SECTION FIVE

COLUMN, BED, SADDLE, AND ENCODERS

TABLE OF CONTENTS
TITLE PAGE
COLUMN....................................................................................................................................................5-1

COLUMN MAINTENANCE........................................................................................................................5-2

BED............................................................................................................................................................5-2

SADDLE.....................................................................................................................................................5-3

BED AND SADDLE MAINTENANCE .......................................................................................................5-4

LINEAR ENCODERS ................................................................................................................................5-4

ANGLE ENCODERS .................................................................................................................................5-8

COLUMN
The column is a machined gray iron casting of the Meehanite Process, which provides the vertical Y-axis
movement for the headstock. The column is constructed with variable wall thickness and interior “X”
bracing (Figure 5-1). The basic components of the column assembly consist of the machined column, the
front and rear box ways, the Y-axis drive, and the linear encoder (all of which vary in length proportionally
to the available headstock travels of 2100, 2600, 3100, or 3600 mm) and mechanical & electrical services
(which are specific for either a two speed or four speed headstock).
The replaceable box ways are bolted through the face of the way onto a hand scraped mating surface on
the column. The front way is pulled
against a guide edge with socket Damper
head cap screws. M16X70 socket Assembly
head cap screws fasten the ways to
the column and are torqued to 150
Nm (110 lb-ft). A special hydraulic
fixture is used to install the way plugs
in these screw holes. It is important
for the plugs to be flush and set to the
proper depth.
The column provides the support for
the Y-axis drive. The 80 mm (3.15”)
diameter ballscrew is held in place on
the lower end by the damper Top View
assembly (Figure 5-1), which is bolted (Shown without Drive Motor)
to the column. Under the damper
assembly are shims which are used Figure 5-1
to align the ballscrew with the ways. Column Views
If the shims are removed, they need Bottom View
to be reinstalled in the exact same
position. The damper assembly
design insures that the bearing preload is not lost due to ballscrew thermal growth. System hydraulic
pressure provides equal pressure on both sides of the bearings within the damper assembly. The other
end of the ballscrew is held in place by bearings within a housing integrated into the column. If bearing
replacement is required, make sure to use the correct drawings for proper orientation (Figure 5-2). The
Y-axis drive top bearings are oriented differently than x & w-axis drive bearings .
The Y-axis drive housing (Figure 5-
3) which is attached to the top of Y-Axis X & W-Axis
the column, serves has the
mounting surface for the idler spur
gear, lube components and the
servo motor. After the housing is
attached to the column, a keyed
spur gear is installed onto the
ballscrew shaft, aligned with the
idler gear.
Figure 5-2
The column is bolted to the column
base portion of the bed with Axes Drive Bearings Orientation
eighteen M20X90 socket head cap (Does not apply to Damper Ass’y Bearings)
screws, torqued to 250 Nm (180 lb-
ft). At each of the four corners are a set of spacers (Figure 5-4). The spacers are ground and marked
during column alignment. If the column is removed, the spacers must be returned to there marked
position when the column is reinstalled.

5-1
COLUMN MAINTENANCE
There are few parts that make up the Motor Drive Gear
column and therefore it requires minimal
maintenance. It is important to keep the
column clean and free from chips and dirt
build-up. Monitor the condition of the
ways and way wipers on the headstock to
make sure that no abnormal wear is
occurring. Make sure the ways are
receiving sufficient lubrication and that
they are not wearing abnormally from
abrasions or chips caught in the wipers.
Servo Drive Motor
The ballscrew nut should be checked for
(Siemens Shown)
chips in the nylon wipers. It is good
practice to occasionally run the headstock Idler Gear
up and down the column at it full travel to
lube the ways and ballscrew and to Figure 5-3
prevent wear spots. Y-Axis Drive Housing with Siemens Motor

