December 2012

HOT LINKS TNC Magazine Trade Show Schedule ISO Certification Contact

New Linear Encoders for Safety-Related Applications

Higher technical requirements inmachine and plant manufacturing aswell as more stringent national andinternational safety requirements havecreated the need for a new generationof sealed absolute linear encoders.HEIDENHAIN's answer – the LC 115and LC 415 series with functionalsafety, resulting in encoders thatachieve SIL2 in accordance with IEC61508 and performance level of ISO13849. Read more »

PRODUCT SPOTLIGHT

TNC 128 – New Point-to-PointControl for Boring Mills

To meet the needs of basic point-to-point CNC milling machines,HEIDENHAIN introduces a newcompact but versatile straight-cutcontrol, the TNC 128. It isdesigned for use on universalmilling, drilling and boringmachines. It is especially useful inapplications that have series andsingle-part production, for machinebuilding, and within prototype andpilot plants, repair departments,training and education facilities.Read more »

Also in this issue:

Did You Know...

...that HEIDENHAINabsolute rotary encoders arewithin the Xenith Solar Car,a solar-powered vehicle builtat Stanford University andunveiled last year?Read more »

Technical Tidbit

ISO 9001 and NationalStandards ComplianceAccording to ISO 9001,certain HEIDENHAINproducts must be traceableto a national standard inregular intervals. Our highaccuracy products aremanufactured in Germany,with various options formeasurement. Read more »

Upcoming Events

HEIDENHAIN Unveils 2013

NEWS

HEIDENHAIN HISTORY– Part 2After the DIADUR is Invented

After Wilhelm Heidenhain's 1889 startup of a metal-etching company inBerlin, Germany, and subsequent move to Traunreut, Germany duringWorld War II with his son Dr. Johannes Heidenhain, the company beganto take on the shape as we know it today. HEIDENHAIN's 1950 inventionof the DIADUR production process gave way to the development ofprecision measurement components never before seen anywhere in theworld. Read more »

Trade Show ScheduleHEIDENHAIN is planning toexhibit at eight trade showsin North America in 2013.Trade Shows 2013 »

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Figure 1 - Optical linear

December 2012

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HEIDENHAIN HISTORY

HEIDENHAIN has been in existence for over 100 years, with an illustrious history. Originating in Europe and now

with approximately 7,500 employees worldwide, HEIDENHAIN continues to serve as an important and significant

force in the precision measurement and motion control industry. This article is the second installment in a series

to share its background.

After the DIADUR is Invented

After Wilhelm Heidenhain's 1889 startup of a metal-

etching company in Berlin, Germany, and subsequent

move to Traunreut, Germany during World War II with his

son Dr. Johannes Heidenhain, the company began to take

on the shape as we know it today. HEIDENHAIN's 1950

invention of the DIADUR production process gave way to

the development of precision measurement components

never before seen anywhere in the world.

In 1952, HEIDENHAIN introduced its first optical linear

(Figure 1) and angle encoders for machine tools. In 1961,

its first photoelectric linear (Figure 2), angle and

incremental rotary (with 10,000 lines) encoders for

position feedback are introduced. All of these products

brought exciting advances to the motion control industry.

Then in 1968, HEIDENHAIN introduces its first sealed

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Figure 2 - Photoelectric linear

Figure 3 - Sealed Linear Encoder

linear encoder with steel tape (40 µm) (Figure 3), as well

as its first digital readouts (DROs) for manual machine

tools, bringing the ability to monitor and guide

measurement movements more accurately than ever

before right on the machine shop floor.

With all of these advanced components becoming well

established into manufacturing machines all over the

world, Dr. Johannes Heidenhain decides in 1970 to put the

successful company into a trust for the benefit of its many

loyal employees in Traunreut. This trust outlines that the

company can never be sold, and establishes itself as a

non-profit organization. It also mandates that the

HEIDENHAIN board of directors must give a portion of its

annual sales to the needy, both for children and adult

charitable organizations alike which it continues to do

today.

At this juncture, HEIDENHAIN really begins to grow.

Stayed tuned for more HEIDENHAIN History in the next

quarterly newsletter.

Click here to read HEIDENHAIN History PART 1

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HEIDENHAIN's New Point-to-Point

Control for Boring Mills

To meet the needs of basic point-to-point CNC milling machines,

HEIDENHAIN introduces a new compact but versatile straight-cut

control, the TNC 128. This new control is well suited for machines

with a central drive as well as those with independent drives and

servo spindle. Designed for use on universal milling, drilling and

boring machines, it is especially useful in applications that have

series and single-part production, for machine building, and within

prototype and pilot plants, repair departments, training and

education facilities.

