SCHUNK ROTA NCA 160, Assembly And Operating Manual

Page 1: ...Translation of Original Operating Manual Power Lathe Chuck ROTA NCA Assembly and Operating Manual Superior Clamping and Gripping ...

Page 2: ...ompany the leading technology supplier of robots and production machines Our team is always available to answer any questions on this product and other solutions Ask us questions and challenge us We will find a solution Best regards Your SCHUNK team H D SCHUNK GmbH Co Spanntechnik KG Lothringer Str 23 D 88512 Mengen Tel 49 7572 7614 0 Fax 49 7572 7614 1099 info de schunk com schunk com Customer Ma...

Page 3: ...sport 13 2 11 Malfunctions 13 2 12 Disposal 13 2 13 Fundamental dangers 13 2 13 1 Protection during handling and assembly 14 2 13 2 Protection during commissioning and operation 14 2 13 3 Protection against dangerous movements 15 2 13 4 Notes on particular risks 15 3 Technical data 19 3 1 Chuck data 19 3 2 Clamping force RPM diagrams 20 3 3 Calculations for clamping force and speed 22 3 3 1 Calcul...

Page 4: ...or chuck with reduction or extension flange 34 5 4 3 Assembly preparation for chuck with direct mount 34 6 Function 35 6 1 Function and handling 35 6 2 Functional testing 35 6 3 Replacement or renewal of jaws 36 7 Maintenance 38 7 1 Lubrication 38 7 2 Maintenance intervals 39 7 3 Disassembling and assembling the chuck 39 8 Spare parts 41 9 Drawing 43 10 Declaration of Incorporation 44 11 Appendix ...

Page 5: ...ions in this manual are provided for basic understanding and may differ from the actual product design In addition to these instructions the documents listed under 1 1 2 Page 6 are applicable Presentation of Warning Labels To make risks clear the following signal words and symbols are used for safety notes DANGER Danger for persons Non observance will inevitably cause irreversible injury or death ...

Page 6: ...60 32 ROTA NCA 200 52 ROTA NCA 225 66 ROTA NCA 280 86 ROTA NCA 330 104 Warranty The warranty period is 24 months after delivery date from factory or 500 000 cycles if it is used as intended under the following conditions Observe the applicable documents 1 1 2 Page 6 Observe the ambient conditions and operating conditions 2 6 Page 10 Observe the specified maintenance and lubrication intervals 7 Pag...

Page 7: ...General 02 00 ROTA NCA en 7 Scope of Delivery 1 Power lathe chuck in the version ordered 3 Mounting screws 6 T nuts with screws or 3 combination T nuts 1 Assembly key from size 280 1 Eye bolt 1 3 ...

Page 8: ...ive clamping task based on the applicable standards and technical specifications of the manufacturer See also Calculations for clamping force and RPM in the chapter Technical data 3 Page 19 Not intended use A not intended use of the product is for example It is used as a press a punch a toolholder a load handling device or as lifting equipment the product is used for unintended machines or workpie...

Page 9: ...equirements of the chuck jaws Stored energy can make the product unsafe and poses the danger of serious injuries and considerable material damage Only change chuck jaws if no residual energy can be released Do not use welded jaws The chuck jaws should be designed to be as light and as low as possible The clamping point must be as close as possible to the chuck face clamping points at a greater dis...

Page 10: ...g conditions Incorrect ambient and operating conditions can make the product unsafe leading to the risk of serious injuries considerable material damage and or a significant reduction to the product s life span Make sure that the product is used only in the context of its defined application parameters 3 Page 19 Make sure that the product is a sufficient size for the application Only use high qual...

Page 11: ...onal qualifications are necessary for the various activities related to the product Due to their technical training knowledge and experience trained electricians are able to work on electrical systems recognize and avoid possible dangers and know the relevant standards and regulations Due to its technical training knowledge and experience qualified personnel is able to perform the delegated tasks ...

Page 12: ...azardous substances Wear close fitting protective clothing and also wear long hair in a hairnet when dealing with moving components Notes on safe operation Incorrect handling of the personnel Incorrect handling and assembly may impair the product s safety and cause serious injuries and considerable material damage Avoid any manner of working that may interfere with the function and operational saf...

