 

DOMEL 

Otoki 21 

64 228 Zelezniki 

Tel.: +386 5 5117 152 

Fax: +386 5 5117 225 

brane.ozebek@domel.si 



Africa, Asia, Australia – incl. Pacific Rim 

Australia - Australien 

AIMS - Australian Industrial 

Machinery Services Pty. Ltd. 

28 Westside Drive 

Laverton North Vic 3026 

Melbourne 

Tel.: +61 3 93 14 3321 

Fax: +61 3 93 14 3329 

Hotlines: +61 3 93 14 3321 

+61 4 19 369 195 

enquires@aimservices.com.au 

China 

Bosch Rexroth China Ltd. 

15/F China World Trade Center 

1, Jianguomenwai Avenue 

Beijing 100004, P.R.China 

Tel.: +86 10 65 05 03 80 

Fax: +86 10 65 05 03 79 

Hongkong 

Bosch Rexroth (China) Ltd. 

6 th Floor, 

Yeung Yiu Chung No.6 Ind Bldg. 

19 Cheung Shun Street 

Cheung Sha Wan, 

Kowloon, Hongkong 

Tel.: +852 22 62 51 00 

Fax: +852 27 41 33 44 

alexis.siu@boschrexroth.com.hk 

Indonesia - Indonesien 

PT. Bosch Rexroth 

Building # 202, Cilandak 

Commercial Estate 

Jl. Cilandak KKO, Jakarta 12560 

Tel.: +62 21 7891169 (5 lines) 

Fax: +62 21 7891170 - 71 

rudy.karimun@boschrexroth.co.id 

Korea 

Bosch Rexroth-Korea Ltd. 

1515-14 Dadae-Dong, Saha-gu 


Pusan Metropolitan City, 604-050 

Tel.: +82 51 26 00 741 

Fax: +82 51 26 00 747 

eunkyong.kim@boschrexroth.co.kr 

Taiwan 

Bosch Rexroth Co., Ltd. 

Taichung Branch 

1F., No. 29, Fu-Ann 5th Street, 

Xi-Tun Area, Taichung City 

Taiwan, R.O.C. 

Tel : +886 - 4 -23580400 

Fax: +886 - 4 -23580402 

jim.lin@boschrexroth.com.tw 

david.lai@boschrexroth.com.tw 


Australia - Australien 

Bosch Rexroth Pty. Ltd. 

No. 7, Endeavour Way 

Braeside Victoria, 31 95 

Melbourne 

Tel.: +61 3 95 80 39 33 

Fax: +61 3 95 80 17 33 

mel@rexroth.com.au 

China 

Bosch Rexroth China Ltd. 

Guangzhou Repres. Office 

Room 1014-1016, Metro Plaza, 

Tian He District, 183 Tian He Bei Rd 

Guangzhou 510075, P.R.China 

Tel.: +86 20 8755-0030 

+86 20 8755-0011 

Fax: +86 20 8755-2387 

India - Indien 

Bosch Rexroth (India) Ltd. 


Plot. No.96, Phase III 

Peenya Industrial Area 

Bangalore – 560058 

Tel.: +91 80 51 17 0-211...-218 

Fax: +91 80 83 94 345 

+91 80 83 97 374 

mohanvelu.t@boschrexroth.co.in 

Japan 

Bosch Rexroth Automation Corp. 

Service Center Japan 

Yutakagaoka 1810, Meito-ku, 

NAGOYA 465-0035, Japan 

Tel.: +81 52 777 88 41 

+81 52 777 88 53 

+81 52 777 88 79 

Fax: +81 52 777 89 01 

Malaysia 

Bosch Rexroth Sdn.Bhd. 

11, Jalan U8/82, Seksyen U8 

40150 Shah Alam 

Selangor, Malaysia 

Tel.: +60 3 78 44 80 00 

Fax: +60 3 78 45 48 00 

hockhwa@hotmail.com 

rexroth1@tm.net.my 

Taiwan 

Bosch Rexroth Co., Ltd. 

Tainan Branch 

No. 17, Alley 24, Lane 737 

Chung Cheng N.Rd. Yungkang 

Tainan Hsien, Taiwan, R.O.C. 