The basic version of the new TNC 128 control hosts three axes

plus a spindle (two optional additional axes) and is an upgrade to

HEIDENHAIN's TNC 124 control. The NC software of the TNC 128 is

based on the new HEIDENHAIN NCK software platform and boasts a HEIDENHAIN HEROS 5 operating

system. The compact main computer behind the screen is an Intel Celeron M process (1 GHz, I GB SDRAM).

An important feature of the new TNC 128 is its user-friendly conversational programming format designed to

assist the user with help graphics, practical prompts and machining cycles. Memorizing G codes is

unnecessary. And for simple work, such as face milling, the user need not write a program on the TNC 128.

It is just as easy to operate the machine manually by pressing the axis keys or, for maximum sensitivity, by

using the optional electronic handwheel for fine movements.

The modern 12.1-inch TFT flat panel color monitor on the TNC 128 shows a clear overview of all relevant

information for programming, operating and inspecting the machine tool and control, such as program blocks,

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comments and error messages. The TNC 128's keyboard is tailored to the programming process as well,

offering strategically-placed configuration of keys to facilitate program input. The operating panel features a

new stainless steel design, and a 2.0 USB port in a handy location (two other ports elsewhere on system as

well).

Well equipped for external access, the TNC 128 can be integrated into networks and connected with

programming stations or other data storage devices. The TNC 128 offers Ethernet (100 Mbps), EnDat input, a

CFR CompactFlash memory card with 8 GB, RS-232 and its new expandable I/O allows it to be utilized in

more complex applications than its predecessor.

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December 2012

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Safe and Absolute —

Linear Encoders with Safe Absolute Position Values

For years now, HEIDENHAIN absolute linear and angle

encoders have been the product of choice for machine

tools wherever high requirements for accuracy, reliability

and productivity must be met. With the absolute

measuring method, the position value is available from the

encoder immediately upon switch-on and can be called at

any time by the subsequent electronics. There is no need

to move the axes to find the reference position. This

absolute position information is read from the scale

graduation, which is formed from a serial absolute code

structure. Because of the advantages of absolute

encoders, HEIDENHAIN is now producing them in larger

quantities than the incremental versions.

Higher technical requirements in machine and plant

manufacturing as well as more stringent safety

requirements in national and international standards have

necessitated a new generation of sealed linear encoders

that are now being introduced to the market.

The heart of these new encoders and the fundamental

innovation is a HEIDENHAIN OPTO-ASIC that was

conceived from the experiences of these last 15 years of

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R&D. Thanks to the integration of optical elements, analog

circuits and digital signal evaluation on a single chip, the

signal quality and reliability have again been significantly

increased. Functions permitting operation of these

encoders in safety-related applications have also been

integrated in the OPTO-ASIC. This means that the

absolute linear encoders of the LC 115 and LC 415 series

with functional safety (as single-encoder systems) achieve

SIL2 in accordance with IEC 61508 and performance

level d of ISO 13849. The safe mechanical connection

required by the standards has also been realized.

With a rapid formation of the position value within 5 µs

and a resolution down to 1 nm, there are no limits to their

possibilities on machine tools. Along with encoders for the

RS 485 interfaces, such as EnDat 2.2, FANUC and

MITSUBISHI, there are also encoders for the Ethernet-

based interface from SIEMENS.

HEIDENHAIN considers ASIC design, ASIC qualification and

all modern manufacturing methods, such as COB (chip on

board) or flip-chip assembly to be essential expertise that

is not to be outsourced. This high manufacturing depth

and the cooperation of interdisciplinary processes with

mechanical and electronics R&D at one location is the

basis for the high reliability of series production of

absolute and incremental encoders by HEIDENHAIN.

Makeup of the encoders

The scale of the absolute linear encoders, which are offered in the full-size and slim-line versions LC 115 and

LC 415, respectively, consists of a 20 µm incremental grating and an absolute grating with serial Pseudo

Random Code (PRC).

Figure 1: Representation of a code structure with additional incremental track

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The incremental track is scanned with the proven single-field method. This type of scanning distinguishes

itself dramatically in its signal quality and signal reliability from the three- or four-field methods.

The large scanning area over the entire width of the scale grating and the arrangement of several scanning

fields in succession make the encoders with single-field scanning extremely insensitive to contamination. The

results of corresponding contamination tests prove this: even if large areas are contaminated, the encoder

continues to provide high-quality signals. The position error remains far below the value specified for the

accuracy grade of the encoder.

Figure 2: Influence of contamination on the output signal (in this example, from an LS 487).

