DF Series Manual
DF Series Manual Version 1.4 27.09.2016 DF Series Manual Version 1.4 27.09.2016 2/60
Inhalt 1 Introduction... 5 1.1 Manufacture... 5 2 Safety instruction... 6 3 Quickstart guide... 7 3.1 Unpacking and installation... 7 3.2 Webbrowser... 8 3.3 Network connection... 9 3.4 Network settings [Windows 7]... 10 3.5 Proxy configuration [Windows 7]... 13 3.6 Web interface... 16 4 Mounting... 17 4.1 Placement... 18 5 Website guide... 20 5.1 Homepage... 21 5.2 Signalbar... 24 5.3 Newdata... 25 5.4 Power supply... 26 5.5 Alarm settings... 27 5.6 Torquemeter... 28 5.7 Measuring 1... 29 5.8 Analog settings... 30 5.9 Frequency settings... 31 5.10 Filter settings... 31 5.11 CAN settings... 32 5.11.1 CAN state... 33 5.11.2 CAN configuration... 34 5.12 State... 37 5.13 Ethernet settings... 38 5.14 General settings... 39 5.15 Service page... 40 6 Technical specs... 41 6.1 Pinallocations... 41 6.2 X770 Power supply / Frequency output... 41 6.3 X771 Analogue / CAN / Alarm / Input... 42 6.4 X772 Ethernet... 43 6.5 X773 Central cable... 43 6.6 General technical data... 44 6.7 High resolution speed encoder option... 45 6.8 Mechanical data... 46 DF Series Manual Version 1.4 27.09.2016 3/60
6.8.1 Single sided clutch device... 47 6.8.2 Dimension rotor DF standard type [mm]... 48 6.8.3 Dimension stator... 50 6.8.4 Dimension TCUIV... 51 6.8.5 Dimension with couplings... 51 6.8.6 Torque and acceleration... 56 DF Series Manual Version 1.4 27.09.2016 4/60
1 Introduction Dear customer, before leaving our company every unit is tested by extensive function and quality examinations, which guarantee that the system complies with the stated specifications. Nevertheless should there be any problem, please contact us. Before shipping a system, the serial number of each component of your configuration is registered by our company, so that an individual and short-term support can be guaranteed. It is understood that we will inform you about innovations and modifications of the system 1.1 Manufacture Konrad-Zuse-Str. 3 52477 Alsdorf Phone: +49 (0) 2404 9870-0 Fax: +49 (0) 2404 9870-59 info@atesteo.com www.atesteo.com DF Series Manual Version 1.4 27.09.2016 5/60
2 Safety instruction The Manual must be read carefully before start-up, maintenance work or any other work on the torque measuring system. Prerequisite for the safe and proper handling of the equipment knows all safety instructions and safety regulations of the attachment. Every safeguard needs to be correctly mounted and fully functional before any start-up. Measurement shafts mounted to the torque meter must be properly designed, so that critical bending speed is avoided. Exclusively qualified laborers are allowed to do maintenance work on any electrical components. Note Improper use and handling as well as constructional changes will invalidate the EC declaration of conformity. DF Series Manual Version 1.4 27.09.2016 6/60
3 Quickstart guide 3.1 Unpacking and installation The package contains the following items 1 : 1. Torque meter (Rotor) 2. DF-Stator 3. TCU IV (Torque Control Unit) 4. Central cable 5. 12-pin connector 6. 16-pin connector 1. 2. 3. Follow the next instructions to connect the system. Mount torque meter and antenna as described in the 2 Mounting guide Connect DF-Stator and TCU IV with the central cable Connect the 12-pin and 16-pin connectors to the TCU IV Note Pin allocations are specified under 4 TECHNICAL SPECS Important Power supply pins are mandatory. Power supply rating: 24V±1V/1A 1 Depending on your order he delivery content can vary DF Series Manual Version 1.4 27.09.2016 7/60
