SCHUNK ROTA THW plus 165-43, Assembly And Operating Manual

Page 1: ...Translation of original operating manual Power chuck ROTA THWplus Assembly and operating manual Superior Clamping and Gripping ...

Page 2: ...ion 02 00 24 04 2017 en SCHUNK GmbH Co KG All rights reserved Dear customer congratulations on choosing a SCHUNK product By choosing SCHUNK you have opted for the highest precision top quality and best service You are going to increase the process reliability of your production and achieve best machining results to the customer s complete satisfaction SCHUNK products are inspiring Our detailed ass...

Page 3: ...peed diagrams 19 6 3 Calculations for clamping force and speed 22 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 Fsp0 for a given rpm n 24 6 3 3 Calculation of the permissible rpm nzul in case of a given initial clamping force Fsp0 26 6 4 Grades of Accuracy 26 6 5 Permissible imbalance 27 7 Attachment and disasse...

Page 4: ...ce intervals 37 9 3 Technical condition 37 10 Disposal 38 11 Chuck mounts and Spare parts 39 11 1 Chuck mounts 39 11 2 Spare parts 39 12 Drawings 41 13 Translation of the original declaration of incorporation 43 14 Appendix on Declaration of Incorporation as per 2006 42 EC annex II No 1 B 44 ...

Page 5: ...hese 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 No...

Page 6: ...bout hot surfaces Applicable documents General terms of business Catalog data sheet of the purchased product Calculation of the jaw centrifugal forces Technology chapter in the lathe chuck catalog The documents marked with an asterisk can be downloaded on our homepage www schunk com 1 2 ...

Page 7: ...lso 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 ...

Page 8: ...he machine must carry out and document a hazard assessment and risk analysis to ensure that suitable measures are taken to main tain the lathe chuck s clamping force 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 re quirements of the EC Machinery Directive specifically they...

Page 9: ...rnet when working on the machine and the lathe chuck WARNING Risk of injury due to dropping the chuck during transport instal lation or removal Take special care in the danger zone when transporting in stalling or removing the chuck Note the relevant load securing regulations for working safely with cranes ground conveyors lifting gear and load handling equipment CAUTION Danger of slipping and fal...

Page 10: ...ctive 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 selected clamping position of the clamping jaws to the workpiece can result in damage to the base and top jaws Make sure that the workpiece clamping is concentric In the case of a chuck with a quick chan...

Page 11: ...y fails the workpiece must remain firmly clamped until the spindle is shut down and the workpiece is se cured The technical safety requirements in the respective operating instructions must be observed exactly 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...

Page 12: ...Accesso ries chapter of the SCHUNK lathe chuck catalog or contact SCHUNK Use a suitable high pressure grease gun to ensure that you reach all the greasing areas To ensure correct distribution of the grease move the clamping piston to its end positions several times lubricate again and then check the clamping force We recommend checking the clamping force using a clamping force tester before starti...

Page 13: ...bserve the following rules 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 distance lead to great er 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 heavi...

Page 14: ... 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 opera tor 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 must at least occasionally c...

Page 15: ... parts 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: ... date under the following con ditions Observe the applicable documents 1 2 Page 6 Observe the ambient conditions and operating conditions Observe the maximum number of clamping cycles 6 Page 19 Observe the specified maintenance and lubrication intervals 9 Page 36 Parts touching the workpiece and wear parts are not included in the warranty 3 ...

Page 17: ...nical equipment screw quality 10 9 Screw size M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 Admissible torque MA Nm 13 28 50 88 120 160 200 290 400 500 1050 1500 Tightening torques for mounting screws used to attach 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 4 ...

Page 18: ...165 185 215 1 Power chuck 1 Set of base jaws 3 Mounting screws 1 Jaw change key 1 Operating manual 1 Short operating manual ROTA THW plus 260 315 1 Power chuck 1 Set of base jaws 3 Mounting screws 1 Jaw change key 1 Operating manual 1 Short operating manual 1 Mounting wrench 5 ...

Page 19: ...e catalogs are also available as down load at www de schunk com The maximum permissible speed for special 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 Warranty and maximum clamping cycles Length of warranty 24 Months Maximum clamping cycle number 500 000 Cycles Ensure minimal weight for all jaws For u...

Page 20: ...ed with SCHUNK LINOMAX 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 Center of gravity radius S Center of gravity Clamping force speed diagrams ROTA THW plus 165 43 Clamping force speed diagrams ROTA THW plus 185 52 ...

Page 21: ...Technical data 01 00 ROTA THWplus en 21 Clamping force speed diagrams ROTA THW plus 215 66 Clamping force speed diagrams ROTA THW plus 260 81 Clamping force speed diagrams ROTA THW plus 315 104 ...

Page 22: ...ce safety factor mB Mass of clamping jaw set kg sz Machining safety factor Mc Centrifugal force torque kgm Σs Max clamping force of the 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 influence of rotation the ja...

Page 23: ...mping force Fspmin Consequently the work piece 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 calculat ed from the product of the machining force FspZ...

Page 24: ... 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 jaws for which the base jaws change their radial position only by the stroke amount the centrifugal torque of the ...

Page 25: ...d 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 Centrifugal torque of base jaw and top jaw specified in Chuck da ta table For the centrifugal torque of the top jaw the following applies Centrif...

Page 26: ...l 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 mounting screws and T nuts are not taken into account Identifying the permissible RPM The calculated RPM nzul 1495 rpm is small...

