Six-row linear recirculating ball bearing and guideway assemblies
Features
Linear recirculating ball bearing and guideway assemblies KUSE are full complement, preloaded units that are used in applications with long unrestricted strokes, very high loads and very high rigidity.
A guidance system comprises at least one carriage supplied fitted with a lubrication connector, one guideway, one dummy guideway, plastic closing plugs and O rings for sealing off the upper relubrication holes.
X-life
In linear recirculating ball guidance systems, the entry zones – the area in which the rolling elements enter the saddle plate up to full load – are considered as areas determining the rating life. They ensure that the load is applied to the rolling element not abruptly but steadily, which gives a more uniform load distribution.
Through optimisation of the entry zone geometry, the six-row linear recirculating ball bearing and guideway assembly KUSE has not only smaller stroke pulsation but also achieves a significant increase in the basic load ratings according to its size and series in comparison with the conventional design.
Full complement
Since they have the maximum possible number of rolling elements, full complement guidance systems have extremely high load carrying capacity and particularly high rigidity.
Carriages
The carriages have saddle plates made from hardened steel and the rolling element raceways are precision ground. The balls are recirculated in enclosed channels with plastic return elements.
Favourably positioned lubrication pockets in the carriage provide a generous grease reservoir and advantageous lubrication, see link.
Guideways
The guideways are made from hardened steel and are ground on all faces, the rolling element raceways are precision ground.
Location from above or below
Guideways TKSD.. (-ADB, -ADK) are located from above and have through holes with counterbores for the fixing screws. Guideways TKSD..-U are located from below and have threaded blind holes.
Slot for covering strip
Guideways TKSD..-ADB have a slot for the adhesive bonded steel covering strip ADB. Guideways TKSD..-ADK have a slot with undercut for the clip fit steel covering strip ADK.
Multi-piece guideways
If the required guideway length lmax is greater than the value in the dimension tables, the guideways are supplied as several segments, see link.
Standard accessories
As standard, the scope of delivery includes various accessory parts.
Dummy guideway
The dummy guideway prevents damage to the rolling element set and prevents the rolling elements from falling out while the carriage is separated from the guideway.
Carriages are always pushed directly from the guideway onto the dummy guideway and must remain there until they are remounted.
Plastic closing plugs
The closing plugs close off the counterbores of the guideway holes flush with the surface of the guideway.
Optionally, brass closing plugs are also available.
Lubrication connector and O rings
A lubrication connector for relubrication from the end is included already fitted.
O rings for sealing purposes if relubrication is carried out from above via the adjacent construction are included in the delivery.
Load carrying capacity
The linear recirculating ball bearing and guideway assemblies have six rows of balls. The four outer rows have a contact angle of 45° and the two inner rows have a contact angle of 60° to the raceways, ➤ Figure.
Four rows of balls support compressive loads while two rows of balls support tensile loads and all six rows support lateral loads.
The units can support loads from all directions, except in the direction of motion, and moments about all axes, ➤ Figure.
Load carrying capacity and contact angle
Acceleration and velocity
Six-row linear recirculating ball bearing and guideway assemblies KUSE permit accelerations up to 150 m/s2 and velocities up to 5 m/s, see table.
Operating limits
Designation | Acceleration up to | Velocity up to |
|---|---|---|
m/s2 | m/s | |
KUSE | 150 | 5 |
Interchangeability
Carriages KWSE and guideways TKSD are interchangeable in any combination within one size, preload class and accuracy class.
Sealing
Elastic end wipers are fitted to the end pieces of the carriages on both sides to retain the lubricant within the system. Size 45 is fitted on both sides with non-contact, corrosion-resistant end plates.
Standard sealing strips ensure reliable sealing and protect the rolling element system against contamination, even in critical environmental conditions, ➤ Figure.
ACHTUNG
Under extremely heavy contamination load, additional wipers can be fitted. Where necessary, additional covers must be used.
Lubrication
Six-row linear recirculating ball bearing and guideway assemblies KUSE are suitable for oil and grease lubrication. A lubrication connector for grease lubrication from the end is included already fitted. Optionally, other lubrication connectors are available.
Lubrication is carried out via lubrication connectors in the end face of the end piece or from above via the adjacent construction and the lubrication holes in the end pieces. Observe the mounting manual MON 22.
ACHTUNG
It must be ensured that the adjacent construction completely covers the carriage (including the end pieces) and the O rings for sealing off the relubrication hole from above are inserted, ➤ Figure. Otherwise, lubricant may escape through the upper lubrication hole.
Sealing strips, wipers, lubricant reservoir
ACHTUNG
If lubrication connectors are fitted, the maximum permissible screw depth must be observed. If additional sealing elements KIT, the screw depth is increased. The standard lubrication connector is then no longer usable. Suitable lubrication connectors must additionally be taken into consideration when ordering.
Operating temperature
As standard, six-row linear recirculating ball bearing and guideway assemblies KUSE can be used at operating temperatures from –10 °C to +80 °C.
Corrosion-resistant design
Six-row linear recirculating ball bearing and guideway assemblies KUSE are available in the accuracy class G3 and preload class V1 or V2 and also in a corrosion-resistant design with the special coating Corrotect.