3.2 Webbrowser One of the following web browsers is required, to use the web interface: Firefox http://www.mozilla.org/en-us/firefox/all/a https://www.google.com/intl/de/chrome/browser/index.html?standalone=1#eula Chrome http://windows.microsoft.com/de-de/internet-explorer/ie-11-worldwidelanguages Internet Explorer If none of the browsers is installed yet, follow the instruction after downloading the browser. Note Please use the latest version of the browser DF Series Manual Version 1.4 27.09.2016 8/60
3.3 Network connection Before startup ensure that the TCU IV is connected properly. Please check: Central cable of Receiver Correct Position of Receiver Power supply connection Requires: Patch cable with RJ45 connector Three options to connect to network: 1. Connect in domain network: Connect the TCU IV using the patch cable with a free network socket. 2. Connect with network-to-usb adapter: The adapter needs to be installed on the computer. Now connect TCU IV with a patch cable to the adapter. 3. Connect directly Connect with a patch cable directly from the Ethernet socket of the computer. DF Series Manual Version 1.4 27.09.2016 9/60
3.4 Network settings [Windows 7] Network settings need to be changed, if option one or two is selected. 1. Open Control Panel 2. Navigate to Network and Sharing Center 3. Open the Status window of the connection 4. To open Connection Properties click on 5. Select Internet Protocol Version 4 and click on 6. Enter the following values a. IP address: 172.16.86.2 b. Subnet mask: 255.255.255.0 Note Administrator rights are required DF Series Manual Version 1.4 27.09.2016 10/60
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3.5 Proxy configuration [Windows 7] 1. Open Control Panel 2. Navigate to Internet Properties 3. Choose the Connections tab 4. Click on 5. Navigate to Proxy Settings by clicking 6. Input the new proxy exception a. Proxy exception: 172.16.86.* DF Series Manual Version 1.4 27.09.2016 13/60
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4. LAN Settings 5. Proxy Settings DF Series Manual Version 1.4 27.09.2016 15/60
3.6 Web interface The web address of the TCU IV is needed to open the web interface. The web address contains of "torque20-" and [SERIAL NUMBER]. Use the following IP address to open the web interface: http://172.16.86.3, Or use the following web address (requires a DNS-Server): http://torque20-[serial NUMBER] The serial number can be seen on the type label of the TCU. Note Type in the serial number without "[ ]" and ignore "TCUIV-" on the type label. DF Series Manual Version 1.4 27.09.2016 16/60
4 Mounting Mounting torque meter with input side to drive train. Type Amount of screws Tightening torque DF1 6x M8 12.9 43 Nm DF2 8x M10 12.9 84 Nm DF3 8x M12 12.9 145 Nm DF4 8x M14 12.9 235 Nm DF5 8x M16 12.9 365 Nm DF Series Manual Version 1.4 27.09.2016 17/60
4.1 Placement Outer edge oft he flange The DF stator must be positioned under the measuring flange that the output flange of the rotor covers the black area of the stator. Note: Radial air-gap between receiver and torque-meter: 3mm +1mm /-2mm. Axial displacement of black area: ±1mm DF Series Manual Version 1.4 27.09.2016 18/60
The following images show the placement options with and without the speed option. Optimal 6mm DF Series Manual Version 1.4 27.09.2016 19/60
5 Website guide LOGIN Web interface is opened as described in the quick start guide. The login password must be entered. By default the password is: admin. Important The password can be changed in the menu item Settings. Protect your device against unauthorized access! DF Series Manual Version 1.4 27.09.2016 20/60
5.1 Homepage The login leads to the homepage. Device information: This overview of currently connected devices includes information about the name of the TCU and the serial number of the stator and the torque sensor. The device name is editable in the Settings menu. Measurement features. The measuring signal is set to zero by pushing the button. The test signals are enabled or disabled by the buttons. DF Series Manual Version 1.4 27.09.2016 21/60
