SCHUNK ROTA-S flex 1000, Assembly And Operating Manual

Page 1: ...Translation of original operating manual Manual chuck ROTA S flex Assembly and Operating Manual Superior Clamping and Gripping ...

Page 2: ...r the purpose of technical improvement Document number 0889139 Version 04 01 04 2019 en H D SCHUNK GmbH Co All rights reserved Dear Customer thank you for trusting our products and our family owned company 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 wi...

Page 3: ...3 Calculations for clamping force and speed 21 6 3 1 Calculation of the required clamping force in case of a given rpm 22 6 3 2 Calculation example required initial clamping force for a given speed 24 6 3 3 Calculation of the permissible speed in case of a given initial clamping force 25 6 4 Grades of Accuracy 26 6 5 Permissible imbalance 26 7 Attachment of the entire manual chuck 27 7 1 Handling ...

Page 4: ...s 4 04 ROTA S flex en 9 2 Jaw change 30 9 3 At least once a month 31 9 4 In the case of decreasing clamping force or after approx 200 operating hours 31 10 Spare parts 32 11 Assembly drawing 33 12 34 13 35 14 36 15 37 ...

Page 5: ...se instructions must also be passed on Illustrations in this manual are provided for basic understanding of the product and may differ from the actual product design We accept no liability for damage resulting from the failure to observe and comply with this operating manual Warnings To make risks clear the following signal words and symbols are used for safety notes DANGER Danger for persons Non ...

Page 6: ...arning about hot surfaces Applicable documents General terms of business Katalogdatenblatt des gekauften Produkts Calculation of the jaw centrifugal forces Technology chapter in the lathe chuck catalog The above mentioned documents can be downloaded at www de schunk com 1 2 ...

Page 7: ...means that the user has read and understood this operating manual in its entirety especially the chapter Basic safety notes The maximum RPM of the chuck and the required clamping force must be determined by the user for the respective clamping task based on the applicable standards and technical specifications of the manufacturer See also Calculations for clamping force and RPM in the chapter Tech...

Page 8: ...chuck must never be exceeded The lathe chuck may only be used on machines and facilities that fulfill the minimum requirements of the EC Machinery Directive specifically they must have effective technical measures to protect against possible mechanical hazards DANGER Possible risk of fatal injury to operating personnel from clothing or hair being caught on the lathe chuck and being dragged into th...

Page 9: ...he danger zone when transporting installing or removing the chuck Note the relevant load securing regulations for working safely with cranes ground conveyors lifting gear and load handling equipment WARNING Risk of injury by catapulted brass cover caps accessory of the clamping bolt in case of rotation of the chuck The brass cover caps accessory of the clamping bolt must only be used for stationar...

Page 10: ...loading is preferred 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 and rotating workpiece Ensure the chuck s axial and concentric runout Check options for remedying imbalances on special top jaws and workpieces Reduce the speed Wear hearing protection...

Page 11: ...g personnel if the chuck s top speed is exceeded and a workpiece is released or parts fly off If the machine tool or technical equipment can reach a higher speed than the chuck s top speed a reliable speed limiter must be installed and proof must be provided that the speed limiter is effective WARNING Vibrations caused by the processing can result a loss of clamping force Risk of injury due drop o...

Page 12: ... performed in the same step as for the respective clamping task In the event of high operating speeds clamping force losses must be accounted for due to the centrifugal force acting on the chuck jaws In this case the value of the operating clamping force has to be determined by a dynamic measurement Move the clamping piston through to its end position several times after 500 clamping strokes at th...

Page 13: ...reater surface pressure in the jaw guidance and can significantly reduce the clamping force Do not use welded jaws If for constructional reasons the chuck jaws in special design are heavier than the top jaws assigned to the clamping device greater centrifugal forces must be accounted for when defining the required clamping force and the recommended speed Screw the jaw mounting screws into the bore...

