SMC ML2B Series Hyrodless Monosashi Kun Stroke Reading Cylinder Instruction Manual

ML2B Series Hyrodless Monosashi Kun Stroke Reading Cylinder
Instruction Manual

PRODUCT NAME: HYRODLESS MONOSASHI-KUN
MODEL: ML2B Series

• READ THIS OPERATION MANUAL CAREFULLY BEFORE USE IT.

Specifications are subject to change without prior notice

Chapter 1: Read before Use

These safety instructions are intended to prevent a hazardous situation and/or equipment damage. These instructions indicate the level of potential hazard by label of “Caution”, ”Warning”, or ”Danger”. To ensure safety, follow the instructions below as well as ISO/IEC, JIS 1) and other safety laws 2).

injury or loss of life.

＊1) ISO 4414: Pneumatic fluid power – General rules relating to systems
ISO 10218-1: 2006: Robots for industrial environments – Safety requirements – Part 1: Robot
IEC 60204-1: Safety of machinery – Electrical equipment of machines – Part 1:General requirements
JIS B 8370: General Rules for Pneumatic systems
JIS B 9960-1: Safety of machinery – Electrical equipment of machines – Part 1: General requirements
JIS B 8433-1: 2007: Robots for industrial environments – Safety requirements – Part 1: Robot
＊2) Labor Safety and Sanitation Law etc.

Warning

1. The compatibility of pneumatic equipment is the responsibility of the person who designs the pneumatic system or decides its specifications.
   Since the products specified here are used in various operating conditions, their compatibility for the specific pneumatic system must be based on specifications or after analysis and/or tests to meet your specific requirements. Ensuring the initial performance and safety are the responsibility of the person who decides the compatibility of the pneumatic system. Pneumatic systems should be constructed after full review of the details of the products other than specifications and possibilities of failures by checking the latest product information.

2. Only trained personnel should operate pneumatically operated machinery and equipment. Assembly, handling, or repair of pneumatic systems should be performed by trained and experienced operators.

3. Do not service machinery/equipment or attempt to remove component until safety is confirmed.
   a. Inspection and maintenance of machinery/equipment should only be performed after confirmation of safe locked-out control positions.
   b. When equipment is to be removed, confirm the safety process as mentioned above. Cut the supply pressure for this equipment and exhaust all residual compressed air in the system.
   c. Before machinery/equipment is re-started, take measure to prevent shooting- out of cylinder piston rod etc.

4. Contact SMC and take necessary safety measures if the products are to be used in any of the following conditions:
   a. Conditions and environments beyond the given specifications, or if products are used outdoors.
   b. Installation on equipment in conjunction with atomic energy, railway, air navigation, vehicles, medical equipment, food and beverages, recreation equipment, emergency stop circuits, press applications, or safety equipment.
   c. An application which has the possibility of having negative effects on people, property, or animals, requiring special safety analysis.
   d. When used in an interlock circuit, dual interlock such as mechanical protection is necessary in case of accident. Periodical inspection is also necessary to confirm proper operation.

Operating and Storage Environments
Warning

1. Environments to avoid
   Avoid using or storing the products in the following environments which may cause failures.
   If the products need to be used or stored in those environments, take necessary measures.
   a. Place where ambient temperature exceeds the range of 5℃ to 60℃.
   b. Place where ambient humidity exceeds the range of 35% to 85% RH.
   c. Place where condensation occurs due to sudden temperature change.
   d. Place where atmosphere containing corrosive gas, flammable gas or organic solvent.
   e. Place where atmosphere containing conductive powder such as dust and iron chips, oil mist, salt, or organic solvent, or splashing cutting chips, dust and cutting oil (water , liquid) over the products.
   f. Place where the products are exposed to direct sunlight or radiated heat.
   g. Place where strong electromagnetic noise is generated (place where strong electric field, strong magnetic field or surge is generated).
   h. Place where static electricity is discharged or condition that the products have electrostatic discharge.
   i. Place where strong high frequency is gene-rated.
   j. Place where damages of thunder are expected.
   k. Place where vibration or impact is directly given to the products.
   l. Condition that the products are deformed by force or weight applied.

2. Do not close any objects which are affected by magnets.
   Since magnets are built in cylinders, do not close magnetic disks, magnetic cards or magnetic tapes. The data may be destroyed.