Test signal [controller] generates a full-scale deflection on every system output independent of the measured inputs. Test signal [torque sensor] generates a half-scale deflection at the torque sensor of torque input 1 and 2. The deflection is generated by an offset jump of the first amplifiers of the respective measurement chain. Note: Test signals must be disabled before measuring DF Series Manual Version 1.4 27.09.2016 22/60
Graph overview Diverse signals are displayed in the main part of the home page. These signals graphically represent Torque input 1, Torque input 2 2, Acceleration input 1, the Speed input 1 and the Temperature of the torque sensor. Graphs are automatically scaled according to their nominal value. Note Signals are not displayed in real-time. This may lead to delayed representations. Navigation menu If the navigation bar is closed, click on the company logo to open it again. 2 Depending on the configuration of the current system DF Series Manual Version 1.4 27.09.2016 23/60
5.2 Signalbar The signal bar is shown on the right-hand side of the website. General states B A C The General tab contains information about the transmission of the system. The LED Transmission quality provides information about transmission quality of measured data from torque meter to torque control unit. The Sensor supply LED indicates the status of the torque sensor supply voltage. Alarm states Alarm values are displayed in the Alarm section. Red indicates that threshold is exceeded. Alarms can be reset by pressing button. Alarm limits can be set in the Alarm settings menu. Measured data Below the alarm states the measured data of the different system inputs Torque input 1, Torque input 2 3, Acceleration input 1, Speed input 1, Power supply torque sensor, Power supply controller and torque sensor Temperature are displayed numerical. Note Signals are not displayed in real-time. This may lead to delayed representations. Important Check the supply voltage and the orientation between torque sensor and stator-antenna to guarantee an optimal transmission quality. A B C Optimal (green) Okay (yellow) Bad (red) Transmitting (green) No Transmitting (gray) Value below Threshold (green) Value above Threshold (red) 3 Depending on the configuration of the current system DF Series Manual Version 1.4 27.09.2016 24/60
5.3 Newdata In the case that another torque meter is connected, the adjusted values of the torque meter and the TCU IV are compared. If the values are different following dialog appears: By pressing the button, the values of the torque meter are transferred to the TCU IV. The outputs are adjusted accordingly. DF Series Manual Version 1.4 27.09.2016 25/60
5.4 Power supply In the menu Power supply the supply voltage of the torque sensor will be adjusted. The power-switch activates and deactivates the power supply. On activation the last adjusted voltagevalue will be reactivated. Because the inductively transmitted power depends on the gap between torque sensor and stator-antenna the supply voltage has to be readjusted after change of position. The optimal supply voltage of the torque sensor is 9.5 V +/- 0.5 V. There are 2 methods for adjusting: 1. By pressing the button, the optimal supply voltage is automatically set. 2. The torque sensor voltage is set manually with the slider. Changes are applied in realtime. The further the slider is moved to the right, the higher the torque sensor supply voltage gets. In the following section, the influence of the torque sensor voltage to the signal quality is shown: Sensor voltage LED Sensor supply Description 9,5 V ± 0,5 V Green Optimal supply voltage 9,5 V ± 1,0 V Yellow Supply voltage is ok. Possibly interrupted transmission, if the supply voltage vary to much during the operation of the test bench 9,5 V ± > 1,0 V Red Poor supply voltage. Possibly interrupted transmission, possibly invalid measurement values Important The optimal torque sensor supply voltage should be at 9.5V. Power supply will be deactivated and set back to zero, if a critically value is adjusted, in order to prevent damage of inductive power supply components. DF Series Manual Version 1.4 27.09.2016 26/60