Page 14: ... equipment in which a chuck is mounted only if they are under the constant guidance and supervision of qualified specialists Organizational measures Obeying the rules Via suitable organizational measures and instructions the operator must ensure that the relevant safety rules are obeyed by the persons asked to operate maintain and repair the chuck Checking the behavior of personnel The operator mu...

Page 15: ...arts Environmental regulations Comply with the applicable legal norms when disposing of waste Using personal protective equipment When using this product you must comply with the relevant health and safety at work rules and you must use the required personal safety equipment minimum category 2 2 7 ...

Page 16: ...te under the following conditions Observe the applicable documents 1 2 Page 6 Observe the ambient conditions and operating conditions Observe the maximum number of clamping cycles 6 1 Page 18 Observe the specified maintenance and lubrication intervals 9 Page 30 Parts touching the workpiece and wear parts are not included in the warranty 3 ...

Page 17: ...ttach top jaws onto the chuck screw quality 12 9 Screw size M6 M8 M10 M12 M14 M16 M20 M24 Max admissible torque MA Nm 16 30 50 70 130 150 220 450 Scope of delivery Centering chuck complete ROTA S plus 2 0 or ROTA S plus 1 Console plate 3 Extensions of guideway 1 Set of long special base jaws 1 Set of short special base jaws 1 Cover plate 2 Centering bolts Ø 32g6 Ø 50g6 Screws and T nuts for mounti...

Page 18: ...y in the SCHUNK power chuck catalog Those catalogs are also available as download at www de schunk com The recommended max speed is only valid for max operating force and the use of the suitable hard standard stepped jaws Warranty and maximum clamping cycles Length of warranty 60 Months Maximum clamping cycle number 50 000 Cycles When using unhardened top jaws or jaws in special design make sure t...

Page 19: ...g force RPM curves were determined using long hard base jaws and hard SHF and SFA standard jaws During this the max actuating force was applied The diagrams showing short hard base jaws and hard SHF and SFA standard jaws can be found in the ROTA Splus or ROTA Splus 2 0 operating manuals contained in the scope of delivery The chucks were in good condition and greased with special SCHUNK grease LINO...

Page 20: ...Technical data 20 04 ROTA S flex en ROTA S flex 550 with long jaws ROTA S flex 700 with long jaws ROTA S flex 1000 with long jaws ...

Page 21: ...torque of top jaws Nm Fsp Effective clamping force N McGB Centrifugal torque of base jaws Nm Fspmin Minimum required clamping force N n Speed rpm Fsp0 Initial clamping force N rs Center of gravity radius mm Fspz Cutting force N rsAB Center of gravity radius of top jaw mm mAB Mass of one top jaw kg ssp Safety factor for clamping force mB Mass of chuck jaw set kg sz Safety factor for machining Mc Ce...

Page 22: ...he effective clamping force Fsp for gripping from the outside inwards for gripping from the inside outwards DANGER Risk to life and limb of the operating personnel and significant property damage when the RPM limit is exceeded With gripping from the outside inwards and with increasing RPM the effective clamping force is reduced by the magnitude of the increasing centrifugal force the forces are op...

Page 23: ...Fsp and the total centrifugal force Fc is multiplied by the safety factor for the clamping force Ssp According to VDI 3106 the following also applies here Ssp 1 5 The total centrifugal force Fc is dependent on both the sum of the masses of all jaws and on the center of gravity radius and the rpm NOTICE For safety reasons in accordance with DIN EN 1550 the centrifugal force may be a maximum of 67 o...

Page 24: ...rpm Chuck data table RPM n 1200 rpm application specific Mass of one top jaw mAB 5 33 kg application specific Center of gravity radius of top jaw 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 calcu...

Page 25: ...permissible RPM for a given initial clamping force during shutdown NOTICE The calculated permissible RPM may not exceed the maximum RPM inscribed on the chuck for safety reasons Example 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 ...

Page 26: ...uck nmax 3200 rpm see Chuck data table 6 1 Page 18 This calculated RPM may be used Grades of Accuracy Tolerances for run out accuracy and axial run out accuracy correspond to the Technical Supply Terms for lathe chucks as per DIN ISO 3089 Permissible imbalance The permissible imbalance for lathe chucks is quality class G 6 3 as per DIN ISO 1940 1 6 4 6 5 ...