BED
The bed is a machined Column Base Surface of Bed Column Ass’y Spacers
gray iron casting of the
Meehanite Process,
which provides the
base for the saddle and
the column. This one
piece bed/column base
design provides
superior vibration
dampening, optimized
structural stiffness and
load carrying capacity. Figure 5-4
It provides the saddle Bed Showing Column Base Surface
movement parallel to
the spindle axis. For most machines this movement is designated as the W-axis with spindle in/out being
Z-axis, however, these designations can be reversed. The basic components of the bed assembly
consist of the machined bed, a pair of heavy duty hardened and ground preloaded roller guide ways, the
W-axis drive, and linear encoder (all of which vary in length proportionally to the available saddle travels
of 1500, 2000, 2500, 3000, or 3500 mm). The bed also supports one end of the cable carrier that
supplies the mechanical and electrical services
used by the saddle and the rotary table/machine Column Base
center if so equipped. The bed is anchored to
the floor by studs which are set into the
foundation (see Installation Section).
The preloaded roller guide ways consist of a rail Runner Blocks
(that depending upon length could be split into (Trucks)
multiple pieces) and pair of runner blocks (also
referred to as trucks). Each of the runner
blocks contains four sets of recirculating roller Figure 5-5
bearings (Figure 5-6). The bearing preload is Bed Assembly
built into the runner blocks and is not
adjustable. Compared to equivalent ball type
linear ways, roller ways have double the load capacity and up to ten times the life. The rails are bolted to

5-2
an accurately machined rail seat which has
been measured with a laser interferometer Guide Rail
and hand scraped to ensure straightness and Recirculating
flatness. Both of the rail seats have a locating Roller Bearings
shoulder with a wedge clamp used to find and
maintain the correct rail position until the rail
is bolted in place (Figure 5-6). The
parallelism of the locating shoulders is
maintained within .013 mm (.0005”TIR). The
ways are held in place by M16X60 socket
Guide Shoulder
head cap screws through the center of the
way, torqued to 195 Nm (145 lb-ft). Wedge Clamp
The bed provides the support for the W-axis Figure 5-6
drive, which moves the saddle in and out from Guide Rail & Runner Block
the face of the headstock (Figure 5-7). The
W-axis and X-axis drives share a common design and can be ordered in 18M/min and 25M/min rapid
traverse with Siemens or Fanuc drive motors. One end of the W or X-axis ballscrew is supported with a
damper assembly, which is identical to the damper assembly used on Y-axis drive. See damper
assembly description in column. The other end of ballscrew is supported by bearings contained within a
housing that is integral to the bed. Note orientation of these bearings compared to Y-axis drive (Figure 5-
2). Unlike the Y-axis drive, the W & X-axis drives do not use an idler gear. Also, the gears are lubricated
with an oil bath that
must be manually filled Housing Axis Drive Damper Ass’y
to a level on a sight
gage. The motor shaft
spur gear varies Oil Fill Port
dependent upon both
rapid traverse and drive
motor type. Each Bearing Housing
motor shaft gear has a Drive Motor Cover
corresponding drive
motor cover. The cover Servo Motor
accomodates the motor
mount pattern and the Figure 5-7
shaft/gear centerline. W-Axis Drive with and without Drive Motor
SADDLE
The saddle is a
machined gray iron Saddle Support Saddle
casting of the
Meehanite Process,
which provides the
base for the work
table. The saddle
provides the X-axis
movement Height Adjustment Screws
perpendicular to the Saddle Support Runway Saddle
Figure 5-8 Support
spindle. The basic (Bottom View)
components of the
Saddle and Saddle Supports
saddle assembly
consist of the machined saddle, a pair of heavy duty hardened and ground preloaded roller guide ways,
the X-axis drive, linear encoder, and saddle supports (support guide roller assembly). The number of
saddle supports required and the length of the other components vary based on total X-axis travel and
the type of table, (PT) plain table or (RT/MC) rotary table/machine center. In addition, the saddle
provides the support for the mechanical services bulkhead connections from the bed; supports one end of