5.5 Alarm settings Alarm thresholds for speed 4, acceleration 1 and torque can be adjusted. Torque input limit An alarm for the torque signal can be set. Alarm is triggered when threshold is exceeded. In dual range systems only the large measurement range 1 is observed. Speed input limit 1 An alarm for the speed signal can be set. Alarm is triggered when threshold is exceeded. Acceleration input limit 1 An alarm for the acceleration signal can be set. Alarm is triggered when threshold is exceeded. 4 Depending on the configuration of the current system DF Series Manual Version 1.4 27.09.2016 27/60
5.6 Torquemeter Important Output switch 5 Improper values can falsify measurements or in worst case damage the measurement device. Proper values can be found in the test report. Output signals can be swapped. The output swap affects the following outputs: Effects of the output swap Output Website output Frequency output 1 Analog output (voltage) 1(*) Analog output (current) 1(*) CAN output 1 State Swapped Swapped Swapped Not swapped Not swapped (*) Only output 1 and output 2 Input settings Rated torque and sensitivity of the measurement system can as well as Torque input 1 and Torque input 2 1 be adjusted. 5 Depending on the configuration of the current system DF Series Manual Version 1.4 27.09.2016 28/60
5.7 Measuring 1 The Measuring Menu appears if the system measures acceleration. Data input is performed as described in the previous chapter. DF Series Manual Version 1.4 27.09.2016 29/60
5.8 Analog settings Voltage 6 range of analog outputs can be adjusted. Current 1 range of analog outputs can be adjusted. Output calibration Outputs must not be calibrated by an untrained user. Incorrect values can falsify the measurement. Outputs are calibrated at the factory and usually do not need to be recalibrated. 6 Depending on the configuration of the current system DF Series Manual Version 1.4 27.09.2016 30/60
5.9 Frequency settings Diverse output ranges can be set in the menu item Frequency. Output 1 to 2 1 can be configured. Output calibration Outputs must not be calibrated by an untrained user. Incorrect values can falsify the measurement. Outputs are calibrated at the factory and usually do not need to be recalibrated. For further information please contact our support. 5.10 Filter settings The filter-settings influences the input signal. The filter is a digital IIR filter 1st order and is related to the torque input channels. For each input channel, the filter can be activated and the cut-off frequency can be set in the corresponding dropdown-box. The following cut-off frequencies between 1 Hz and 4000 Hz are supported: 1 Hz, 10 Hz, 50 Hz, 100 Hz, 150 Hz, 250 Hz, 500 Hz, 1000 Hz, 2000 Hz and 4000 Hz. The button is clicked to save the settings. DF Series Manual Version 1.4 27.09.2016 31/60
5.11 CAN settings CAN communication can be configured in the CAN menu. Scaling factor Received torque values need to be divided by the scale factor manually by the user. DF Series Manual Version 1.4 27.09.2016 32/60
