Relay system reduces space requirements and wiring effort in milling machines

Overview

Milling at high speed  

The milling machines achieve a cutting speed of up to 1000 meters per minute.

  • The high-speed milling machines from Röders TEC GmbH are used wherever high demands are placed on cutting performance and surface finish.
  • Numerous coupling relays, which need to be assembled and wired efficiently, are used to control the machines.
  • The relay modules from the RIFLINE complete product range not only reduce the installation time, but also save space in the control cabinet.

Customer profile

Röders TEC headquarters  

Röders TEC has its headquarters in Soltau, Germany

The high-speed milling machines from Röders TEC GmbH, of which more than 2000 have been installed in over 50 countries (as of 2014), are used, among other things, to manufacture high-precision molds for medical technology as well as dies for striking coins.

The company has subsidiaries in China, France, the USA, and Vietnam.

Application

Five-axis milling machine  

A special geometrical compensation ensures a high degree of accuracy

Röders TEC uses numerous coupling relays to control its milling machines, as a wide range of switching tasks need to be performed. “We use the fast RIF-0 relay module to couple signals between the controller and field. These may be feedback signals from an external dust extraction plant, for example, that are only 24 V and just a few mA in size.

To multiply signals, we use the RIF-2 relay module, because it provides up to four changeover contacts,” reports Olaf Hartmann, who is responsible for the electrical design of the machines. The high cutting speed places high demands on the spindles, which are therefore coated with an oil/air mixture every three seconds. A solid-state relay actuates the oil pump that provides the lubricant mixture. The relay works without any wear and therefore guarantees reliable machine operation.

Solution

Push-in connection technology  

Very convenient operation with Push-in connection technology

As the milling machines contain numerous coupling relays, the efficient assembly and wiring of the modules plays an important role. “That's another reason why we opted for relay modules from the RIFLINE complete product range,” explains Olaf Hartmann. “The RIFLINE relays are easy and convenient to wire.” This is the result of the innovative Push-in technology, which enables solid and stranded conductors with ferrules, from a cross section of 0.34 mm2, to be connected safely and quickly, without any tools. The engaging force required for the conductors is reduced by 50 percent. The lower force required means that there is increased comfort during operation for employees, as well as speedier wiring, which, at the end of the day, reduces costs. To pull the conductors out again, installation engineers just have to actuate the orange lever so that the spring releases.

The RIFLINE portfolio comprises narrow relay modules in an overall width of just 6.2 mm, with one changeover contact as well as power relay modules with two, three or four changeover contacts. Relay modules resembling small power contactors are also available. Relay retaining brackets and plug-in function modules with LED display, protection against polarity reversal, and protective circuit complete the range. If the application requires high switching frequencies, wear-free semiconductor relays can also be used with the RIF-0 and RIF-1 socket versions. The highlight of the range is a small, plug-in timer module with three time functions: switch-on delay, passing make contact, and flasher unit. The user can adjust four time ranges here, from 0.5 seconds to 100 minutes. The module that establishes RIFLINE complete as a time relay can be coupled with all versions from RIF-1 to RIF-4, as is the case with all standard function modules with the same construction.

Summary

RIFLINE complete uses the plug-in bridges, the marking material, and the test plugs from Phoenix Contact's CLIPLINE complete terminal block range that many users already have in place. This reduces effort when it comes to planning, purchasing, and storing components.

“The shared range of accessories is a true advantage for us because we've been using the terminal blocks that are connected with Push-in technology for a long time now,” concludes Hartmann. The advantages of the connection technology are also provided by various other components such as controllers, the I/O system, signal conditioners or hybrid motor starters.

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