SCHUNK ROTA TB2 1000-560, Assembly And Operating Manual

Page 1: ...Translation of the original operating manual Pneumatic front end chuck ROTA TB2 ROTA TB2 LH Assembly and Operating Manual Superior Clamping and Gripping ...

Page 2: ...2 12 2020 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 will find a solution Best regards Your SCHUNK team H D SCHUNK GmbH Co Spannte...

Page 3: ...nt 16 2 9 Transport 16 2 10 Malfunctions 17 2 11 Disposal 17 2 12 Fundamental dangers 17 2 12 1 Protection during handling and assembly 18 2 12 2 Protection during commissioning and operation 18 2 12 3 Protection against dangerous movements 18 2 12 4 Notes on particular risks 19 2 13 2 jaw chuck 22 3 Technical data 23 3 1 Chuck data 23 3 2 Clamping force speed diagrams 25 3 3 Calculations for clam...

Page 4: ...ple of Operation 46 6 2 Air transmission system 47 6 3 Pilot controlled check valve 48 6 4 Faults causes and solutions 49 7 Commissioning and maintenance 51 7 1 Commissioning 51 7 2 Maintenance 52 7 2 1 Maintenance intervals 55 7 2 2 Hardened Reversible Jaws and Soft Top Jaws 56 8 Disassembly and assembly 57 8 1 Disassembly and cleaning 57 8 2 Assembly 59 8 2 1 Mounting of optional mechanical pres...

Page 5: ...safety instructions in this manual Illustrations 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 in...

Page 6: ...0 185 470 185 LH ROTA TB2 520 191 LH ROTA TB2 600 275 600 275 LH ROTA TB2 630 175 LH ROTA TB2 685 325 685 325 LH ROTA TB2 850 375 850 375 LH ROTA TB2 1000 560 1000 560 LH 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 an...

Page 7: ...General 04 00 0889132_ROTA TB2 ROTA TB2 LH en 7 Scope of delivery 1 Lathe chuck ROTA TB2 LH 6 T nuts 2 Elbow connectors 2 Straight connectors 9 or 12 Fastening screws 1 Eye bolt 1 Operating manual 1 3 ...

Page 8: ...ements of the documentation The parameters limitations ambient conditions characteristic values etc for proper operation are defined in the operating manual Intended use This product is intended for clamping workpieces on machine tools and other suitable technical devices The product may only be used within the scope of its technical data 3 Page 23 The product is intended for industrial and indust...

Page 9: ...y the manufacturer if it is used in working environments that are not permissible if the product is operated without a protective cover Constructional changes Implementation of structural changes By conversions changes and reworking e g additional threads holes or safety devices can impair the functioning or safety of the product or damage it Structural changes should only be made with the written...

Page 10: ...checked after a certain period of operation 7 2 1 Page 55 With the smallest possible actuating pressure hydraulic cylinder the base jaws should move evenly This method only provides a limited indication and is not a substitute for measuring the clamping force If the clamping force has dropped too much or if the base jaws and piston no longer move properly the chuck must be disassembled cleaned and...

Page 11: ... must be reached Stroke control The pressure should be monitored by the lathe via mechanical pressure sensing via sensors or wirelessly via a RSS P1 Stroke control lathe chuck ROTA TB2 with continuous stroke The base jaw edge should be within the marked range during clamping Lathe chuck ROTA TB2 with rapid and clamping stroke LH version Visual inspection The gold colored indicator pin on each jaw ...

Page 12: ...onnel 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 Maintenance instructions The chuck s reliability and safety can only be guaranteed if the operator complies wit...

Page 13: ...ive 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 should be measured dynamically Move the clamping piston through to its end position several times after 500 clamping strokes at the latest This moves the lubricant back to the surfaces of the...

Page 14: ...e chuck face clamping points at a greater distance lead to greater 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 r...

Page 15: ...e read and understood the complete assembly and operating manual Observe the national safety regulations and rules and general safety instructions The following personal 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 dange...

Page 16: ...rd against sharp edges and corners or rough surfaces Wear heat resistant protective gloves when handling hot surfaces Wear protective gloves and safety goggles when handling hazardous substances Wear close fitting protective clothing and also wear long hair in a hairnet when dealing with moving components Transport Handling during transport Incorrect handling during transport may impair the produc...