5.11.1 CAN state CAN transmission is enabled and disabled by toggling the button. The CAN State tab also contains information about the current state of the CAN bus. The different states are explained in the following sections. MODULE_ACTIVE: The CAN bus is working without any significant problems. The receive error counter (RX) and the transmit error counter (TX) are < 128. MODULE_PASSIV: The CAN bus works, however, a transmission or reception error occurred. TX or RX is > 127. In case that no more errors occurred, the counters are decremented and the status changes to MODULE_ACTIVE. Otherwise, the bus should be checked. BUS_OFF: The CAN module has been disconnected due to many transmission errors (TX > 255).Check the CAN settings and perform a CAN reset. INIT_ERROR: The CAN module cannot connect to the CAN bus. Check the CAN settings and perform a CAN reset. NOTE: CAN State can be reset by switching the output off and on again. DF Series Manual Version 1.4 27.09.2016 33/60
5.11.2 CAN configuration The general CAN transmission can be configured. Selected values need to fit the values of the current receiver system. Baud (250kbit, 500kbit, 1Mbit) Transmit interval (between 1 and 1000 ms) Data format (Intel, Motorola) Identifier-Length (11 Bit, 29 Bit) Send configuration DF Series Manual Version 1.4 27.09.2016 34/60
CAN messages are formatted (dependent on configurations) in the following way: Intel Data byte 0-3 Data byte 4-7 Identifier D0 D1 D2 D3 D4 D5 D6 D7 CAN-Identifier Torque 1 x Factor Torque 2 x Factor CAN-Identifier Speed 0 Motorola Identifier D3 D2 D1 D0 D7 D6 D5 D4 CAN-Identifier Torque 1 x Factor Torque 2 x Factor CAN-Identifier Speed 0 DF Series Manual Version 1.4 27.09.2016 35/60
Four CAN messages at most can be configured. CAN Messages can be enabled and disabled. Messages one, two and three can be manually chosen and adjusted. The fourth message cannot be configured. It is reserved for watchdog and state and the transmit interval is fixed at 1000ms. Receive configuration The receiving identifier for CAN message can be chosen. The following CAN messages can be received: Messages Type Hex Dec Zero 0x4B1 1201 Test signal (on) 0x4B2 1202 Test signal (off) 0x4B3 1203 MD1/MD2 0x4B5 1205 MD2/MD1 0x4B6 1206 State reset 0x4BB 1211 Request state 0x4BC 1212 Power supply (off) 0x514 1300 Power supply (on) 0x515 1301 Alarm reset 0x578 1400 Request Ethernet settings 0xD05 3333 The command must be included in the first 4 bytes [data bytes 0-3]. While receiving, distinction is made between Motorola and Intel. A response message is sent if a message is successfully received. The response massage is formatted in the following way: Response message Identifier Data byte [0-3] Data byte [4-7] receive identifier +1 last command state DF Series Manual Version 1.4 27.09.2016 36/60
GENERAL STATES MEASUREMENT STATES ERROR STATES 5.12 State The status word is a 16-bit long data word, and is structured in the following way: STATE DESCRIPTION Bit alarm rx aborted transmission 15 alarm md exceeded the torque threshold 14 alarm n exceeded the speed threshold 13 alarm acc exceeded the acceleration threshold 12 signal quality poor signal quality 11 current error shutdown due overcurrent 10 current warning excessive current. current error in 4 minutes md2/md1 channel switch is active 8 9 zero zero adjustment was performed 7 test mode torque sensor test signal is on 6 test mode TCU test signal is on 5 - reserved 4 - reserved 3 - reserved 2 - reserved 1 power power supply is active 0 DF Series Manual Version 1.4 27.09.2016 37/60
5.13 Ethernet settings Relevant adjustments for embedded measurement system in the intranet can be configured. Important Improper settings can break the device. In some cases the device cannot be reconfigured! In that case the torque control unit must be reprogrammed in factory. Administration must be consulted before configuring to get the proper settings. If the network settings of the TCU have been forgotten, the settings can be queries via the following CAN command: Messages Type Hex Dec Request Ethernet settings 0xD05 3333 The response of the TCU has the following structure: Type IP Address Subnet Mask Byte i Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Content (HEX) Result (DEC) AC 10 56 2 FF FF FF 0 172 16 86 3 255 255 255 0 DF Series Manual Version 1.4 27.09.2016 38/60