Tel : +886 - 6 –253 6565 

Fax: +886 - 6 –253 4754 

charlie.chen@boschrexroth.com.tw 

China 

Shanghai Bosch Rexroth 

Hydraulics & Automation Ltd. 

Waigaoqiao, Free Trade Zone 

No.122, Fu Te Dong Yi Road 

Shanghai 200131 - P.R.China 

Tel.: +86 21 58 66 30 30 

Fax: +86 21 58 66 55 23 

richard.yang_sh@boschrexroth.com.cn 

gf.zhu_sh@boschrexroth.com.cn 

China 

Bosch Rexroth (China) Ltd. 

A-5F., 123 Lian Shan Street 

Sha He Kou District 

Dalian 116 023, P.R.China 

Tel.: +86 411 46 78 930 

Fax: +86 411 46 78 932 




Advance House, II Floor 

Ark Industrial Compound 

Narol Naka, Makwana Road 

Andheri (East), Mumbai - 400 059 

Tel.: +91 22 28 56 32 90 

+91 22 28 56 33 18 

Fax: +91 22 28 56 32 93 

singh.op@boschrexroth.co.in 

Japan 

Bosch Rexroth Automation Corp. 


2F, I.R. Building 

Nakamachidai 4-26-44, Tsuzuki-ku 

YOKOHAMA 224-0041, Japan 

Tel.: +81 45 942 72 10 

Fax: +81 45 942 03 41 

Singapore - Singapur 

Bosch Rexroth Pte Ltd 

15D Tuas Road 

Singapore 638520 

Tel.: +65 68 61 87 33 

Fax: +65 68 61 18 25 

sanjay.nemade 

@boschrexroth.com.sg 

Thailand 

NC Advance Technology Co. Ltd. 

59/76 Moo 9 

Ramintra road 34 

Tharang, Bangkhen, 

Bangkok 10230 

Tel.: +66 2 943 70 62 

+66 2 943 71 21 

Fax: +66 2 509 23 62 

Hotline +66 1 984 61 52 

sonkawin@hotmail.com 

China 

Shanghai Bosch Rexroth 

Hydraulics & Automation Ltd. 

4/f, Marine Tower 

No.1, Pudong Avenue 

Shanghai 200120 - P.R.China 

Tel: +86 21 68 86 15 88 

Fax: +86 21 58 40 65 77 

China 

Melchers GmbH 

BRC-SE, Tightening & Press-fit 

13 Floor Est Ocean Centre 

No.588 Yanan Rd. East 

65 Yanan Rd. West 

Shanghai 200001 

Tel.: +86 21 6352 8848 

Fax: +86 21 6351 3138 



S-10, Green Park Extension 

New Delhi – 110016 

Tel.: +91 11 26 56 65 25 

+91 11 26 56 65 27 

Fax: +91 11 26 56 68 87 

koul.rp@boschrexroth.co.in 

Korea 

Bosch Rexroth-Korea Ltd. 

Electric Drives and Controls 

Bongwoo Bldg. 7FL, 31-7, 1Ga 

Jangchoong-dong, Jung-gu 

Seoul, 100-391 

Tel.: +82 234 061 813 

Fax: +82 222 641 295 

South Africa - Südafrika 

TECTRA Automation (Pty) Ltd. 