Page 17: ...rrect handling of disposal may impair the product s safety and cause serious injuries as well as considerable material and environmental harm Follow local regulations on dispatching product components for recycling or proper disposal Fundamental dangers General Observe safety distances Never deactivate safety devices Before commissioning the product take appropriate protective measures to secure t...

Page 18: ...ervision Do not leave suspended loads unattended Protection during commissioning and operation Falling or violently ejected components Falling and violently ejected components can cause serious injuries and even death Take appropriate protective measures to secure the danger zone Never step into the danger zone during operation Protection against dangerous movements Unexpected movements Residual e...

Page 19: ...sk of fatal injury to operating personnel due to the workpiece falling down or being flung out in the event of a power failure In the event of a power failure the lathe chuck s clamping force may fail immediately and the workpiece may be released in an uncontrolled manner This poses a risk of death or injury to the operating personnel and can result in serious damage to the system The machine manu...

Page 20: ...erating personnel from clothing or hair being caught on the lathe chuck and being dragged into the machine Loose clothing or long hair may become caught on projecting parts of the lathe chuck and be drawn into the machine The machines and equipment must fulfill the minimum requirements of the EC Machinery Directive specifically they must have effective technical measures to protect against potenti...

Page 21: ...vention regulations during operation of the chuck especially in connection with machining centers and other technical equipment CAUTION Risk of burns due to workpieces with high temperatures Wear protective gloves when removing the workpieces Automatic loading is preferred CAUTION Danger of damage due to incorrectly selected clamping position of the clamping jaws to the workpiece An incorrectly se...

Page 22: ...oise 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 2 jaw chuck In the 2 jaw version the maximum actuating force must be limited to 6 bar temporary load In the 2 jaw version the working pressure must be limited to 5 5 ...

Page 23: ...pressure min max bar 2 8 2 8 2 8 2 8 2 8 Speed of rotation RPM 1700 1300 1000 750 500 Weight kg 182 366 440 908 1012 Jaw serration 3 32 x90 Centrifugal torque of the base jawMcGB kgm 0 68 1 06 1 81 4 17 4 33 Max jaw eccentricity of center of gravity in axial direction amax mm 36 36 36 42 42 ROTA TB2 470 185 LH 520 191 LH 600 275 LH 630 275 LH 850 375 LH 1000 560 LH Outer diameter Ftk distributor r...

Page 24: ... clamping force and the SHB type hard standard stepped jaws that go with the chuck WARNING Risk of personal injury and property damage due to parts flying off in the 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 If unhardened top jaws or chuck jaws in a special design are us...

Page 25: ...ed and the jaws were placed flush with the base jaw outer edge The chuck is in perfect condition and lubricated with SCHUNK LINO MAX special grease Should one or several of the above mentioned parameters be changed the diagrams are no longer valid Chuck set up for clamping force speed diagram F 3 Clamping force per jaw S Center of gravity rs Center of gravity radius amax Max jaw eccentricity of ce...

Page 26: ...Torques per screw 26 04 00 0889132_ROTA TB2 ROTA TB2 LH en Clamping force RPM diagram for ROTA TB2 470 185 Clamping force RPM diagram for ROTA TB2 600 275 Clamping force RPM diagram for ROTA TB2 685 325 ...

Page 27: ...rques per screw 04 00 0889132_ROTA TB2 ROTA TB2 LH en 27 Clamping force RPM diagram for ROTA TB2 850 375 Clamping force RPM diagram for ROTA TB2 1000 560 Clamping force RPM diagram for ROTA TB2 470 185 LH ...

Page 28: ...es per screw 28 04 00 0889132_ROTA TB2 ROTA TB2 LH en Clamping force RPM diagram for ROTA TB2 520 191 LH Clamping force RPM diagram for ROTA TB2 600 275 LH Clamping force RPM diagram for ROTA TB2 630 275 LH ...

Page 29: ...Torques per screw 04 00 0889132_ROTA TB2 ROTA TB2 LH en 29 Clamping force RPM diagram for ROTA TB2 850 375 LH Clamping force RPM diagram for ROTA TB2 1000 560 LH ...