5-3
the cable carrier that supplies the mechanical and electrical services used by the table; and provides the
mounting surface for the hydraulic and pneumatic services required for rotary tables and pallets if so
equipped. The roller guide ways and X-axis drive are the same design as described for the bed.
Saddle supports and runways are used to support the weight of the table when it is positioned out at the
end of the saddle (Figure 5-8). Two saddle supports are used per runway. There are two to six runways
per machine with the number of runways dependent on table travel. Runway lengths increase for each of
the available saddle travels of 1500, 2000, 2500, 3000, or 3500 mm. As the table is positioned farther
towards the end of the saddle, the supports will carry more of the table load, keeping the saddle level.
The saddle supports ride on a roller system which circulates around an oval shaped track. These rollers
are lubricated automatically by the lubrication system. Within the saddle support is a wedge arrangement
which is used to raise or lower the support. On the end of the support is a M16X40 setscrew used for
adjusting the wedge and two M10X50 cap screws used to lock wedge into position once adjusted (Figure
5-8). On the opposite end is a centered M10X35 cap screw which must be loosened before attempting to
adjust the wedge. Refer to the mechanical print books for a cross sectional view of the saddle supports
(support guide roller assembly).
Note: The saddle supports are only for supporting the saddle while the table weight is
positioned out from center. They should never be used to raise or lower the saddle for
alignment purposes.

BED AND SADDLE MAINTENANCE

There are few parts that make up the bed and saddle and therefore require minimal maintenance. It is
important to keep the bed and saddle clean and free from chips and dirt build-up. Monitor the condition of
the roller guide ways to make sure that no abnormal wear is occurring. Make sure they are receiving
sufficient lubrication. Since the ways are covered by way covers, this should protect the ways from daily
exposure to chips and dirt, lengthening the intervals between inspections. However, whenever the covers
are removed for other maintenance, inspect the ways and way wipers. It is good practice to occasionally
run the axes at their full travel to lube the ways and ball screws and to prevent wear spots.
The X-axis and W-axis gear housings require manual fill with Mobil SHC 634. Reservoir should be filled
every three months as required.

LINEAR ENCODERS
Sealed linear encoders made by Heidenhain® are used to measure the positions of the W, X, & Y-axes.
At the time of this writing the model used for all three axes is the LB 382C. Sealed linear encoders can
be either of two design types, absolute or incremental, with the LB model being an incremental linear
encoder. Absolute linear encoders provide the absolute position value immediately upon switch-on.
Incremental linear encoders need to traverse to a reference-point in order to determine absolute position.
Heidenhain linear encoders operate on the principle of photoelectrically scanning very fine gratings. The
LB model uses the AURODUR process to produce gratings on steel scale tape with a grating period of 40
µm and an accuracy grade of ± 5 µm (± 0.0002”). The “C” at the end of the model number denotes that
these encoders have distance-coded reference marks. These marks speed and simplify the reference
procedure that is used to determine absolute position. The absolute position value is available after
traversing two successive reference marks, which for a LB model is 80 mm maximum travel.
Sealed linear encoders are specifically designed to operate in harsh environments. The scale, scanning
unit and guideway are protected from chips, dirt and splashwater by an aluminum housing and flexible
sealing lips. For measuring lengths of up to 3040 mm (120”) the housing comes in a single section.
Measuring lengths greater than 3040 mm will have a number of housing sections (in lengths ranging from
1000 to 2000 mm at 200 mm increments) with two separate end sections, one for the scale clamping
device and one for the scale tensioning device (Figure 5-9). In order to provide the maximum protection
from contamination, compressed air is introduced directly into the encoder housing. Using compressed
air allows for protection to the degree IP 64 according to IEC 529 and EN 60529.

5-4
The accuracy of position
measurement with linear encoders Tensioning End Section
is mainly determined by: Indicator Setup
1. The quality of the graduation Aligning Housing to
2. The quality of the scanning Guide Way
3. The quality of the signal
processing electronics
4. The error of the scanning unit
guideway along the scale
The LB model has an accuracy
grade of ± 5 µm (± 0.0002”) which
is defined as “the extreme values of Clamping End Section
the deviation F with reference to
their mean value lie within ± 5 µm
for a position within any maximum
1 m section of the measuring
length”. The accuracy grade
applies to the complete encoder Scanning Unit
system including the scanning unit.
Poorly mounted encoders can Figure 5-9
aggravate the effect of guideway
Linear Encoder
error on measuring accuracy. The Adapter Cable
encoder mounting surface has been (Multi-Section Housing)
machined parallel to the linear
guide way mounting surface. During the encoder mounting process, the housing surface opposite of the
scanning unit has been indicated within the tolerances specified (Figure 5-10). If there is a need to
remove/replace an encoder, this alignment process has to be repeated. Typical indicator setup is shown
in Figure 5-9.