Precaution on Design
Warning

1. There is a possibility of dangerous sudden action by cylinders if sliding parts of machinery are twisted due to external forces, etc.
   In such cases, human injury may occur; e. g., by catching hands or feet in the machinery, or damage to the machinery itself may occur.

2. Provide a cover to minimize the risk of human injury.
   When a driven object or moving parts of a cylinder may cause the risk of human injury, design a structure to avoid contact with human body.

3. Securely tighten all stationary parts and connected parts of cylinders so that they will not become loose.
   Tighten cylinders securely especially when they are used in high frequency or in locations where direct vibration or impact shock, etc. will be applied to the body of the cylinder.

4. Deceleration circuits or shock absorbers are needed in some cases.
   If a driven object travels at a high speed or is heavy, impact will not be sufficiently absorbed only with the cylinder cushion. In such cases, use a circuit to decelerate the cylinder speed before the cushion becomes effective or use external shock absorbers to reduce impact. At this time, take the rigidity of machinery into account.

5. Consider possible drop of pressure in circuit due to power outage.
   For cylinders used in clamping mechanism, a work may become loose due to less clamping force by pressure drop in circuit at the time of power outage. Install safety devices to prevent human injury and machinery damage. Measures should be taken to prevent drop of hanging or lifting equipment.

6. Consider possible loss of power sources.
   Measures should be taken to protect against human injury and machinery damage in the event that there is a loss of air pressure, electricity or hydraulic power.

7. Design circuit to prevent shooting out of a driven object.
   A driven object is quickly shot out when pressure is supplied from one side of the piston after air in the cylinder is exhausted in such cases that cylinder is actuated by exhaust center type of directional control valve or started after residual air is exhausted from the circuit. At this time, human injury may occur; e.g., by catching hands or feet in the machinery, or damage to the machinery itself may occur. Therefore, the machine should be designed and constructed to prevent shooting out.

8. Consider emergency stops.
   Design the machinery so that human injury and/or damage to machinery and equipment will not be caused when machinery is stopped by a safety device under abnormal conditions, a power outage or a manual emergency stop.

9. Consider actions when operation is restarted after an emergency stop or abnormal stop.
   Design the machinery so that human injury or equipment damage will not occur upon restart of operation. When the cylinder is required to return to the initial position, provide the equipment with a safe override.

10. Construct the machinery so that moving objects and the moving parts of the cylinder with brake do not come into direct contact with the human body.

11. Use a balanced circuit in which lurching of the cylinder is prevented. When operation is locked in specified intermediate positions of the stroke, and air pressure is applied to only one side of the cylinder, the piston will lurch when the lock is released. This might cause injury or damage to machinery.

Selection
Warning

1. Confirm the specifications.
   The product in this manual is designed to be used only in industrial compressed air system. The product should not be used with pressures or temperatures outside the range of the specifications, as this may cause damage or malfunction, etc.

2. Intermediate stop
   When cylinder piston is stopped intermediately by 3-position closed center type of directional control valve, intermediate stop positions may not be as precise and exact as hydraulic operation due to comprehensibility of air. Valves and cylinders are not guaranteed for zero air leakage, and stop position may not be held in a long period of time. Consult SMC for long term holding of stop positions.

3. When a cylinder is in a no-load and locked state, the holding force (maximum static load) is the lock’s ability to hold a static load that does not involve vibrations or shocks. To ensure braking force, the maximum load must be set as described below.
   ① For constant static loads, such as for drop prevention:
   35% or less of holding force (Maximum static load)
   Note) For applications such as drop prevention, consider situations in which the air source is shut off, and make selections based on the holding force of the spring locked state. Do not use the pneumatic lock for drop prevention purposes.
   ② When kinetic energy acts upon the cylinder, such as when effecting an intermediate stop, there are constraints in terms of the allowable kinetic energy that can be applied to the cylinder in a locked state. Refer to the allowable kinetic energy of the respective series. Furthermore, during locking, the mechanism must sustain the thrust of the cylinder itself, in addition to absorbing the kinetic energy. Therefore, even within a given allowable kinetic energy level, there is an upper limit to the amount of the load that canbe sustained.
   – Maximum load for horizontal mounting: 70% or less of the holding force (Maximum static load) for spring lock
   – Maximum load for vertical mounting: 35% or less of the holding force (Maximum static load) for spring lock
   ③ In a locked state, do not apply impact, strong vibrations or rotational forces. Any impact, strong vibrations or rotational forces from external sources could damage or shorten the life of the lock unit.
   ④ Although the cylinder can be locked in both directions.