Page 30: ... of chuck jaw set kg sz Safety factor for machining Mc Centrifugal torque kgm Σs Max clamping force of lathe chuck N kgm 9 81 Nm 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 influence of rotation the jaw mass generate...

Page 31: ...tly 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 and the safety factor Sz This...

Page 32: ...y 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 torque Mc In case of toolholders with split chuck jaws i e with base jaws and top jaws for which the base jaws change their radial position only by the stroke amount the centrifug...

Page 33: ...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 following applies Take the centrifugal torque of the base jaw and top jaw specified from the Lathe chuck data table For the centrifugal torque of...

Page 34: ... 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 the jaw ...

Page 35: ...peeds asymmetrical workpieces or the use of various top jaws as well as uneven application of lubricants In order to prevent damage resulting from these residual risks the entire rotor is to 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 S...

Page 36: ...out The maximum permissible value is 0 005 mm according to DIN 6386 and ISO 3089 The bore holes on the locating face must be chamfered and the face must be completely clean CAUTION Excessively long fastening screws can stand up in the tapping drill hole or damage the machine spindle During assembly of the chuck and flange the length of the mounting screws must be taken into account In case of opti...

Page 37: ...set up of the chuck on the spindle nose of the lathe the height of the spacer bracket is defined For the execution of the spacer bracket it is important to know whether the screw on surface on the front of the spindle box of the lathe is machined or unmachined NOTE The axial labyrinth gap between the chuck body and the distributor ring must be 1 5 mm for all TB2 chucks Only then is the correct tra...

Page 38: ...ch have been drilled in at a 60 angle When the threaded mounting holes in the headstock and the holes in the spacing console have been drilled the spacing console is screwed onto the distributor ring The chuck with the distributor ring and the bolted on spacing console are now finally mounted on the spindle nose The outer diameter of the distributor ring matches the max outer diameter of the chuck...

Page 39: ...ue running check Dimensions of the console ROTA TB2 TB 470 LH TB 600 LH TB 630 LH TB 685 TB 850 LH TB 1000 LH Ø A 448 585 585 666 830 910 Ø B 497 630 630 715 880 960 Ø C 410 645 645 620 785 869 Ø D 467 605 605 685 850 925 Example only deviations possible ...

Page 40: ...ned according to the chapter Mounting with bracket 5 2 1 Page 38 During assembly this 2 part clamping ring is first screwed to the threads of the distributor ring Then the entire assembly is clamped to the rigid collar of the machine For fastening the chuck with a bayonet or camlock the clamping ring should have a cavity in order to access the flanged nuts or clamping cams with the corresponding w...

Page 41: ...Assembly 04 00 0889132_ROTA TB2 ROTA TB2 LH en 41 Distributor ring mounting ...

Page 42: ...nge is mounted on the spindle nose 9 or 12 M16 or M24 hexagon socket screws are used to screw the chuck onto the chuck flange by the front face side SCHUNK provides standard flanges that can be used to mount the ROTA TB2 chuck on spindles in accordance with DIN 55026 DIN 55027 and DIN 55029 5 3 ...

Page 43: ...the chuck and the distributor ring the mechanical pressure monitoring system should be put into operation Insert the switch cam 93 into the rod 99 and tighten the set screw 107 Pressurize the chuck to the working pressure 6 bar so that the jaws move radially inward The switch cam moves to the right Adjust the inductive proximity switch mounted on the machine so that it is triggered by a 1 mm leftw...

Page 44: ... operation Path control is only possible if the lathe chuck is in a certain position in the lathe The left hand inductive proximity switch see Fig 7 Mechanical monitoring is adjusted so that it just responds in the position in which the base jaws are radially outward The right hand inductive proximity switch should trigger when the dimension L of the control cam has the following dimension ROTA TB...

Page 45: ... up despite the indication on the proximity switch display The machine may be released for machining only if the right inductive proximity switch responds and the left one does not The lathe chuck may be enabled in the workpiece loading position and for automatic workpiece loading only if the left hand proximity switch responds and the right hand one does not ...

Page 46: ...one pressure chamber and the forced and simultaneous venting of the second pressure chamber This triggers the piston stroke and the wedge hooks move the base jaws The pressure in the chuck body is shut off and stored by the valve system retensioning while the profile seals are lifted off the chuck body by their elasticity via the venting of the feed lines and therefore cannot wear out while the ch...