71 Watt Street, Meadowdale 

Edenvale 1609 

Tel.: +27 11 971 94 00 

Fax: +27 11 971 94 40 

Hotline: +27 82 903 29 23 

georgv@tectra.co.za


Nordamerika – North America 

USA 

Headquarters - Hauptniederlassung 

Bosch Rexroth Corporation 


5150 Prairie Stone Parkway 

Hoffman Estates, IL 60192-3707 

Tel.: +1 847 6 45 36 00 

Fax: +1 847 6 45 62 01 

servicebrc@boschrexroth-us.com 

repairbrc@boschrexroth-us.com 

USA East Region – Ost 



Charlotte Regional Sales Office 

14001 South Lakes Drive 

Charlotte, North Carolina 28273 

Tel.: +1 704 5 83 97 62 

+1 704 5 83 14 86 

Canada East - Kanada Ost 

Bosch Rexroth Canada Corporation 

Burlington Division 

3426 Mainway Drive 

Burlington, Ontario 

Canada L7M 1A8 

Tel.: +1 905 335 5511 

Fax: +1 905 335 4184 

Hotline: +1 905 335 5511 

michael.moro@boschrexroth.ca 

USA Central Region - Mitte 



Central Region Technical Center 

1701 Harmon Road 

Auburn Hills, MI 48326 

Tel.: +1 248 3 93 33 30 

Fax: +1 248 3 93 29 06 

USA Northeast Region – Nordost 



Northeastern Technical Center 

99 Rainbow Road 

East Granby, Connecticut 06026 

Tel.: +1 860 8 44 83 77 

Fax: +1 860 8 44 85 95 

Canada West - Kanada West 

Bosch Rexroth Canada Corporation 

5345 Goring St. 

Burnaby, British Columbia 

Canada V7J 1R1 

Tel. +1 604 205 5777 

Fax +1 604 205 6944 

Hotline: +1 604 205 5777 

david.gunby@boschrexroth.ca 

Südamerika – South America 

Argentina - Argentinien 

Bosch Rexroth S.A.I.C. 

"The Drive & Control Company" 

Rosario 2302 

B1606DLD Carapachay 

Provincia de Buenos Aires 

Tel.: +54 11 4756 01 40 

+54 11 4756 02 40 

+54 11 4756 03 40 

+54 11 4756 04 40 

Fax: +54 11 4756 01 36 

+54 11 4721 91 53 

victor.jabif@boschrexroth.com.ar 

Columbia - Kolumbien 

Reflutec de Colombia Ltda. 

Calle 37 No. 22-31 

Santafé de Bogotá, D.C. 

Colombia 

Tel.: +57 1 368 82 67 

+57 1 368 02 59 

Fax: +57 1 268 97 37 

reflutec@neutel.com.co 

reflutec@007mundo.com 

Argentina - Argentinien 

NAKASE 

Servicio Tecnico CNC 

Calle 49, No. 5764/66 

B1653AOX Villa Balester 

Provincia de Buenos Aires 

Tel.: +54 11 4768 36 43 

Fax: +54 11 4768 24 13 

Hotline: +54 11 155 307 6781 

nakase@usa.net 

nakase@nakase.com 

gerencia@nakase.com (Service) 

USA Southeast Region - Südwest 



Southeastern Technical Center 

3625 Swiftwater Park Drive 

Suwanee, Georgia 30124 

Tel.: +1 770 9 32 32 00 

Fax: +1 770 9 32 19 03 

USA West Region – West 


7901 Stoneridge Drive, Suite 220 

Pleasant Hill, California 94588 

Tel.: +1 925 227 10 84 

Fax: +1 925 227 10 81 

Mexico 

Bosch Rexroth Mexico S.A. de C.V. 

Calle Neptuno 72 

Unidad Ind. Vallejo 

07700 Mexico, D.F. 

Tel.: +52 55 57 54 17 11 

Fax: +52 55 57 54 50 73 

mariofelipe.hernandez@boschrexroth.com.mx 

Brazil - Brasilien 

Bosch Rexroth Ltda. 

Av. Tégula, 888 

Ponte Alta, Atibaia SP 

CEP 12942-440 

Tel.: +55 11 4414 56 92 

+55 11 4414 56 84 

Fax sales: +55 11 4414 57 07 

Fax serv.: +55 11 4414 56 86 

alexandre.wittwer@rexroth.com.br 

USA SERVICE-HOTLINE 

Mexico 

- 7 days x 24hrs - 

+1-800-REX-ROTH 

+1 800 739 7684 

Bosch Rexroth S.A. de C.V. 

Calle Argentina No 3913 

Fracc. las Torres 

64930 Monterrey, N.L. 

Tel.: +52 81 83 65 22 53 

+52 81 83 65 89 11 

+52 81 83 49 80 91 

Fax: +52 81 83 65 52 80 

mario.quiroga@boschrexroth.com.mx 

Brazil - Brasilien 

Bosch Rexroth Ltda. 