Caution

1. Mount speed controller and adjust cylinder operation speed gradually from low speed to a desired speed.

Air Supply
Warning

1. Do not use the product out of the specified ranges for pressure and temperature to pre-vent equipment damage and malfunction.
   ① Operating pressure:
   Actuating part: 0.1 – 1.0MPa
   Braking part: 0.3 – 0.5MPa
   ② Fluid & ambient temperature: 5 to 60ºC

2. Use clean air.
   Do not use the product with compressed air includes chemicals, synthetic materials(including organic solvents), salinity, corrosive gases, etc., as this may cause damage or malfunction.

Caution

1. Install air filter.
   Install air filter before and in vicinity of valve. The filter should be able to collect particles of 5 microns or smaller. A large quantity of drain may cause malfunction of pneumatic components.

2. Install after cooler, air dryer, auto drain, etc.
   Compressed air that includes excessive condensate may cause malfunction of valve and other pneumatic equipment. To prevent this, install after cooler, air dryer, auto drain, etc.

Pneumatic circuit
Warning

1. Be certain to use a pneumatic circuit which will apply balanced pressure to both sides of the piston when in a locked stop. (Refer to Chapter 6 for recommended pneumatic circuit.)
   In order to prevent the cylinder lurching after a locked stop, use a circuit which applies balanced pressure to both sides of the piston when restarting or when manually releasing the lock, thereby canceling the force generated by the load in the direction of piston movement.

2. Use a solenoid valve for unlocking which has a larger effective area, as a rule 50% or more of the effective area of the cylinder drive solenoid valve.
   (Refer to Chapter 6 for recommended pneumatic components.)
   The larger the effective area is, the shorter the locking time will be, and stopping accuracy will be improved.

3. Place the solenoid for unlocking close to the cylinder, and no farther than the cylinder drive solenoid valve.
   The shorter the distance from the cylinder, the shorter the overrun amount will be, and stopping accuracy will be improved.

4. Allow at least 0.5 seconds from a locked stop (intermediate stop of the cylinder) until release of the lock.
   When the locked stop time is too short, the piston rod may lurch at a speed greater than the control speed of the speed controller.

5. When restarting, control the switching signal for the unlocking solenoid valve so that it acts before or at the same time as the cylinder drive solenoid valve.
   If the signal is delayed, the piston rod may lurch at a speed greater than the control speed of the speed controller.

Installation
Warning

1. Connect the slider end and the load with the lock released.
2. Ensure that the equipment operates properly before the use.
3. Operation manual
   Do not install the products unless the safety instruction have been read and understood. Keep this operation manual on file for future reference.

Caution

1. Maintenance space
   When installing the products, allow space for maintenance.

2. Do not give strong impact and/or excessive moment when work is mounted.
   External force other than allowable moment may cause rattle at guide part and/or increase in sliding resistance.

3. Be careful to avoid scratches or dents, etc. on the sliding sections of the slider.

Wiring
Warning

1. Preparation for wiring
   Shut off the power before wiring (including insertion and removal of connectors). Mount a protective cover on the terminal block after-wiring.

2. Check the power
   Make sure the power has sufficient capacity and voltages are within the specified range before wiring.

3. Grounding
   Ground terminal block F.G. (Frame Ground). Do not ground it with devices generating strong electromagnetic noise.

4. Check wiring
   Incorrect wiring may cause damage or malfunction of the products. Make sure the wiring is correct before operation.

Caution

1. Separation of signal wires from power wire
   Avoid common or parallel wiring of signal and power wires to prevent malfunction due to noise.

2. Wiring arrangement and fixation
   Avoid bending cables sharply at connector part or electrical entry in wiring arrangement.
   In-proper arrangement may cause disconnection which in turn causes malfunction. Fix cables close enough not to give excessive force to the connector.