Page 47: ...m static seal of the profile seal at the air transfer interface The air can thus flow into the cylinder chamber of the chuck through the passage openings in the profile seal with low loss When the compressed air supply is stopped the double check valve closes and the pretensioned profile seal lifts itself off the chuck body again due to its elasticity and cannot wear out while the chuck is rotatin...

Page 48: ...king pistons It can easily be serviced from the face side of the chuck by means of a locking screw The valve unit controls the flow of two air channels from and to the profile seals through the two blocking pistons The change of the air flow at the profile seals causes the air channel to one cylinder chamber release chamber to be ventilated The reversal of compressed air from one cylinder chamber ...

Page 49: ...tall Distributor ring becomes hot Profile ring seals are in contact with the chuck body resulting in wear check pressure distributor ring must be without pressure during the rotary movement completely dismantle the chuck clean grease and replace profile ring seals Distributor ring becomes hot stationary mounting Align distributor ring to chuck see chapter Distributor ring 5 2 Page 37 the gap betwe...

Page 50: ...in in the chuck body is countersunk during O D clamping or the base jaw edge is within the Clamping Zone or if stroke monitoring is installed the machines receives a release signal Pressure monitoring with the inductive proximity switch sends no release signal Check working pressure Clamping cylinder is leaking in the cylinder or valve area check working pressure Replace defective seal elements If...

Page 51: ...6 Behind the locking screw 15 the pilot controlled double check valve controls the pressurization and ventilation of the two pressure chambers and shuts off the pressure toward the outside It is very important to lightly lubricate the bore hole of the valve system with Klüber special grease QNB 50 100 to ensure a smoothly operating valve system Excessive grease as well as impurities in the valve b...

Page 52: ...ith oil supplies all sliding parts of the cylinder chamber with an oil film The oil level of the oil tank must be checked daily and oil must be added if necessary If the oil consumption is too low i e if the oil level does not visibly drop over a period of 2 to 3 days the oil adjustment screw must be opened slightly Depending on the accumulation of condensation the condensation drain screw must be...

Page 53: ...nside 3 Protective metal cage with container made of transparent polycarbonate 9 Pressure gauge Ø 40 4 Fill level indication for condensate small inspection port 10 Protective cage lock 5 Fill level indication for oil min max large inspection port 11 Distributor module as accessory with two connections Ø T at front and rear and one already mounted seal plug 6 Semi automatic condensate drain G 1 8 ...

Page 54: ...ication of the chuck The uniform clamping force accuracy and life span of the chuck depend greatly on regular cleaning and sufficient lubrication Rust scale casting dust and chips produce friction and reduce motion The chuck must therefore be lubricated after every 40 operating hours by means of the grease gun at the 3 base jaw lubrication nipples with LINOMAX plus special grease Afterwards the ch...

Page 55: ...though there is optimal sealing provided by the hardened guide bushing in the through hole and by the closed base jaws Coolant washes away lubricant Therefore every chuck occasionally must be completely disassembled cleaned and lubricated and the sealing rings replaced The time for which the chuck can be used before full maintenance is required depends on the level of dirt it accumulates and the c...

Page 56: ... ensure that the indicator pin is completely recessed or that the correctly configured path control releases the clamping Hardened reversible jaws should only be used in sets in accordance with the packaging as they are ground on the chuck in sets 1 set of hardened reversible jaws is normally ordered for a chuck When installing and removing the reversible jaws numbered 1 to 3 make sure that the in...

Page 57: ...hen the profile ring seals item 47 are reinserted ensure that air passage openings do not align with the pneumatic connections of the distributor ring WARNING Pressure in the chuck Risk of injury due to ejected parts It is absolutely necessary to carefully remove the valve system item 13 before any further disassembly 3 Valve insert ROTA TB2 470 LH Carefully unscrew the locking plug item 15 with O...

Page 58: ... to pull the sleeve item 95 out to the front If the sleeve bore is worn remove the sleeve item 98 Replace the O rings items 102 105 106 111 Mounting of the mechanical pressure monitoring as per the chapter Mounting mechanical pressure monitoring option 8 2 1 Page 61 8 On the chuck mount item 7 with O ring items 39 44 unscrew the hexagon socket screws item 23 and screw 3 of these screws into the th...