R. Dr.Humberto Pinheiro Vieira, 100 

Distrito Industrial [Caixa Postal 1273] 

89220-390 Joinville - SC 

Tel./Fax: +55 47 473 58 33 

Mobil: +55 47 9974 6645 

prochnow@zaz.com.br 


Rexroth IndraDyn L Appendix 16-1 

16 Appendix 

16.1 Recommended suppliers of additional components 

Length Measuring System 

Linear Guide 

Energy Chains 


DR. JOHANNES HEIDENHAIN GmbH 

Dr.-Johannes-Heidenhain-Straße 5 • D-83301 Traunreut 

Tel.: +49 (0) 8669 31 0 

Fax: +49 (0) 8669 50 61 

E-Mail: verkauf@heidenhain.de 

Internet: http://www.heidenhain.de/ 

Renishaw GmbH 

Karl-Benz Strasse 12 • D-72124 Pliezhausen 

Tel.: +49 (0) 712 797 960 

Fax: +49 (0) 712 788 237 

E-Mail: germany@renishaw.com 

Internet: http://www.renishaw.com/encoder/ 


Ernst-Sachs-Str. 90 • D-97419 Schweinfurt 

Tel.: +49 (0) 9721 937 0 

Fax: +49 (0) 9721 937 350 

E-Mail: info@rexroth-star.com 

Internet: http://www.rexroth.com/rexrothstar 



Tel.: +49 (0) 9721 937 0 

Fax: +49 (0) 9721 937 350 


Internet: http://www.rexroth.com/rexrothstar 

igus GmbH 

Spicher Straße 1a • D-51147 Köln 

Tel.: +49 (0) 2203 9649 0 

Fax: +49 (0) 2203 9649 222 

E-Mail: info@igus.de 

Internet: http://www.igus.de/ 

KABELSCHLEPP GMBH 

Marienborner Straße 75 • 57074 Siegen 

Tel.: +49 (0) 271 5801 0 

Fax: +49 (0) 271 5801 220 

E-Mail: info@kabelschlepp.de 

Internet: http://www.kabelschlepp.de/

16-2 Appendix Rexroth IndraDyn L 

Heat-exchanger Unit 

Coolant Additives 

Coolant Tubes 

Axis Cover System 

SCHWÄMMLE GmbH & Co KG 

Dieselstraße 12-14 • D-71546 Aspach 

Tel.: +49 (0) 7191 9242 0 

Fax: +49 (0) 7191 225 10 

E-Mail: info@schwaemmle-gmbh.de 

Internet: http://www.schwaemmle-gmbh.de/ 

Universal Hydraulik GmbH 

Siemensstrasse 33 • D-61267 Neu-Anspach 

Tel.: +49 (0) 6081 9418 0 

Fax: +49 (0) 6081 9602 20 

E-Mail: 

Internet: http://www.universalhydraulik.com/ 

See Fig. 9-27 

Polyflex AG 

Dorfstasse 49 • CH-5430 Wettingen 

Tel.: +44 (0) 56-4241088 

Fax: +44 (0) 56-4241114 

E-Mail: 