Piping
Caution

1. Before piping
   Remove cutting chips, cutting oil, dust, etc. in piping by flushing or cleaning before piping. Care should be taken especially that any cutting chips, cutting oil, dust, etc. do not exist after a filter.

2. At piping
   ① Foreign matter should not enter. Entering of foreign matter will cause malfunction.
   ② Cutting chips and sealing materials at piping threads should not enter valves when piping and fittings are screwed in. Leave 1.5 to 2 threads when seal tape is used.

Lubrication
Caution

1. Lubrication of cylinder
   ① This cylinder is pre-lubricated and can be used without lubrication.
   ② In case of lubrication, use a equivalent of the turbine oil type 1 ISO VG32. Once lubrication is performed, it should be continued since the initial lubricant flows out causing malfunction.

Adjustment
Caution

1. The locks are manually disengaged when the cylinder is shipped from the factory. Be sure to change them to the locked state before using the cylinder.
2. Adjust the cylinder’s air balance. In the state in which a load is attached to the cylinder, disengage the lock and adjust the air pressure on the rod side and the head side of the cylinder to obtain a load balance. By maintaining a proper air balance, the piston rod can be prevented from lurching when the lock is disengaged.
3. Adjust the mounting position of detection devices such as auto-switches.

Sensor unit
Caution

1. Do not remove the sensor unit.
   The position and sensitivity of the sensor is adjusted properly before shipment.
   Removing or replacing the sensor may cause malfunction.

2. Operate the system with an external magnetic field of 14.5mT or less.
   Strong magnetic field in the vicinity may cause malfunction, since ML2 sensor is magnetic type.
   This is equivalent to a magnetic field of approximately 18 cm in radius from a welding area using a welding current of almost 15,000 amperes. To use the system in a magnetic field that exceeds this value, use a magnetic material to shield the sensor unit

3. Do not pull sensor cable strongly.
   Such action may cause failure.

4. Water shall be kept away from the sensor unit to avoid failure.

5. Power supply line
   Do not mount any switch or relay to power supply line (12 VDC).

Measurement
Caution
SMC products are not intended for use as instruments for legal metro logy.
Measurement instruments that SMC manufactures or sells have not been qualified by type approval tests relevant to the metro logy (measurement) laws of each country. Therefore, SMC products cannot be used for business or certification ordained by the metro logy (measurement) laws of each country.

Maintenance and Check
Warning

1. Performing regular check
   Check regularly that the products do not operate with failures unsolved. Check should be done by trained and experienced operators.

2. Dismantling of product and supply/exhaust of compressed air.
   Before dismantling, ensure that drop preventing and runaway preventing treatments are properly provided, shut the power source of air supplied, and exhausts compressed air in the system. When starting operation again, operate the product with care after ensuring that a treatment for preventing extrusion is properly provided.

3. Prohibition of disassembly and modification
   To prevent accidents such as failures and electric shocks, do not remove the cover to perform disassembly or modification. If the cover has to be removed, shut off the power before removal.

4. Disposal
   Request a special agent for handling industrial waste to dispose the products.

Chapter 2: General Description/Features

2-1 General Description
Positioning with high reproducible has been realized by Hyrodless Mononucleosis, which brake and stroke sensor are installed in mechanical joint type godless cylinder (MY1B Series). (Stopping accuracy is ±0.5mm when specified controller. CEU2, is used.)
2-2 Features
Brake Structure

• Adoption of integrated pneumatic and spring
  Slider stops instant due to quick response of brake. Also the current position is hold by spring lock when the air pressure is lowered or the compressed air is stopped.

• Lock is possible for both directions
  Lock is possible for reciprocation of cylinder stroke.

• Easy maintenance
  Brake can be replaced and disassembled, and can be opened manually for its unit structure.

• Brake structure which does not give a load on cylinder
  Slider can be stopped without losing its performance since brake does not give a load on cylinder for its structure, which spring acts on brake shoe directly to put between upper and lower brake plates.

Scale

• Minimum measuring unit : 0.1mm
  This is measured by scale plate and detection head built-in body.