Page 27: ...Technical data 01 00 ROTA THWplus en 27 Permissible imbalance The permissible imbalance for lathe chucks is quality class G 6 3 as per DIN ISO 1940 1 6 5 ...

Page 28: ... faces Use personal protective gear especially safety gloves Check the delivery for completeness and for transport damage Mounting of the Chuck to the Machine Spindle Checking the chuck mounting Check the machine spindle head or the finish machined adapter plate for concentricity and face runout The permissible limit is 0 005 mm as per DIN 6386 1 The contact surface must be clean and deburred Moun...

Page 29: ...e base jaws into the chuck s jaw guidance as shown on markings 1 2 or 3 Check that the base jaw and jaw stroke are easy to move Chucks in sizes 260 and 315 Offset the base jaws to the outermost marking see drawings chapter 11 Remove the screws item 43 and use the threaded extraction hole to push off the protection sleeve item 4 away from the chuck body item 1 and then pull it out completely Lift t...

Page 30: ...1 5 15 0 52 62 0 2 4 58 60 x 2 ROTA THW plus 215 66 M78 x 1 5 17 0 66 76 0 2 4 70 76 x 2 ROTA THW plus 260 81 M90 x 2 0 20 3 81 87 0 2 4 84 86 x 2 ROTA THW plus 315 104 M115 x 2 0 22 5 104 110 0 3 2 107 110 x 3 Lubricate before commissioning the chuck Before commissioning move the chuck in the open position Press three strokes SCHUNK special grease LINOMAX into each of the grease nipples using a h...

Page 31: ...h compression spring item 35 and spring bolt item 13 Use a suitable tool to push out and remove the jaw change bolt item 8 with the balls item 37 through the bore hole for the safety bolt Check the seal item 33 for damage and wear and replace it if necessary NOTE The bearing mechanism may cause metallic noise Pull the chuck piston item 3 together with the three wedge bars item 9 out of the chuck b...

Page 32: ... re duced through slight pressure on the serration Secure the thrust bolt item 12 against flying off and then completely remove the eccentric bolt item 10 out of the wedge bar item 9 Take the angle with plunger pin item 15 and pressure piece item 16 with compression spring item 34 off the wedge bar The pin item 11 is securely glued into the eccentric bolt item 10 Clean all individual components an...

Page 33: ...ally CAUTION There is a risk of crushing during manual loading due to the large jaw stroke We recommend automatic loading If manual loading is used set up the jaw position so that there is no risk of injury when inserting the parts The maximum opening gap must be less than 4 mm when the workpiece is in contact with one of the jaws For each jaw guidance a jaw change bolt item 8 with hexagon socket ...

Page 34: ...anical system of the chuck Wear protective gloves Base jaw position A marking line between the jaw guides is milled on the face side of the chuck see drawing 12 Page 41 This marking line is the positioning aid for the base jaws or top jaws The outermost base jaw or monoblock position is reached when the front face of the base jaw or the unsplit top jaw agrees with the marking line in the jaw chang...

Page 35: ... base jaws and top jaws screwed in place for recurring work Tighten the jaw mounting screws to the specified torque 4 Page 17 Tighten the jaw mounting screws with a torque wrench On no account tighten the screws with an extension pipe or with ham mer blows ...

Page 36: ...ing on the chuck side of SCHUNK LINO MAX special grease at each nipple For optimum grease distribution the clamping piston must travel the entire clamping stroke several times after lubrication Check the clamping force repeat the procedure if necessary Chuck size 165 185 215 260 315 400 Number of strokes 2 2 4 4 4 6 Lubricate all three segments evenly in order to avoid imbalances For product infor...

Page 37: ...ding on type and degree of contamination Technical condition With the smallest possible actuating pressure clamping cylinder the base jaws should move evenly This method only provides a limited indication and does not replace the measurement of the clamping force If the clamping force has dropped too far or if the base jaws and clamping piston no longer move properly the chuck has to be dis assemb...

Page 38: ...the escaping liquids and dispose of them properly in line with the statutory provisions Remove any identifiable plastic or aluminum parts installed in or on the chuck and dispose of them properly in line with the statutory provisions Dispose of the chuck s metal parts as scrap metal Alternatively you can return the chuck to SCHUNK for proper dis posal 10 ...

Page 39: ...0 0800631 0800632 0800633 ROTA THW plus 315 104 Z 220 A8 A11 0800640 0800641 0800642 Spare parts When ordering spare parts it is imperative to specify the type size and above all the manufacturing no of the chuck Seals sealing elements screw connections springs bearings screws and wiper bars plus parts coming into contact with the workpiece are not covered by the warranty Item Designation Quantity...

Page 40: ...on spring for pressure piece 6 35 Compression spring for safety bolt 3 36 Compression spring for thrust bolt 3 37 Steel ball for jaw change bolt 3 39 Tapered lubricating nipple 3 40 Mounting screws DIN EN ISO 4762 10 9 3 41 Mounting screws DIN EN ISO 4762 10 9 3 42 Mounting screws DIN EN ISO 4762 10 9 3 43 Mounting screws DIN 7984 8 8 3 44 Mounting screws DIN EN ISO 4762 10 9 3 47 Compression spri...

Page 41: ...Drawings 01 00 ROTA THWplus en 41 Drawings 12 ...

Page 42: ...Drawings 42 01 00 ROTA THWplus en ...

Page 43: ...lete 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 con struction of work holding chucks Other related technical stand...

Page 44: ...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 stability X 1 3 2 Risk of break up during operation X 1 3 3 Risks due to falli...

Page 45: ... 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 ...