Internet: http://www.polyflex.ch/ 

igus GmbH 

Spicher Straße 1a • D-51147 Köln 

Tel.: +49 (0) 2203 9649 0 

Fax: +49 (0) 2203 9649 222 

E-Mail: info@igus.de 

Internet: http://www.igus.de/ 


Postfach 910762 • D-30427 Hannover 

Tel.: +49 (0) 511 2136 0 

Fax: +49 (0) 511 2136 269 

E-Mail: infomaster@rexroth-mecman.se 

Internet: http://www.rexroth.com/rexrothmecman 

Möller Werke GmbH 

Möller Balg 

Kupferhammer • D-33649 Bielefeld 

Tel.: +49 (0) 521 4477 0 

Fax: +49 (0) 521 4477 333 

E-Mail: info@moellerbalg.de 

Internet: http://www.moellerflex.de/ 



End Position Shock Absorbers 

Metal Braid Shock Absorbers 


HCR-Heinrich Cremer GmbH 

Oppelner Str. 37 • D-41199 Mönchengladbach 

Tel.: +49 (0) 2166 964900 

Fax: +49 (0) 2166 609157 

E-Mail: info@hcr.de 

Internet: http://www.hcr.de/ 

Gebr. HENNIG GmbH 

Postfach 1137 • 85729 Ismaning 

Tel.: +49 (0) 89 96096 0 

Fax: +49 (0) 89 96096 120 

E-Mail: HENNIGGMBH@aol.com 

Internet: http://www.hennig-gmbh.de/ 

ACE Stoßdämpfer GmbH 

Postfach 1510 • D-40740 Langenfeld 

Herzogstraße 28 • D-40764 Langenfeld 

Tel.: +49 (0) 2173 92 26 10 

Fax: +49 (0) 2173 92 26 19 

E-Mail: info@ace-ace.de 

Internet: http://www.ace-ace.de/ 


Postfach 910762 • D-30427 Hannover 

Tel.: +49 (0) 511 2136 0 

Fax: +49 (0) 511 2136 269 

E-Mail: infomaster@rexroth-mecman.se 

Internet: http://www.rexroth.com/rexrothmecman 

Rhodius GmbH 

Treuchlinger Str. 23 • D-91781 Weißenburg 

Tel.: +49 (0) 9141 919 0 

Fax: +49 (0) 9141 919 45 

E-Mail: rhodius@rhodius.com 

Internet: http://www.rhodius.com/ 

Clamping Elements for Linear Guideways 



Tel.: +49 (0) 9721 937 0 

Fax: +49 (0) 9721 937 350 


Internet: http://www.rexroth.com/rexrothstar


External Mechanical Brakes 

Weight Compensation Systems 

Wipers 

Pneumatic 

Hydraulic 

Kendrion Binder Magnete GmbH 

Mönchweilerstr. 1 • D-78048 Villingen-Schwenningen 

Tel.: +49 (0) 7721 877 455 

Fax: +49 (0) 7721 877 462 

E-Mail: 

Internet: http://www.binder-magnete.de/ 

Ortlinghaus-Werke GmbH 

Kenkhauser Str. 125 • D-42929 Wermelskirchen 

Tel.: +49 (0) 2196 85-0 

Fax: +49 (0) 2196 855-444 

E-Mail: info@ortlinghaus.com 

Internet: http://www.ortlinghaus.com/ 

Ross Europa GmbH 

Robert-Bosch-Str. 2 • D-63225 Langen 

Tel.: +49 (0) 6103 7597 0 

Fax: +49 (0) 6103 7469 40 

E-Mail: 

Internet: 


Jahnstr. 3-5 • D-97816 Lohr am Main 

Tel.: +49 (0) 9352 18 0 

Fax: +49 (0) 9352 18 2598 

E_Mail: 

Internet: http://www.rexroth.com/ 

Hunger DFE GmbH 

Dichtungs- und Führungselemente 

Alfred-Nobel Str. 26 • D-97080 Würzburg 

Tel.: +49 (0) 931 900 97 0 

Fax: +49 (0) 931 900 97 30 

E-Mail: info@hunger-dichtungen.de 

Internet: http://www.hunger-dichtungen.de/ 

HME Dichtungssysteme 

Richthofenstr. 31 • D - 86343 Königsbrunn 

Tel.: +49 (0) 8231 9623 0 

Fax: +49 (0) 8231 865 16 

E-Mail: hme@hme-seals.de 

Internet: http://www.hme-seals.de/ 



16.2 Enquiry form for Linear Drives 

Rexroth Indramat 

Fax: 

Contact person: 

1. Information for the user 


.............................................................. 

.............................................................. 

Date: .......................... 

Company ..................................................... Name ........................................................... 

Street ..................................................... Department ........................................................... 

Zip Code ..................................................... Phone ........................................................... 

Place ..................................................... Fax ........................................................... 

Email ........................................................... 

Requesting to: O Recall O Drive dimensioning O Offer O .................................................. 

2. General information on use 

Sector O Machine Tools O Automation O Packaging O Printing 

O ........................................................................................................ 

Type of use ............................................................................................................ 

............................................................................................................ 

Designation of the 

Axis 

............................................................................................................ 

Axis Grouping O Single axis O Grouping of ............ axis within the machine 

O only linear drives O rotative and linear drives 

Quantity ........................... per year 

3. Mechanical and cinematic requirements 

Installation position O Horizontal O Vertical O Slant, axis angle: ............degrees 

Moved motor 

component 

O Primary part moves O Secondary part moves 

Moved mass ....................... kg (incl. guides, power feeders, etc.) 

