Four-row linear recirculating ball bearing and guideway assemblies
Features
Four-row linear recirculating ball bearing and guideway assemblies are the most extensive and complex group within the range of monorail guidance systems. They are used where heavy loads must be moved with high running and positional accuracy as well as low friction. The guidance systems are of a full complement design, preloaded and are suitable for long, unlimited stroke lengths.
A guidance system comprises at least one carriage, one guideway, one dummy guideway, two-piece plastic closing plugs and one lubrication connector included in the delivery.
The four-row linear recirculating ball bearing and guideway assemblies are supplied with basic greasing as standard.
X-life
Linear recirculating ball bearing and guideway assemblies of the design High-Speed are supplied in X-life quality. These bearings are characterised by optimised technological characteristics, increased robustness and a longer operating life at significantly higher velocities.
High-Speed
The four-row linear recirculating ball bearing and guideway assembly KUVE25-B-HS is the design High-Speed and represents an expansion of the existing extensive KUVE range in the field of highly dynamic applications.
Systems KUVE25-B..-HS are supplied as standard with an initial greasing (greasing ready for operation). In highly dynamic applications in particular, an adequate supply of lubricant is indispensable as early as the commissioning stage.
This variant is extremely robust and is currently the fastest four-row linear recirculating ball bearing and guideway assembly with steel balls on the market. In order to achieve 10 m/s, the end pieces and ball return systems were optimised for highly dynamic requirements. As a result, the total length of the carriage is slightly longer compared to the standard version. The design envelope corresponds, as before, to DIN 645-1. The loads are supported by standard steel rolling elements.
The design High-Speed is only available in size 25. In accordance with the modular concept, it is interchangeable with the other KUVE25-B units.
The unit KUVE High-Speed is used where there are very high dynamic requirements. Since hybrid technology is not used, the full performance capacity of the rolling contact can be implemented, with the associated advantages in terms of load carrying capacity, rigidity, robustness and crash safety.
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.
A generous grease reservoir and beneficial lubrication is provided by means of favourably positioned lubricant pockets in the carriage, 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 TKVD ( -ADB , -ADK ) and TKVD..W are located from above and have through holes with counterbores for the fixing screws.
Guideways TKVD..-U and TKVD..-W-U are located from below and have threaded blind holes.
Slot for covering strip
Guideways TKVD..-ADB have a slot for the adhesive bonded steel covering strip ADB. Guideways TKVD..-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 in several segments, see link.
Standard accessories
The scope of delivery includes various accessory parts as standard.
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
A lubrication connector for relubrication from the end is included in the scope of delivery.
Load carrying capacity
The rows of balls are in an O arrangement with two point contact on the raceways.
The units can support loads from all directions, except in the direction of motion, and moments about all axes, ➤ Figure.
Load carrying capacity
Acceleration and velocity
Four-row linear recirculating ball bearing and guideway assemblies KUVE permit accelerations up to 150 m/s2 and velocities up to 6 m/s, see table. The design High-Speed permits velocities up to 10 m/s, depending on the operating conditions.
Operating limits
Designation | Acceleration up to | Velocity up to |
|---|---|---|
m/s2 | m/s | |
KUVE | 150 | 6 |
Interchangeability
Carriages KWVE and guideways TKVD are interchangeable in any combination within one size, preload class and accuracy class.
Sealing
The end pieces of the carriages are fitted on both sides with non-contact, corrosion-resistant end plates and elastic end wipers that retain the lubricant in the system. Carriages of the W design are only fitted with elastic end wipers on both sides.
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
Linear recirculating ball bearing and guideway assemblies KUVE..-B and KUVE..-W are suitable for oil and grease lubrication. The systems are supplied with a basic greasing. A lubrication connector for relubrication from the end is included in the scope of delivery. Optionally, other lubrication connectors are available.
The lubrication connectors can be screw mounted into the end piece on the left, right or end face in the design KUVE..-B, while this is only permissible on the end face in the designs KUVE High-Speed and KUVE..-W. All relubrication holes are closed off by means of grub screws. Before the lubrication connector is screwed in, the corresponding grub screw must be removed. Observe the mounting manual MON 38.
Lubricant reservoir KUVE..-B and sealing
ACHTUNG
If lubrication connectors are fitted on the end or side, the maximum permissible screw depth must be observed. If additional sealing elements KIT are used, the screw depth is increased for the end relubrication facility. The standard lubrication connector is then no longer usable. Suitable lubrication connectors must additionally be taken into consideration when ordering.
In order to ensure optimum lubricant distribution, we recommend that carriages of design High-Speed should be moved several times at low speed before commissioning and after maintenance and lubrication intervals.
Operating temperature
As standard, four-row linear recirculating ball bearing and guideway assemblies can be used at operating temperatures from –10 °C to +80 °C.