Left: four-field scanning, right: single-field scanning

A proven technique from absolute rotary encoders, but new for linear encoders, was adapted to produce the

absolute encoder signals. The individual PRC bits are scanned "differentially." Each bit consists of a dark and

Figure 3: Schematic representation

of the double sealing lip

a light field. Similar to the differential data transfer of an RS 485 interface, disturbances influence both fields

and have only a slight effect on signal processing. The combination of both technologies makes it possible to

attain a very high signal quality and reliability.

Functional safety

Safety is becoming increasingly important in machine and plant construction. Proof of this can be seen in new

legislation and in the heightened safety requirements of national and international standards. These high

requirements mainly serve to protect human beings, but material assets and the environment are also

receiving more consideration.

In order to fulfill the high requirements placed on the measuring technology by the new standards,

HEIDENHAIN and TÜV-Süd together subjected HEIDENHAIN's safety concept to type examination. The

certification applies to the complete system—from the formation of the position value over the data

transmission to the evaluation in the subsequent electronics. The fault exclusion regarding the mechanical

elements coming loose is the finishing touch in this consideration. The new absolute linear encoders of the

LC 115/415 series are the first linear encoders that can provide the OEM with a PFH value for consideration

of the complete system. The number of encoders available with functional safety will increase gradually.

Certification of the RCN series of angle encoders is planned for 2012.

If a machine tool builder has prepared a different safety concept, HEIDENHAIN can assist him with MTTF

values and a fault table specifically prepared for the encoder. Details in both cases must always be

coordinated with the machine tool builder.

Reliability

The productivity of a machine tool is determined by its

accuracy (whether it can safely manufacture the required

part quality), the dynamics (in what time) and the

availability. The new LC encoders set standards in all

three requirements. The attainable accuracy was already

described above. With regard to dynamics, the permissible

traversing speed of 3 m/s and a maximum acceleration in

measuring direction of 10 g should present no limit for

linear motion.

The use of filtered compressed air together with linear

encoders provides a maximum of reliability. This produces

an overpressure in the encoder and prevents the ingress

of dirt and liquids.

Since peak loads of condensed liquids can repeatedly

occur in compressed air supplies, the LC 115 features a

design detail to minimize the effects of this contamination.

The compressed air is conducted into a "chamber"

between the inside and outside pairs of sealing lips (see

Figure 3 for double sealing lip). This results in a main

current from the encoder and a much smaller secondary

current of compressed air into the encoder interior. This

prevents contamination from coming directly into the

encoder. Briefly contaminated sealing air can therefore no

longer influence reliability.

LC 211—absolute even over lengths

up to 28 meters

On long machine-tool axes, the LC 211 sets new

standards in linear measurement. The successor of the

well-known multi-section LB 382 linear encoder now

provides the advantages of absolute position acquisition

for measuring lengths up to 28 meters. The LC 211 uses

the above described new OPTO-ASIC, however with a

changed beam path, because here the measuring

standard is a steel tape instead of glass. This METALLUR

steel tape graduation—known from the LB 382—with a 40

µm incremental track and a PRC track consists of a highly

reflective gold layer and light-absorbent grating lines. The

scanning provides unique absolute position values over

the entire measuring length at a resolution down to

10 nm. The long measuring lengths of up to 28 m

inevitably necessitate long cables. Serial data

transmission is particularly advantageous for such

applications, since, for example, the signals from a 1 VPP

interface have a significantly lower useable component as

a result of the long cable lengths. In comparison, the

serial interface transmits the data without loss, regardless

of the cable length. Just like the LC 100 and LC 400, the

LC 200 will have protocols for the EnDat, FANUC and

MITSUBISHI interfaces.

To facilitate mounting of such a long encoder, a new

mounting technique was developed for the LC 211. The

seals are premounted on the sections, which are up to 2

meters long, and are designed to provide a tolerance of

up to 2 mm in measuring direction during mounting.

However, it is essential that the mounting tolerance for the overall measuring length be maintained in order

for the clamping mechanism to function correctly. The new mounting strategy significantly reduces the time

required for mounting, and at the same time increases the quality and reliability.

www.heidenhain.com ©HEIDENHAIN 2012

Summary

The new sealed LC 115/415 linear encoders are more accurate, more reliable and safer than ever before.

The combination of single-field scanning and digital signal processing provides high-accuracy absolute

position values. The double sealing lips improve resistance to briefly contaminated compressed air.

Certification by TÜV makes a single-encoder system possible with safe, purely digital, absolute position

values. The LC 211 adds large measuring lengths up to 28 m to the product program. All LC encoders can be

used with EnDat, FANUC and MITSUBISHI controls. The LC 1x5/4x5 series can even be connected directly to

the SolutionLine control from SIEMENS.

Author:

Helmut Kügel

Product Marketing, Traunreut, Germany

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