Page 59: ...he cylinder chamber of the chuck must be oiled Jaw guidances in the chuck body base jaws and piston at the wedge hooks are greased with SCHUNK LINO MAX special grease Assembly 1 Tighten all screws to the torque specified in the chapter Screw torques 4 Page 35 using a torque wrench Insert compression spring item 28 and pin item 18 into the chuck body bore CAUTION The indicator pin is under spring t...

Page 60: ...ubricate the valve system item 13 and valve bore hole with oil install the valve system and seal it with the locking screw item 15 and O ring item 37 10 ROTA TB2 600 1000 LH Insert the valve insert into the bore and mount it in the chuck body with the three hexagon socket screws 11 Insert the sleeve item 4 with inserted O ring item 46 from the front of the chuck and secure with the hexagon socket ...

Page 61: ...y stick together the piston pos 94 with extension pos 99 After the drying time insert O ring pos 111 and insert from the front to the stop into the bore hole of the chuck body 8 Insert the springs pos 101 into the piston Screw in locking screw pos 96 with inserted bolt against the spring pressure into the chuck body CAUTION The parts are under spring tension 9 Apply fluid screw lock to the threade...

Page 62: ...e operating manual A maintenance unit consisting of filter water separator and oiler must be connected upstream of this control block TB2S TB2S LH stationary power chucks CAUTION No distributor ring no check valve always continuous pressure The operating manual for the types TB2 TB2 LH also applies analogously for the types TB2S TB2S LH Due to the horizontal chuck utilization extra care should be ...

Page 63: ...ual stroke chucks LH series for I D clamping Also do not clamp workpieces on the fast stroke since this stroke executes very large jaw strokes but very low clamping forces 1 In chucks of the TB2 LH series make sure that the entire fast stroke plus at least 1 3 of the clamping stroke corresponding to the basic overlap is traveled during workpiece clamping 2 11 ...

Page 64: ...7 Mount ROTA TB2 850 and TB2 1000 cylinder 8 Distributor ring 9 T nut 10 Locking screw 11 Flat gasket 12 Cover 13 Insert or with ROTA TB2 470 LH double check valve 15 ROTA TB2 470 LH locking screw 16 Filling plug 17 LH version Indicator pin 18 LH version Pin 19 DIN ISO 4762 10 9 cylindrical screw 20 DIN ISO 4762 10 9 cylindrical screw 21 DIN 7984 8 8 cylindrical screw 23 DIN ISO 4762 10 9 cylindri...

Page 65: ...IN 3771 46 O ring DIN 3771 47 Profile seal 48 O ring DIN 3771 50 Sound absorber 52 Straight screw connection 53 Swivel fitting 54 Fiber seal 65 Copper sealing ring ROTA TB2 470 LH 69 Plug 70 Dummy insert RSS P1 89 Path control extension LH version 90 Plate LH version 91 Bolt LH version 92 Bolt LH version 99 Extension 103 Set screw 105 O ring DIN 3771 108 DIN ISO 4762 10 9 cylindrical screw LH vers...

Page 66: ...leeve 96 Bolt 97 Thrust bolt 98 Sleeve 100 Set screw 101 Compression spring 102 O ring DIN 3771 105 O ring DIN 3771 106 O ring DIN 3771 107 Set screw 111 O ring DIN 3771 Valve insert ROTA TB2 600 1000 LH Item Designation 1 Insert 2 Double check valve 11 DIN 7984 8 8 cylindrical screw 12 O ring DIN 3771 15 Locking screw 37 O ring DIN 3771 ...

Page 67: ...Assembly drawings 04 00 0889132_ROTA TB2 ROTA TB2 LH en 67 Assembly drawings Scope of delivery for dual stroke chucks ROTA TB2 470 LH only valve without insert 13 ...

Page 68: ...Assembly drawings 68 04 00 0889132_ROTA TB2 ROTA TB2 LH en Mechanical pressure monitoring Valve insert ...

Page 69: ...ion until conformity 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 2010 Safety of machinery General principles for design Risk assessment and risk reduction DIN EN 1550 1997 A1 2008 Machine tools safety Safety requirements for the design and co...