Corrosion-resistant design
Four-row linear recirculating ball bearing and guideway assemblies KUVE..-B are available in the accuracy class G3 and also in a corrosion-resistant design with the special coatings Corrotect (with the preload class V1 or V2) and Protect A (with the preload class V2).
Design and safety guidelines
Preload
Linear recirculating ball bearing and guideway assemblies KUVE 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 · C |
V2** | 0,1 · C |
**Standard preload class.
**Not for design High-Speed.
Influence of preload on the linear guidance system
The preload of a linear guidance system defines the rigidity of the system. The four-row linear recirculating ball bearing and guideway assembly KUVE 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 μKUVE | ||
|---|---|---|---|
from | to | from | to |
4 | 20 | 0,0007 | 0,0015 |
Rigidity
The deflection curves show the deformation of the linear recirculating ball bearing and guideway assembly KUVE, 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 38 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 or two rows of holes
Maximum number of pitches between holes
The number of pitches between holes is the 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, see dimension tables, 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, ➤ Figure. 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 adjacent 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 surface and parallelism of the 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 38 for KUVE.
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 | ||
TKVD15-B (-U) | 8 | 5 |
TKVD15-W (-U) | ||
TKVD20 (-U, -ADB, -ADK) | 9 | 6 |
TKVD20-W (-U) | ||
TKVD25 (-U, -ADB, -ADK) | 11 | 7 |
TKVD25-W (-U) | ||
TKVD30 (-U, -ADB, -ADK) | 13 | 8 |
TKVD30-W (-U) | ||
TKVD35 (-U, -ADB, -ADK) | 15 | 10 |
TKVD35-W (-U) | ||
TKVD45 (-U, -ADB, -ADK) | 17 | 12 |
TKVD55-B (-U, -ADB, -ADK) | 20 | 14 |
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. | ||
KUVE15-B (-H, -S, -E, -EC, -ES, -ESC) | 4,5 | 3,5 | 1 | 0,3 |
KUVE15-W | 4,5 | 1,6 | 1 | 0,5 |
KUVE20-B (-L, -H, -HL, -S, -SL, -SN, | 5 | 4 | 1 | 0,5 |
KUVE20-W (-WL) | 5 | 4 | 1 | 0,5 |
KUVE25-B (-L, -H, -HL, -S, -SL, -SN, | 5 | 4,5 | 1 | 0,8 |
KUVE25-B (-E, -ES, -H, -S, -SN, -N) -HS | 5 | 4,5 | 1 | 0,8 |
KUVE25-W (-WL) | 5 | 4,5 | 1 | 0,8 |
KUVE30-B (-L, -H, -HL, -S, -SL, -SN, | 6 | 5 | 1 | 0,8 |
KUVE30-W | 6 | 5 | 1 | 0,8 |
KUVE35-B (-L, -H, -HL, -S, -SL, -SN, | 6,5 | 6 | 1 | 0,8 |
KUVE35-WL | 6,5 | 6 | 1 | 0,8 |
KUVE45-B (-L, -H, -HL, -S, -SL, -SN, | 9 | 8 | 1 | 1 |
KUVE55-B (-L, -S, -SL) | 12 | 10 | 1 | 1,5 |
Locating heights and corner radii
Accuracy
Accuracy classes
Four-row linear recirculating ball bearing and guideway assemblies are available in the accuracy classes G1 to G4, ➤ Figure and table. The standard is class G3.
Parallelism of raceways to locating surfaces
The parallelism tolerances of the guideways are dependent on the accuracy class, ➤ Figure.
In coated systems, 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** | G4 | ||
μm | μm | μm | μm | ||
Tolerance for height | H | ±10 | ±20 | ±25 | ±80 |
Difference in height** | ΔH | 5 | 10 | 15 | 20 |
Tolerance for spacing | A1 | ±10 | ±15 | ±20 | ±80 |
Difference in spacing** | ΔA1 | 7 | 15 | 22 | 30 |
**Standard accuracy class.
**Difference between several carriages on one guideway, measured at the same point on the guideway.
Datum dimensions for accuracy
Units with 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 | Protect A | |
|---|---|---|---|
RROC | KD | ||
μm | μm | ||
Tolerance for height | H | +6 | +6 |
Difference in height** | ΔH | +3 | +3 |
Tolerance for spacing | A1 | +3 | +3 |
Difference in spacing** | ΔA1 | +3 | +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, ➤ Figure and tables.
The hole pattern corresponds to DIN EN ISO 1101.
Positional and length tolerances of guideways TKVD with one row of holes
Positional and length tolerances of guideways TKVD..-W with two rows of holes
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 each of 1 500 mm | ||
**Minimum length of one segment = 600 mm.