Page 13: ... departments persons Order appropriately trained personnel to rectify the malfunction Do not recommission the product until the malfunction has been rectified Test the product after a malfunction to establish whether it still functions properly and no increased risks have arisen Disposal Handling of disposal The incorrect handling of disposal may impair the product s safety and cause serious injur...

Page 14: ...iately qualified personnel For all work secure the product against accidental operation Observe the relevant accident prevention rules Use suitable assembly and transport equipment and take precautions to prevent jamming and crushing Incorrect lifting of loads Falling loads may cause serious injuries and even death Stand clear of suspended loads and do not step into their swiveling range Never mov...

Page 15: ...d accidents and or material damage human access to the movement range of the machine must be restricted Limit prevent accidental access for people in this area due through technical safety measures The protective cover and protective fence must be rigid enough to withstand the maximum possible movement energy EMERGENCY STOP switches must be easily and quickly accessible Before starting up the mach...

Page 16: ...orce until the machine comes to a standstill and the workpiece can be secured e g using a crane or suitable lifting equipment The machines and equipment must fulfill the minimum requirements of the EC Machinery Directive specifically they must have effective technical measures to protect against potential mechanical hazards DANGER Possible risk of fatal injury to operating personnel if a jaw break...

Page 17: ...hine and the lathe chuck CAUTION Danger of slipping and falling in case of dirty environment where the chuck is used e g by cooling lubricants or oil Ensure that the working environment is clean before starting assembly and installation work Wear suitable safety shoes Follow the safety and accident prevention regulations when operating the chuck especially when working with machine tools and other...

Page 18: ...become damaged The T nuts for connecting the top jaws to the base jaws must not protrude beyond the base jaws in the radial direction The diameter of the workpiece may not be bigger than the chuck diameter CAUTION Hazard from vibration due to imbalanced rotating parts and noise generation Physical and mental strains due to imbalanced workpieces and noise during the machining process on the clamped...

Page 19: ...g force and when using the hard standard chuck jaws that go with the chuck The maximum permissible RPM for the specific machining has to be defined by the user on the basis of the required clamping forces This speed must not exceed the maximum speed of the chuck Ensure minimal weight for all jaws For unhardened top jaws or chuck jaws in special design the permissible RPM according to VDI 3106 must...

Page 20: ... force was applied and the jaws were set flush with the outer diameter of the chuck The chuck is in perfect condition and lubricated with SCHUNK LINOMAX plus special grease If one or more of these prerequisites is modified the graphs will no longer be valid Chuck setup for clamping force RPM graph F 3 Clamping force per jaw Fmax Max actuating force rs Radius of centre S center of gravity Clamping ...

Page 21: ...Torques per screw 02 00 ROTA NCA en 21 Clamping force RPM graph for ROTA NCA 200 52 Clamping force RPM graph for ROTA NCA 225 66 Clamping force RPM graph for ROTA NCA 280 89 ...

Page 22: ...aw kg ssp Safety factor for clamping force mB Mass of chuck jaw set kg sz Safety factor for machining Mc Centrifugal force torque Kgm Σs Max clamping force of chuck N Calculation of the required clamping force in case of a given rpm The initial clamping force Fsp0 is the total force impacting radially on the workpiece via the jaws due to actuation of the lathe chuck during shutdown Under the influ...

Page 23: ...mping force Fspmin Consequently the workpiece is released spontaneously Do not exceed the calculated RPM Do not fall below the necessary minimum clamping force Reduction in effective clamping force by the magnitude of the total centrifugal force for gripping from the outside inwards The required effective clamping force for machining Fsp is calculated from the product of the machining force FspZ a...

Page 24: ...d the rpm CAUTION For safety reasons in accordance with DIN EN 1550 the centrifugal force may be a maximum of 67 of the initial clamping force The formula for the calculation of the total centrifugal force Fc is For this n is the given speed of rotation in RPM The product mB rs is referred to as the centrifugal force torque Mc In case of toolholders with split chuck jaws i e with base jaws and top...

Page 25: ...rsAB 0 107 m application specific Safety factor Sz 1 5 according to VDI 3106 Safety factor Ssp 1 5 according to VDI 3106 Note Masses of the jaw mounting screws and T nuts are not taken into account First the required effective clamping force Fsp is calculated using the machining force stated Initial clamping force during shutdown Calculation of total centrifugal force For two part chuck jaws the f...