Design and safety guidelines
Preload
Linear recirculating ball bearing and guideway assemblies KUSE are available in the preload classes V0, V1 and V2, see table.
Preload classes
Preload class | Preload setting |
|---|---|
V0 | Very small clearance to clearance-free |
V1** | 0,04 · CII** |
V2 | 0,13 · CII** |
**Standard preload class.
**Basic dynamic load rating of the central rows of balls.
Influence of preload on the linear guidance system
The preload of a linear guidance system defines the rigidity of the system. The six-row linear recirculating bearing and guideway assembly KUSE can be obtained in the preload classes V0 to V2, where the preload class V1 is the standard preload class. If special requirements are present, the alternative preload classes may be used.
Increasing the preload increases the rigidity of the guidance system. The preload influences not only the rigidity but also the displacement force of the guidance system. The higher the preload, the larger the displacement force. Furthermore, preload also influences the operating life of the guidance system.
Friction
The coefficient of friction is dependent on the ratio C/P, see table.
Coefficient of friction
Load C/P | Coefficient of friction μKUSE | ||
|---|---|---|---|
from | to | from | to |
4 | 20 | 0,001 | 0,002 |
Rigidity
The deflection curves show the deformation of the linear recirculating ball bearing and guideway assemblies KUSE, including the deformation of the screw connections to the adjacent construction.
ACHTUNG
The rigidity curves are valid only for screw mounting in accordance with the mounting manual MON 22 and the standard preload class V1.
Hole patterns of guideways
Unless specified otherwise, the guideways have a symmetrical hole pattern, where aL = aR, ➤ Figure.
An asymmetrical hole pattern may also be available upon request. In this case, aL ≧ aL min and aR ≧ aR min, ➤ Figure.
ACHTUNG
Irrespective of the orientation of the locating face, aL is on the left and aR on the right, ➤ Figure. When ordering, the required orientation of the locating face (top or bottom) must be indicated.
Hole patterns of guideways with one row of holes
Maximum number of pitches between holes
The number of pitches between holes is the rounded whole number equivalent to:
The spacings aL and aR are generally determined as follows: 
For guideways with a symmetrical hole pattern: 
Number of holes: 
| aL, aR | mm | Spacing between the start and the end of the guideway and the nearest hole |
| aL min, aR min | mm | Minimum values for aL, aR |
| l | mm | Guideway length |
| n | – | Maximum possible number of pitches between holes |
| jL | mm | Spacing between holes |
| x | – | Number of holes. |
ACHTUNG
If the minimum values for aL and aR are not observed, the counterbores of the holes may be intersected. Risk of injury.
Multi-piece guideways
If the guideway length required is greater than lmax or joined guideways are required, these guideways are made up from segments that together comprise the total required length. The segments are matched to each other and marked. The pitch is always located centrally between the fixing holes.
Marking of multi-piece guideways
1A, 1A 1B, 1B 1C, 1C
2A, 2A 2B, 2B 2C, 2C
ACHTUNG
In the case of multi-piece guideways, the gap at the end faces between two segments must be ＜ 0,05 mm.
Guideways suitable for joining as required
If partial guideway lengths (l ＜ lmax) are to be combined with each other to form a guideway set as requested by the customer, the following postscript must be added to the order for the relevant guideway segment: “Guideway suitable for joining as required”.
If the guideway segment is an end segment, it is recommended that the guideway end has a chamfer, in order to make it easier to slide the carriages onto the guideway and protect the seals against damage. In this case, the position of the chamfer (left or right) and the position of the locating face (top or bottom) must be taken into consideration when ordering.
This design facilitates easier logistics.
Demands on the adjacent construction
The running accuracy is essentially dependent on the straightness, accuracy and rigidity of the fit and mounting surfaces.
The straightness of the system can be achieved most easily when the guideway is pressed against a locating face.
If the guideway cannot be aligned as recommended by means of locating faces or very high requirements are placed on the running accuracy, the guideway straightness must be restricted. The following postscript must be added to the order: “Restricted guideway straightness”.
Geometrical and positional accuracy of the mounting surfaces
The higher the requirements for accuracy and smooth running of the guidance system, the more attention must be paid to the geometrical and positional accuracy of the mounting surfaces.
ACHTUNG
Observe the tolerances for the mounting surfaces and parallelism of mounted guideways, ➤ Bild, and table.
Surfaces should be ground or precision milled with the objective of achieving a mean roughness value Ramax 1,6.
Any deviations from the stated tolerances will impair the overall accuracy, alter the preload and reduce the operating life of the guidance system.
Height difference ΔH
For ΔH, permissible values are in accordance with the following equation:
| ΔH | μm | Maximum permissible deviation from the theoretically precise position, ➤ Figure |
| a | – | Factor, dependent on the preload class, see table |
| b | mm | Centre distances between guidance elements. |
Factor a
Preload class | Factor a |
|---|---|
V0 | 0,2 |
V1** | 0,2 |
V2 | 0,1 |
**Standard preload class.
ACHTUNG
Observe the guidelines in the mounting manual MON 22 for KUSE.