Page 27: ...ct surface must be chamfered and clean Rectify any damage of the machine table contact surfaces Assembly of the entire manual chuck Insert the T nuts item 15 into the grooves provided in the machine table Then lift the toolholder and supplied eye bolts onto the machine table Align centrally with the centering bolts item 8 and radially with the location bolts item 21 Align the chuck and then attach...

Page 28: ... screw the cover item 4 with the O ring item 18 onto the chuck face using the screws item 11 The base jaws must always move under the cover so as to keep the toolholder through bore sealed However the base jaws must only be moved inwards to the extent that the first tongue and groove of the base jaws does not move onto the cover item 4 in the course of clamping If standard jaws are used on the too...

Page 29: ...he base jaws item 6 7 See also the ROTA S plus or ROTA S plus 2 0 Assembly and Operating Manual WARNING Risk of injury from mounting screw brass caps items 9 and 10 being flung out when chuck turns The mounting screw brass caps items 9 and 10 must only be applied for stationary use of the chuck Important notes on the ROTA S plus or ROTA S plus 2 0 manual chuck See the ROTA S plus or ROTA S plus 2 ...

Page 30: ...o grease in contact with skin Wear gloves Disassembling and assembling the chuck Remove the base jaws from the chuck as described in chapter Handling and jaw change 8 1 Page 28 Unscrew the screws item 33 and remove the guideway extension item 4 Screw out the screws item 33 and undo the ROTA S flex from the baseplate item 3 taking it off to the front For further disassembly and assembly of the chuc...

Page 31: ...rease After lubricating open and close the chuck 2 3 times without a workpiece to evenly distribute the grease across all the functional surfaces Clean the guideway extensions and apply LINO MAX with a brush In the case of decreasing clamping force or after approx 200 operating hours If the clamping force decreases the inside of the chuck is contaminated or the coolant has washed out or decomposed...

Page 32: ...on Quantity 999 ROTA S plus 2 0 or ROTA S plus centering chuck complete 1 60 Base plate 1 61 Guideway extension 3 62 Cover 1 64 Pressure bolt 3 63 Long base jaw 3 40 Short base jaw 3 68 69 Centering bolt 2 66 Cover bore cover 15 85 Cover bore cover 13 71 Countersunk screws 3 70 Cylindrical screws 15 75 Cylindrical screws 3 74 Cylindrical screws 13 73 Nut for T slot 13 78 Cylindrical screws 12 76 C...

Page 33: ...Assembly drawing 04 ROTA S flex en 33 Assembly drawing ROTA S flex 11 ...

Page 34: ... 1 1 6 Wedge bar 2 1 7 Sliding block 3 2 8 Spindle 1 1 9 Spindle nut 1 1 10 Bearing seat 1 1 11 Wiper starting for size 200 3 2 12 Slide 3 2 13 Locking slide 3 2 14 Pressure bolt 3 2 15 Traverse slide 3 2 17 Indicator pin 1 1 30 Cylindrical pin 1 1 31 Compression spring for pressure bolt 3 2 32 Compression spring for locking slide 3 2 33 Spring loaded pressure piece 3 2 34 Cylindrical screw 3 4 35...

Page 35: ...04 ROTA S flex en 35 Assembly drawing ROTA S plus 2 0 13 ...

Page 36: ...Wedge bar with thread 7 Sliding block 8 Spindle 9 Wedge bar without thread 10 Safety bolt 13 Seat of bearing with bore hole 15 Seat of bearing 17 Indicator pin 18 Ball 19 Cartridge 24 2nd plunger pin 25 The plunger pin 26 Washer 27 Compression spring for plunger pin 28 Compression spring for indicator pin 29 Compression spring for safety bolt 30 Clamping pin 31 Screw for plunger pin 32 Lubrication...

Page 37: ...04 ROTA S flex en 37 Assembly drawing ROTA S plus 15 ...