Page 26: ...ple of calculation Permissible RPM for a given effective clamping force The following data is known from previous calculations Initial clamping force during shutdown Fsp0 17723 N Machining force for machining job Fspz 3000 N application specific Total centrifugal torque of all jaws Mc 2 668 kgm Safety factor Sz 1 5 according to VDI 3106 Safety factor Ssp 1 5 according to VDI 3106 NOTE Masses of th...

Page 27: ...order to prevent damage resulting from these residual risks the entire rotor must be dynamically balanced in accordance with DIN ISO 21940 11 Torques per screw Tightening torques for mounting screws used to clamp the chuck on lathes or other suitable technical equipment screw quality 10 9 Screw size M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 7 16 1 2 5 8 3 4 7 8 1 Tightening torques MA Nm 13 28...

Page 28: ...ing Make sure that no residual energy remains in the system CAUTION Danger of injury due to sharp edges and rough or slippery surfaces Wear personal protective equipment particularly protective gloves 1 Checking the spindle nose for mounting the chuck flange 5 3 Page 30 2 Chuck assembly Chuck assembly with cylindrical recess 5 4 1 Page 31 If required Assembly preparation for chuck with reduction o...

Page 29: ...ube side If they cannot be attached directly to the draw tube an adapter must be used A B C D E F O ring ROTA NCA 160 32 M38 x 1 5 15 32 36 2 4 28 38 x 1 5 ROTA NCA 200 53 M67 x 1 5 15 52 65 2 4 58 66 x 2 ROTA NCA 225 66 M74 x 1 5 14 5 66 72 2 4 70 72 x 2 ROTA NCA 280 86 M94 x 1 5 20 86 91 2 4 89 93 x 2 ROTA NCA 330 104 M115 x 2 22 5 104 110 3 2 107 110 x 3 5 2 ...

Page 30: ...e spindle for concentricity and axial run out accuracy using a dial indicator There should be a maximum concentricity error in the centering of the mount of 0 005 mm and a maximum axial run out error in the contact surfaces of 0 005 mm The flat surface of the spindle must also be checked for flatness using a straightedge Make sure that the surface area of the flat surface is deburred at the bore h...

Page 31: ...aration for chuck with direct mount 5 4 3 Page 34 Chuck assembly with cylindrical recess NOTE If the mount of the machine spindle and the lathe chuck are identical chuck assembly takes place without assembly preparation If the mount of the machine spindle deviates from the mount of the lathe chuck a connecting flange must be affixed before the chuck is assembled See 5 4 2 Page 34 or 5 4 3 Page 34 ...

Page 32: ... depth gauge R2 R1 0 1 mm max 0 3 mm It must be ensured that the piston can be brought into the foremost jaw change position To do this ensure that the dimensions for the attachment are complied with 3 Push the chuck piston item 3 to the frontmost position chuck open 4 Lift the lathe chuck flush to the center of the spindle 5 Screw the rotating center sleeve item 6 in the chuck onto the draw tube ...

Page 33: ...xial run out tolerances table shows the concentricities and axial run out accuracies to be achieved 10 Check the actuating force is functioning and is sufficient 11 Check the jaw stroke of the base jaws Item 2 Fasten the top jaws marked 1 2 and 3 to the base jaws using T nuts item 27 and screws item 26 The spindle is disassembled in the same way but in the reverse order Concentricity and axial run...

Page 34: ...of the chuck 3 After assembly ensure that the flange is in contact with the entire surface 4 Check the concentricity and axial run out accuracy of the flange see Fig Lathe chuck assembly B 5 4 Page 31 5 Then the chuck is assembled 5 4 1 Page 31 Assembly preparation for chuck with direct mount If the bolt pitch circle of the short taper machine spindle is identical to that of the lathe chuck a dire...

Page 35: ...ng force If the workpiece is released in an uncontrolled manner there is a risk of personal injury and damage to the system Refer to the Technical data chapter Functional testing Functional test After installation of the chuck its function must be checked prior to start up Two important points are Clamping Force The clamping force of the chuck must be achieved at max operating force pressure Strok...