Tolerances of mounting surfaces and parallelism of mounted guideways and carriages
Parallelism of mounted guideways
For guideways arranged in parallel, the values for t are in accordance with➤ Bild, and the table. If the maximum values are used, this may increase the displacement resistance.
Values for geometry and position
Guideway | Preload class | |
|---|---|---|
V0, V1 | V2 | |
Parallelism, flatness and perpendicularity t | ||
μm | ||
TKSD20 (-U, -ADB, -ADK) | 9 | 6 |
TKSD25 (-U, -ADB, -ADK) | 11 | 7 |
TKSD30 (-ADB, -ADK) | 13 | 8 |
TKSD35 (-ADB, -ADK) | 15 | 10 |
TKSD45 (-ADB, -ADK) | 17 | 12 |
Locating heights and corner radii
For the design of the locating heights and corner radii, see table and ➤ Figure.
Locating heights, corner radii
Designation | Locating heights | Corner radii | ||
|---|---|---|---|---|
h1 | h2 | r1 | r2 | |
mm | mm | mm | mm | |
max. | max. | max. | ||
KUSE20 (-L, -H, -HL) | 5 | 4 | 1 | 0,5 |
KUSE25 (-L, -H, -HL) | 5 | 4,5 | 1 | 0,8 |
KUSE30 (-L, -H, -HL) | 6 | 5 | 1 | 0,8 |
KUSE35 (-L) | 6,5 | 6 | 1 | 0,8 |
KUSE45 (-L) | 9 | 8 | 1 | 1 |
Locating heights and corner radii
Accuracy
Accuracy classes
Six-row linear recirculating ball bearing and guideway assemblies are available in accuracy classes G1 to G3, ➤ Figure. The standard is class G3.
Parallelism of raceways to locating surfaces
The parallelism tolerance of the guideways is dependent on the accuracy classes, ➤ Figure.
In systems with Corrotect coating, there may be deviations in tolerances compared with uncoated units.
Accuracy classes and parallelism tolerances of guideways
Tolerances
The tolerances are arithmetic mean values, see table and ➤ Figure. They are relative to the centre point of the screw mounting or locating surfaces of the carriage.
The dimensions H and A1 should always remain within the tolerance irrespective of the position of the carriage on the guideway, see table.
Tolerances for height H and spacing A1
Tolerance | Accuracy | |||
|---|---|---|---|---|
G1 | G2 | G3** | ||
μm | μm | μm | ||
Tolerance for height | H | ±10 | ±20 | ±25 |
Difference in height** | ΔH | 5 | 10 | 15 |
Tolerance for spacing | A1 | ±10 | ±15 | ±20 |
Difference in spacing** | ΔA1 | 7 | 15 | 22 |
**Standard accuracy class.
**Difference between several carriages on one guideway, measured at the same point on the guideway.
Datum dimensions for accuracy
Units with Corrotect coating
For these units, the values for the appropriate accuracy class must be increased by the values for the coating, see table.
ACHTUNG
Coated systems are only available in the accuracy class G3.
Tolerances for coated parts
Tolerance** | Corrotect | |
|---|---|---|
RROC | ||
μm | ||
Tolerance for height | H | +6 |
Difference in height** | ΔH | +3 |
Tolerance for spacing | A1 | +3 |
Difference in spacing** | ΔA1 | +3 |
**Displacement in tolerance zone (guideway and carriage with coating).
**Difference between several carriages on one guideway, measured at the same point on the guideway.
Height sorting 2S
If there are particular requirements for the accuracy of parallel systems, it is possible to restrict the height tolerance by specific sorting.
The height difference ΔH2S is measured at the centre of the guideway (l/2). At this point, the height difference between all carriages of linear recirculating ball bearing and guideway assemblies supplied as a set is max. ΔH2S, ➤ Figure and table.
Height sorting 2S
Height difference in 2S
Height difference | Accuracy | ||
|---|---|---|---|
G1 | G2 | G3 | |
μm | μm | μm | |
ΔH2S** | 10 | 20 | 25 |
**Measured at the centre of the guideway.
Positional and length tolerances of guideways
The positional tolerances are not dependent on the guideway length, ➤ Figure and tables.
Positional and length tolerances of guideways
Length tolerances of guideways
Length tolerance | |||
|---|---|---|---|
Dependent on guideway length l | Multi-piece guideways | ||
mm | mm | ||
≦ 1 000 | 1 000 – 3 000 | ＞ 3 000 | |
–1 | –1,5 | ±0,1% | ±3 |
ACHTUNG
If the ordering designation does not specify delivery of the guideway as a single piece, the guideway can optionally be supplied as several segments. Permissible pitch, see table.
Segments for multi-piece guideways
Guideway length** | Maximum permissible number of segments | |||
|---|---|---|---|---|
mm | ||||
＜ | 3 000 | 2 | ||
| 3 000 | – | 4 000 | 3 |
| 4 000 | – | 6 000 | 4 |
＞ | 6 000 | 4 plus 1 segment of 1 500 mm | ||
**Minimum length of one segment = 600 mm.