Alignment Single Housing Encoders Alignment Multi-Housing Encoders

(Machine Guideway = Datum F) (Machine Guideway = Datum F)
Gauging position at the ends, with further Gauge starting from clamp end section,
gauging positions at regular intervals. continuing to each of the subsequent housings.

Figure 5-10
Encoder Alignment

For complete explanation of the mounting and adjusting process see the vendor information shipped with
your machine or the CD included with your machine. As stated earlier, linear encoders with measuring
lengths (ML) of 3040 mm or less will have a single housing section. Be sure to use the proper
instructions for either single-section or multi-section. Note: overall length of encoders from end cap to
end cap is (276 mm + ML).

5-5
The information on the previous pages and Figures 5-10 to 5-12 was taken from information produced by
the Heidenhain Corporation. It has been reproduced in this manual with permission of the Heidenhain
Corporation.

Protect the Electronics from Accumulating

Electrostatic Charge with a Ground Strap.
Make Sure That Electrical Power Is Off
Touching Connector Ends is Not
Recommended. Before Connecting or Disconnecting
Electrical Connectors.

Maximum Permissible Acceleration Value

for Shock and Impact, Valid for 11 ms:
≤ 300m/s2 (IEC 68-2-27)
Never Use a Hammer or Similar Implement
to Adjust or Position the Encoder.
Slide shipping Braces Away from
Scanning Unit and Remove Them before
Putting Encoder into Operation.

Occasionally Lightly
Lubricate the Inside
of the Sealing Lips
with the Grease (FT)
Provided. Minimum
Once a Year.

Figure 5-11
Precautions to Take when Working with Heidenhain Encoders

5-6
 Figure 5-12
Mechanical Data for LB 382C Linear Encoder

5-7
ANGLE ENCODERS
Heidenhain angle encoders,
capable of precision measurement
to accuracies within several arc
seconds, are used in machines that
are equipped with rotary tables.
The rotary table angular position,
defined as the B-axis, is measured
using either of two Heidenhain
models: RON 285C or RON 786C
(Figure 5-13). At the time of this
writing, machines equipped with
plain rotary tables use RON 285C. RON 285C RON 786C
For machines equipped with pallet
rotary tables RON 786C is used. Figure 5-13
Refer to your machine Angular Encoders
documentation for exact model
used since some of the initial machines built may have used a different model.
Angular encoders can be either of two measurement design types, absolute or incremental, with the RON
models being an incremental angular encoder. Incremental encoders require traversing to a reference
point to determine absolute position, were as, absolute encoders have absolute position value information
immediately after restarting the machine. The “C” in the model number refers to an option, (distance-
coded reference marks), used to speed up the availability of absolute position information. This option
allows determination of the absolute reference after crossing two consecutive reference marks compared
to basic incremental angular encoder that may require rotation up to 360°.
The mechanical design type of RON angular encoders uses an integral bearing, hollow shaft and integral
stator coupling. The drive shaft is connected directly to the encoder shaft. This particular design is
characterized by excellent dynamic performance.

Angular Encoder Specifications by Heidenhain Model Number

RON 285C RON 786C
Incremental Signals ~ 1 VPP ~ 1 VPP
Line Count 18000 18000
Recommended Measuring Step 0.0001° 0.0001°
System Accuracy ± 5” ± 2”
Max Cable Length 150 m (492 ft) 150 m (492 ft)
Natural Frequency ≥ 1200 Hz ≥ 1000 Hz
2
Vibration (55 to 2000 Hz) ≤ 100 m/s ≤ 100 m/s2
Shock (6 ms) ≤ 1000 m/s2 ≤ 1000 m/s2
Maximum Operating Temperature 70 °C (158 °F) 50 °C (122 °F)
Minimum Operating Temperature
Moving Cable -10 °C (14 °F) 0 °C (32 °F)
Rigid Cable -20 °C (-4 °F) 0 °C (32 °F)
Protection (IEC 60529) IP 64 IP 64

5-8