Page 36: ...eat accuracy the chuck jaws must be turned or ground in the lathe chuck under clamping pressure CAUTION When turning or grinding ensure that the turning ring or turning pin is clamped by the top jaws and not by the base jaws Tighten the jaw mounting screws screw grade 12 9 to the specified torque 4 Page 27 CAUTION Tighten the mounting screws of the top jaws with a torque wrench Never tighten the A...

Page 37: ...e event of a screw breakage on unhardened top jaws Soft standard top jaws must be hardened in the countersink region They should only be depth hardened not surface hardened Changing the top jaws When changing the top jaws the serration has to be cleaned and lightly greased with SCHUNK LINOMAX plus special grease ...

Page 38: ...cal or hanging chuck the upper ventilation hole must be opened When lubricating press the grease gun until grease is pushed out on the 120 offset upper ventilation hole For optimum grease distribution the chuck piston must travel the entire clamping stroke several times after lubrication CAUTION Allergic reactions due to grease in contact with skin Wear gloves Operating conditions Depending on the...

Page 39: ...0 days or after 15 000 clamping cycles high use of coolant after one year or after 250 000 clamping cycles Full cleaning with disassembly of chuck depending on type of contamination and quantity Disassembling and assembling the chuck The item numbers specified for the corresponding individual components relate to chapter drawings 9 Page 43 The chuck can only be disassembled once it has been remove...

Page 40: ... chuck body item 1 Remove seal item 22 10 Lift seal item 20 as before over the base jaw item 2 and remove the base jaw item 2 outwards out of the chuck body 11 The sleeves items 6 and 8 may not be removed 12 Remove the screws item 13 Degrease and clean all parts and check them for damage Before assembly grease well with LINOMAX Only use genuine SCHUNK spare parts when replacing damaged parts 1 Whe...

Page 41: ...ith the workpiece are not covered by the warranty Seal kit Seal kits Seal kit Ident number ROTA NCA 160 1352529 ROTA NCA 220 1352530 ROTA NCA 225 1352531 ROTA NCA 280 1352532 ROTA NCA 330 1352533 Spare parts Item Designation Quantity a b c d e 1 Chuck body 1 2 Base jaw 3 3 Piston 1 4 Protection sleeve 1 5 Cover 3 6 Sleeve 3 x 7 Mount 1 8 Sleeve 6 x x 9 Center sleeve 1 x 10 Screw 3 11 Screw 6 12 Sc...

Page 42: ... 20 Seal 3 x 21 Seal 3 x 22 Seal 3 x 23 Seal 6 x x 24 Eye bolt 1 25 Seal 3 x x 26 T nut 36 27 Screw 6 28 Screw 6 29 Pin 1 30 Emblem 1 35 Lubrication nipple 1 a not in size 160 b only size 280 and 330 c not in size 33 d the positions are fixed and cannot be removed e included in the sealing kit ...

Page 43: ...Drawing 02 00 ROTA NCA en 43 Drawing 9 ...

Page 44: ...ity of the machine into which the partly completed machine is to be installed with the provisions of the Machinery Directive 2006 42 EC is confirmed Applied harmonized standards especially DIN EN ISO 12100 2011 03 Safety of machinery General principles for design Risk assessment and risk reduction EN 1550 1997 A1 2008 Machine tools safety Safety requirements for the design and construction of work...

Page 45: ...8 Seating X 1 2 Control Systems 1 2 1 Safety and reliability of control systems X 1 2 2 Control devices X 1 2 3 Starting X 1 2 4 Stopping X 1 2 4 1 Normal stop X 1 2 4 2 Operational stop X 1 2 4 3 Emergency stop X 1 2 4 4 Assembly of machinery X 1 2 5 Selection of control or operating modes X 1 2 6 Failure of the power supply X 1 3 Protection against mechanical hazards 1 3 1 Risk of loss of stabil...

Page 46: ...Warning devices X 1 7 2 Warning of residual risks X 1 7 3 Marking of machinery X 1 7 4 Instructions X 1 7 4 1 General principles for the drafting of instructions X 1 7 4 2 Contents of the instructions X 1 7 4 3 Sales literature X The classification from Annex 1 is to be supplemented from here forward 2 Supplementary essential health and safety requirements for certain categories of machinery X 2 1...