5.14 General settings A password and a custom name for the measurement system can be adjusted. Following characteristics must be fulfilled: Total length between 4 and 8 signs At least one upper-case letter At least one lower-case letter At least one digit Important Write down your password and keep it in a safe place. The password cannot be set back to default! DF Series Manual Version 1.4 27.09.2016 39/60
5.15 Service page The up to date firmware version of the device and manufacturer s contact details can be found on the Service page. For service purposes, it s also possible to export a list of system parameters. DF Series Manual Version 1.4 27.09.2016 40/60
6 Technical specs 6.1 Pinallocations 6.2 X770 Power supply / Frequency output 12-pin connector, type M23 Pin Signal Description Cable color (cable optional) Cross- Section in mm 1 F2_out- * 1 Frequency output ch. 2 RS422 White 0,25 2 F2_out+ * 1 Brown 0,25 3 N2_out+ * 1 Speed pulses output track 2 Gray 0,25 4 N2_out- * 1 RS422 Pink 0,25 5 N1_out+ * 1 Speed pulses output track 1 Blue 0,25 6 N1_out- * 1 RS422 Red 0,25 7 F1_out- Frequency output ch. 1 RS422 Yellow 0,25 8 F1_out+ Green 0,25 9 Aux_in Not used TTL 3.3 or TTL 5.0 White 0,5 10 Power+ Supply voltage Green 0,5 11 Power- 24-30 V / 1 A Yellow 0,5 12 Digital GND Ground connection of digital signals Brown 0,5 DF Series Manual Version 1.4 27.09.2016 41/60
6.3 X771 Analogue / CAN / Alarm / Input 16-pin connector, type M23 1 Test_in Activate pos. full range of all outputs White 0,25 TTL 3.3 or TTL 5.0 2 Zero_in Zero balance input TTL 3.3 or TTL Brown 0,25 5.0 3 Digital GND Ground connection of digital signals Green 0,25 4 Digital GND Yellow 0,25 5 CAN_H CAN HIGH connection Grey 0,25 6 CAN_L CAN LOW connection Pink 0,25 7 An4_out * 1 Galvanic isolated analog voltage output Blue 0,25 8 An2_out * 1 Galvanic isolated analog voltage output Red 0,25 9 An3_out * 1 Galvanic isolated analog voltage output Black 0,25 10 An1_out * 1 Galvanic isolated analog voltage output Purple 0,25 11 Alarm MD_out Alarm torque limit open-collector Grey/Pink 0,25 12 Analog GND Ground connection of analog signals Red/Blue 0,25 13 Alarm N_out Alarm speed limit open-collector White/Green 0,25 14 Alarm Rx_out Alarm receiving limit open-collector Brown/Green 0,25 15 Alarm Reset_in Reset all alarms TTL 3.3 or TTL 5.0 White/Yellow 0,25 16 IP Reset_in Coming soon Yellow/Brown 0,25 DF Series Manual Version 1.4 27.09.2016 42/60
6.4 X772 Ethernet Can be connect with a standard Kat 5e cable for diagnostics or setup. For permanent installation inside the teststand use the special connector. Hummel - 7R10400000 6.5 X773 Central cable 15-pin connector, type M16 not for external periphery Pin Signal Description Cable color Cross-Section in mm / typ A Power+ Supply voltage White 0,5 / straight B Power- * 2 Brown 0,5 / straight C 7V-Power+ Green 0,5 / straight 1 Data-in+ Digital rotor data LVDS White 0,25 / twisted 2 Data-in- Brown 0,25 / twisted 3 7V-Power- * 2 Supply voltage (Reserved) NC 0,25 / twisted 4 N2- Speed-pulses track 2 Green 0,25 / twisted 5 N2+ Yellow 0,25 / twisted 6 N1- Speed-pulses track 1 Grey 0,25 / twisted 7 N1+ Pink 0,25 / twisted 8 PICUP Frequency pic up NC NC for analog systems (Reserved) 9 PICLVOUT+ System diagnostic (Reserved) NC NC 10 PICLVOUT- NC NC 11 PICLVIN+ NC NC 12 PICLVIN- NC NC * 1 Optional depending on the configuration of the system * 2 Pin B and Pin 3 are connected together in the circuit-board of the stator-antenna The following applies to double channel systems: Channel 1 corresponds to the measuring channel with the lower rated torque. Channel 2 corresponds to the measuring channel with the higher rated torque. DF Series Manual Version 1.4 27.09.2016 43/60