Maximum velocity ..................... m/min Maximum 

acceleration 

Base force ....................... N (friction, energy supply, etc. ) 

Machining force ....................... N (detailed specifications see point 5) 

....................... m/s²


4. Ambient conditions 

Ambient temperature ....................... °C 

Machined material O Steel / cast iron O Light metal O Plastic O Wood 

O Other:......................................... O None(only handling) 

Dirt and aggressive media O Chips O Dust 

Protection of 

motor components 

5. Thermal conditions and cooling 

O Oil or lubricants: ......................................................................... 

O Other: ......................................................................................... 

O Bellows O Telescopic cover O Wiper on secondary 

O Other: 

................................................................................................ 

Liquid cooling Coolant and additives: ............................................................................. 

Inlet temperature, minimum: .............°C maximum: ...............°C 

Max. flow quantity: .........l/min Max. system pressure: .........bar 

Maximum heating of the machine structure: ........... K O Not relevant 

Maximum coolant temperature rise: ....................... K O Not relevant 

Additional cooling at machine O Yes O No 

O Air cooling, natural convection (Reducing the continuous forces to approximately 25 %) 

6. Drive and Control 

Drive series O ECODRIVE03 O DIAX04 O IndraDrive 

Main 

voltage 

Drive 

interface / 

bus system 

O 1 x 230 V O 3 x 400 V O 3 x 480 V O ................................ 

O SERCOS interface O ANALOG ±10V O Parallel interface 

O Profibus O Interbus O CANopen O DeviceNet O PWM 

O ..................................................................................................................... 

Control 

O ..................................................:.................................................................. 

7. Linear scale 

Measuring principle O absolut ENDAT 

and interface 

O incremental, sine signals 1 VSS 

O incremental, sine signals 1 VSS, distance-encoded reference marks 

Model O open O encapsulated O integradted in linear 

buides 

Positioning accurary ......................... µm 



8. Motion profile 

Specification of 

motion profile 

8.1 Data for motion selection exists: 


O Not required, drive selection data exist (see 8.1) 

O Strokes, positioning and idle times, maximum velocity and acceleration as 

specified under item 3 (see 8.2) 

O Sketch of velocity profile v(t) and process forces FP(t) (see 8.2 and 8.3) 

O Operating phases and duty cycles (see 8.4) 

O Equation of motion for s(t) and / or v(t) (see 8.5) 

O s(t) and / or v(t) can ve specified in digital form: 

O MathCad O Excel O ASCII O ........................... 

Fmax: .............. N FEFF / FdN: .............. N vFmax: ............. m/min vmax: ............. m/min 

8.2 Specification of strokes, position and idle times 

Stroke Travel Positioning time Idle time Stroke Travel Positioning time Idle time 

1 8 

2 9 

3 10 

4 11 

5 12 

6 13 

7 14 

8.3 Sketch of velocity profile and process forces 

wÉáí==áå=KKKKKK 

wÉáí==áå=KKKKKK


8.4 Specification of operating phases and related duty cycle 

Force Fi 

Acceleration, deceleration at .............m/s² 

EDi 

............. % .............. N 

Acceleration, deceleration at .............m/s² and machining ............. % .............. N 

Rapid traverse at v = constant = ............ m/min ............. % .............. N 

Machining at v = ............ m/min ............. % .............. N 

Standstill with machining ............. % .............. N 

Standstill without machining ............. % .............. N 

................................................................................ ............. % .............. N 

Total: 

8.5 Equation of motion for s(t) or v(t) 

100 % 

Equation of motion, 

e.g.: s( t) 

= r ⋅ sin( ω⋅ 

t) 

Explanation: 

9. Miscellaneous/comments/sketches 

............................................................................................................................................................ 

............................................................................................................................................................ 

............................................................................................................................................................ 

............................................................................................................................................................ 

............................................................................................................................................................ 

............................................................................................................................................................ 

............................................................................................................................................................ 

............................................................................................................................................................ 

............................................................................................................................................................ 

............................................................................................................................................................ 

............................................................................................................................................................ 

............................................................................................................................................................ 