Chapter 3: System Configuration

3-1 System Configuration
HYRODLESS MONOSASHI-KUN (ML2 Series) can be used for measurement or to prevent falling besides positioning application.

| Model type| Function| Connected equipment| Application
---|---|---|---|---
Brake| Scale| Keeping| Intermediate stop| Measurement| Positioning
①| ML2B※| | | CEU1| | | |
②| ML2B※| | | CEU2| | | |
③| ML2B※S| | | CEU1| | | |
④| ML2B※B| | | Sequence, etc.| | | |

3-2 Example of system Configuration

• For Keeping
  Hyrodless Monosashi-kun + Counter
  3 points preset counter : CEU1 Series

• For precise positioning (Stopping accuracy ±0.5mm)
  Hyrodless Monosashi-kun + Controller
  Controller : CEU2 Series

3-3 Pneumatic Circuit
< Air Circuit Diagram>

| Sol.1| Sol.2| Sol.3
---|---|---|---
A| ON| OFF| ON
B| OFF| ON| ON
Stop| OFF| OFF| OFF

Pneumatic Equipment

• Air Balance
  ・ With the above circuit, maintaining the slider at center by balancing both sides (left & right) supply pressure to achieve air balance state.
  ・ At the situation of vertical mounting, maintain the slider at the center and reduce the upper portion’s supply pressure accordingly to counter for the weight due to gravity. If air balance is not achieved, motion after center positioning will be either accelerating abnormally or false movement. Hence, the accuracy of positioning will be affected.

• Tubing
  ・ Use larger diameter’s tube and reduce the tubing length between solenoid valve and cylinder, so as to increase position determination’s precision.
  ・ Connect brake valve near to slider. If tubing between brake valve and slider is long, its motion response time will be slower. Moreover, it may rush vigorously when brake is released.
  ・ During installation, connected tubing should be flushed thoroughly, and prevent dust and chips from entering into cylinder.

• Supply Pressure
  ・ Set brake release port’s supply pressure as 0.3~0.5MPa. With supply pressure of below 0.3MPa, brake’s release will not be activated. While with pressure of above 0.5MPa, brake’s life span will be shortened.
  ・ Direct pressure supply from pressure line will cause pressure variation problem and thus, affect cylinder performance. Hence, it is advisable to connect regulator before driving and brake solenoid valve. Besides that, if there is a lot of cylinder activated and moving at the same time, use regulator with larger flow characteristic and install air tank.
  ・ Connect head cover tubing wisely with consideration of surrounding conditions.

The most suitable tubing can be selected according to the situation when tubing head cover.

Note:

1. Tubing should be group according to the grouping in the table above, 6 on each sides.
2. SMC’s one-touch speed controller can be mounted directly on tubing No.1,2,4 and 5.

Installation dimension of bottom face

| φ25,φ32| φ40
---|---|---
O-ring| C9| C11.2
φA| φ6| φ8

Chapter 4: Operating Principle

4-1 Operating principle of brake

Brake operation
Spring force caused by brake spring and the air pressure supplied from brake operating port work on brake shoe 1 fixed with brake holder, bend brake plate fixed on head cover on both sides, and stop slider by putting brake plate between brake shoe 1 and brake shoe 2 fixed on the slider side.
Brake release
The air pressure supplied from brake releasing port work on diaphragm, decline brake spring, and cancel brake.

Chapter 5: Selecting Procedure

5-1 Precaution
Be sure to check with the procedure below before using Hyrodless Monosashi- kun. For positioning with CEU2, check with the procedure of “Operation Manual of Brake Positioning System (Rod less type)”.

5-2 Selecting Procedure
Follow the procedure below to select the most suitable ML2 series.
As allowable moment, maximum movable load, and allowable kinetic energy vary with the conditions, such as mounting position, piston speed, and with / without guide,

1. maximum movable load,
2. static moment,
3. dynamic moment (during impact with stopper and locking), and
4. allowable kinetic energy should be considered so that the total amount of load factor will not exceed 1 (∑an≦1) when calculating allowable load. (In the case of ∑an＞1, select a cylinder with larger bore size.) When positioning is necessary, maximum speed should be not more than 500mm/s.

Operating Condition
W: Load (N)
Va: Average Speed (mm/s)
P: Operating Pressure (Mpa)
Mounting Direction:
Guide:
Impact Absorption:
Auto switch:

5-3 Selection Information