6.6 General technical data Type DF1S DF2S DF3S DF4S DF5S Single Range Operation Rated Torque Mn nom Nm 1) 50 2) 100 3) 200 4) (500) Measuring range % of Mn nom 120 Accuracy class % 0.05 1) (200) 2) 500 3) 1000 1) (1000) 2) 2000 3) 3000 1) 4000 2) 5000 Nominal speed rpm 20000 2000 15000 12000 10000 Rel. standard deviation % FSO 0.03 of repeatability Overload rating % 300 Temperature influence on zero point TK0 Temperature influence on nominal value TKC Signal span frequency output Signal span voltage output Signal span current output (option) Rated Temperature C 10 70 Range Zero point stability at % FSO 0.03 reference temperature (48h) Operating temperature C 0 85 range Measurement frequency khz 3 range, -3dB, at zero frequency of 60kHz Protection Class IP 54 % 0.05 FSO/10 K % 0.05 FSO/10 K khz 10 ± 5 60 ± 20 60 ± 30 240 ± 120 V 0 ± 5 0 ± 10 2,5 ± 2,5 5 ± 5 ma 12 ± 8 1) (5000) 2) 10000 DF Series Manual Version 1.4 27.09.2016 44/60
Type DF1S DF2S DF3S DF4 S DF5S Dual Range Operation Smallest second range 1:5 Accuracy Class for each range Overload Rating % of high range 6.7 High resolution speed encoder option 0.05 300 Type DF1S DF2S DF3S DF4S DF5S Measurement principle Magnetized speed encoder with high resolution sensor head Output signal V 2 square wave signals 90 degree phase shifted, 5V (RS422) Nominal pulses per ppr 680 808 1 000 1 176 1 448 revolution Minimum pulse number ppr 340 404 500 588 724 (option) Maximum pulse number ppr 1 360 1 616 2 000 2 352 2 896 (option) Reference Pulse on request Maximum counting rpm 14 000 11 000 9 000 8 000 6 000 speed Maximum allowable rpm 14 000 11 000 9 000 8 000 6 000 speed Cyclic error arc sec ± 30 Max. counting frequency khz 8 Max. axial displacement mm 1 between encoder and sensor Airgap Encoder Sensor mm 0,1-1 DF Series Manual Version 1.4 27.09.2016 45/60
6.8 Mechanical data Ty pe DF1 DF2 DF3 DF4 DF5 Maximum rated torque Alternating torque Nm 1) 50 2) 100 3) 200 4) 500 Nm 1) 200 2) 500 3) 1000 1) 1000 2) 2000 3) 3000 equal selected maximum rated torque 1) 4000 2) 5000 1) 5000 2) 10000 Torsional stiffness Torsional angle Radial stiffness Axial stiffness Max. bending moment Radial load limit at run out error of 0,02mm Axial load limit knm/rad 1) 115 2) 177 3) 177 4) 272 1) 0,02 2) 0,03 3) 0,06 4) 0,11 kn/mm 1) 59,3 2) 82,1 3) 82,1 4) 119 kn/mm 1) 254 2) 331 3) 331 4) 456 Nm 1) 41 2) 57 3) 57 4) 83 kn 1) 1185 2) 1642 3) 1642 4) 2372 kn 1) 8 2) 10 3) 10 4) 14 Mass kg 1) 1,4 2) 1,4 3) 1,4 4) 1,4 1) 431 2) 391 3) 658 1) 0,03 2) 0,07 3) 0,09 1) 168 2) 156 3) 245 1) 530 2) 509 3) 705 1) 127 2) 119 3) 273 1) 3352 2) 3128 3) 4896 1) 16 2) 15 3) 21 1) 1,8 2) 1,8 3) 1,9 1) 1080 2) 1744 3) 2304 1) 0,05 2) 0,07 3) 0,07 1) 231 2) 374 3) 511 1) 497 2) 711 3) 914 1) 180 2) 292 3) 399 1) 4622 2) 7487 3) 10210 1) 15 2) 22 3) 28 1) 2,9 2) 3 3) 3 1) 3893 2) 4466 1) 0,06 2) 0,06 1) 534 2) 659 1) 686 2) 816 1) 427 2) 527 1) 10684 2) 13185 1) 21 2) 25 1) 4,35 2) 4,4 1) 5508 2) 8463 1) 0,05 2) 0,07 1) 559 2) 930 1) 517 2) 982 1) 537 2) 892 1) 11180 2) 18591 1) 16 2) 30 1) 7,7 2) 8 DF Series Manual Version 1.4 27.09.2016 46/60
Inertia kgm² 1) 0,00201 2) 0,00202 3) 0,00202 4) 0,00202 Balancing Q 2.5 class 1) 0,00384 2) 0,00384 3) 0,00387 1) 0,0095 2) 0,0095 3) 0,0096 1) 0,0197 2) 0,0197 1) 0,057 2) 0,052 Mechanical Shock (EN 60068-2-27) Vibration Loads (EN 60068-2-6) Quantity n 1000 Frequency range Hz 1. 2000 Duration ms 3 Duration Hz 2.5 Acceleration m/s² 650 Acceleration m/s² 200 6.8.1 Single sided clutch device COUPLING ON OUTPUT SIDE Type DF1CR DF2CR DF3CR DF4CR DF5CR Rated torque (nominal) Nm 1) 50 2) 100 3) 200 4) 450 Nominal Speed rpm 1) 13600 2) 13600 3) 13600 4) 13600 1) (200) 2) 500 3) 1000 1) 12400 2) 11000 1) 1000 2) 2000 1) 9000 2) 8000 1) 4000 2) 5000 1) 8000 2) 6400 1) (5000) 2) 10000 1) 6400 2) 5600 input output DF Series Manual Version 1.4 27.09.2016 47/60