Rexroth IndraDyn L Index 17-1 

17 Index 


A 

Air gap 9-19 

Appropriate use 

Introduction 2-1 

Uses 2-2 

Attractive forces 9-18 

Average velocity 5 

B 

Braking Systems 9-53 

C 

Commutation adjustment 14-9 

Connection cable 8-1 

Connection of DIAX04 and EcoDrive Drive-Controllers 8-8 

Connection of IndraDrive Drive Controller 8-6 

Connection of linear feedback devices 8-10 

Continuous Output 15 

Coolant temperature 9-28 

Cooling capacity 9-32, 17 

Customer’s receiving inspection 12-5 

D 

Delivery status 12-2 

different motor/controller combinations 10-1 

Dimensions 5-1 

Duty cycle 13 

E 

Enclosure surface 9-45 

F 

Factory checks 12-5 

feed forces 3 

Flow quantity 9-30 

Frame length 3 

G 

Gantry Arrangement 9-16 

General construction 9-2 

General equations of motion 2 

General start-up procedure 14-4 

H 

Holding Devices 9-53 

I 

Identification 12-1 

Inappropriate use 2-2 

Consequences, Discharge of liability 2-1 

Installation 13-1 

Integrating the linear scale 9-8

17-2 Index Rexroth IndraDyn L 

L 

Load Rigidity 

Dynamic load rigidity 9-65 

Static load rigidity 9-65 

M 

Magnetic Fields 9-43 

Maintenance 14-21 

Mass reduction 9-7 

Maximum Acceleration Changes 9-61 

Maximum Output 16 

maximum system pressure 9-28 

Measuring principle 9-48 

Mechanical rigidity 9-7 

Mechanically linked axes 9-7 

Motor cooling 

Coolants 9-26 

Standard encapsulation 9-24 

Thermal encapsulation 9-24 

Thermal time constant 9-22 

Motor cooling 

Power loss 9-22 

Motor cooling 9-22 

Motor Design 9-2 

Mounting 13-1 

Mounting Sizes 

size 070 5-6 

size 100 5-9 

size 140 5-12 

size 200 5-15 

size 300 5-18 

Mounting Sizes 5-3 

size 040 5-3 

N 

Natural frequencies 9-7 

Noise emission 9-45 

O 

on axis cover system 9-55 

Operation without liquid cooling 9-29 

P 

Packaging 12-2 

parallel arrangement 9-10 

Parameter settings 14-18 

Performance Overview 2 

pH-value coolant 9-27 

Position and Velocity Resolution 9-63 

Pressure drop 9-29, 9-31 

Protection class 9-42 

R 

Reactive forces 9-8 

Reduced overlapping 9-20 

Regeneration energy 17 

S 

Safety Instructions for Electric Drives and Controls 3-1 

Sensors temperature measurement external 9-38 


Rexroth IndraDyn L Index 17-3 


Shock 9-44 

shock absorber 9-54 

Shutdown by a master control 9-59 

Shutdown by the drive 9-58 

Shutdown upon EMERGENCY STOP 9-58 

Shutdown via mechanical braking device 9-59 

single arrangement 9-9 

Sinusoidal velocity 11 

Sizing the cooling circuit 9-29 

Specifics for transporting 12-4 

Standard encapsulation 9-3 

Standards 4 

Storage 12-3 

Symmetry 5-2 

T 

Temperature sensor motor protection 9-38 

Thermal encapsulation 9-3 

Tolerances 5-1 

Transportation 12-3 

Trapezoidal velocity 6 

Triangular velocity 10 

type code 1 

U 

Use See appropriate use and inappropriate use 

Utilization factor 9-41 

V 

Vertical axes 9-17 

Vibration 9-44 

W 

Weight compensation 9-17 

Winding 3 

Wipers 9-56

R911293635 


Electric Drives and Controls 

P.O. Box 13 57 

97803 Lohr, Germany 

Bgm.-Dr.-Nebel-Str. 2 

97816 Lohr, Germany 

Phone +49 (0)93 52-40-50 60 

Fax +49 (0)93 52-40-49 41 

service.svc@boschrexroth.de 

www.boschrexroth.com 

Printed in Germany

Rexroth IndraDyn L Synchronous Linear Motors - Elogia

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