6.8.2 Dimension rotor DF standard type [mm] Type Nominal rated torque DF1S 50/ 100 / 200/ (500) Nm ØD1 without speed encoder ØD1 with speed encoder ØD2 B B1 B2 101 107 107 45 10 20 DF2S (200)/ 500 / 1000 Nm 122 128 128 48 10 20 DF3S (1000)/ 2000/ 3000) Nm 152 158 158 49 10 20 DF4S 4/ 5 knm 181 187 187 50 11 20 DF5S (5)/ 10 knm 224 230 230 60 12 20 DF Series Manual Version 1.4 27.09.2016 48/60
Type Nominal rated torque ØC T1 T2 PCD 1 N PCD 2 DF1S 50/ 100 / 200/ (500) Nm 57 H6/ g5 4.2 2 84 / Ø9 6x 84 / M8 DF2S (200)/ 500 / 1000 Nm 75 H6/ g5 4.2 2 101,5 / Ø11 8x 101,5 / M10 DF3S (1000)/ 2000 / 3000 Nm 90 H6/ g5 4.2 2.5 130 / Ø13 8x 130 / M12 DF4S 4/ 5 knm 11 0 H6/ g5 DF5S (5)/ 10 knm 14 0 H6/ g5 4.2 2.8 155,5 /Ø15 4.2 3.5 196 / Ø17 8x 8x 155,5 / M14 196 / M16 Note Dimension will change with adapted couplings DF Series Manual Version 1.4 27.09.2016 49/60
6.8.3 Dimension stator DF Series Manual Version 1.4 27.09.2016 50/60
6.8.4 Dimension TCUIV 6.8.5 Dimension with couplings DF Series Manual Version 1.4 27.09.2016 51/60
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Type Rated torque (Nm) DF1CR 50/100 /200/ (450) DF2CR (200)/ 500 Max speed (rpm) L (mm) D1 (without speed encoder) D1 (with speed encoder) C1 (mm) 13600 81.5 Ø101 Ø107 Ø57 H6 12400 85 Ø122 Ø128 Ø75 H6 DF2CR 1000 11000 92 Ø122 Ø128 Ø75 H6 DF3CR (1000)/ 9000 99.5 Ø152 Ø158 Ø90 2000 H6 DF3CR 3000 8000 103.5 Ø152 Ø158 Ø90 H6 DF4CR 4000 8000 104.5 Ø181 Ø187 Ø110 H6 DF4CR 5000 6400 118.5 Ø181 Ø187 Ø110 H6 DF5CR (5000) 6400 128.5 Ø224 Ø230 Ø140 H6 DF5CR 10000 5600 141.5 Ø224 Ø230 Ø140 H6 T1 (m m) PCD1 (mm, quantity, drill hole) B1 (m m) 4.2 Ø84 6x Ø9 10 4.2 Ø10 1,5 4.2 Ø10 1,5 4.2 Ø13 0 4.2 Ø13 0 4.2 Ø15 5,5 4.2 Ø15 5,5 4.2 Ø19 6 4.2 Ø19 6 8x 8x 8x 8x 8x 8x 8x 8x Ø1 1 Ø1 1 Ø1 3,5 Ø1 3,5 Ø1 5,5 Ø1 5,5 Ø1 7,5 Ø1 7,5 10 10 10 10 10 10 12 12 DF Series Manual Version 1.4 27.09.2016 54/60
Type Rated torque (Nm) D2 (mm) C2 (mm) C3 (mm) T2 (mm) B2 (mm) PCD2 (mm, quantity, thread size) k a DF1CR 50/ 100 /200/ (450) DF2CR (200)/ 500 Ø136 Ø75 h7 Ø148 Ø85 h7 DF2CR 1000 Ø166 Ø95 h7 DF3CR (1000)/ Ø201 Ø120 2000 h7 DF3CR 3000 Ø223 Ø130 h7 DF4CR 4000 Ø223 Ø130 h7 DF4CR 5000 Ø275 Ø160 h7 DF5CR (5000) Ø275 Ø160 h7 DF5CR 10000 Ø315 Ø170 h7 Ø126 h9 Ø138 h9 Ø156 h9 Ø191 h9 Ø213 h9 Ø213 h9 Ø265 h9 Ø265 h9 Ø305 h9 1 12 Ø114 4 x 3 M6 22, 50 90 1.5 12 Ø123 6 x 3 M8 13 60 1.5 15 Ø140 6 x 3 M8 13 60 2 18 Ø172 6 x 3 M10 13 60 2 20 Ø193 6 x 3 M12 13 60 2 20 Ø193 6 x 3 M12 13 60 3 25 Ø239 6 x 3 M16 13 60 3 25 Ø239 6 x 3 M16 13 60 4 31 Ø275 6 x 3 M16 13 60 DF Series Manual Version 1.4 27.09.2016 55/60
6.8.6 Torque and acceleration Specification Acceleration Sensor Range g ±12g ±25g ±50g ±100g ±200g ±400g Frequency Hz 1500 1500 2000 2500 3000 4000 Response Max. Mechanical g 5000 5000 5000 5000 5000 5000 Shock Non- Linearity % of span 0.15 0.15 0.15 0.25 0.4 0.7 Available Torque Ranges combined with Acceleration Measurement DF1S Nm 50 / 100 DF2S Nm (200) / 500 / 1000 DF3S Nm (1000) / 2000 / 3000 DF4S Nm 4000 / 5000 DF5S Nm (5000) / 10000 Specification Acceleration Sensor Output Signal span frequency output khz 10 ± 5 60 ± 20 60 ± 30 240 ± 120 Signal span voltage output V 0 ± 5 0 ± 10 2,5 ± 2,5 5 ± 5 Measurement frequency range, -3dB, at zero frequency of 60kHz khz 3 DF Series Manual Version 1.4 27.09.2016 56/60
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Want to learn more about our products, solutions and services in the fields of measurement systems, vehicle equipment and actuators? Then please call us under +49 (0) 2404 9870 570 or email us at equipment@atesteo.com. Your personal ATESTEO contact is always at your disposal. Konrad-Zuse-Str. 3 52477 Alsdorf T +49 (0) 2404 9870-0 F +49 (0) 2404 9870-59 info@atesteo.com Art. No. 10002080 DF Series Manual Version 1.4 27.09.2016 60/60