SCHUNK VERO-S WDB 99, Assembly And Operating Manual

Page 1: ...Translation of Original Operating Manual VERO S modular system for direct workpiece clamping WDB 99 Assembly and Operating Manual Superior Clamping and Gripping ...

Page 2: ...the purpose of technical improvement Document number 0489075 Version 02 00 16 11 2017 en H D SCHUNK GmbH Co All rights reserved Dear Customer thank you for trusting our products and our family owned company the leading technol ogy 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 ...

Page 3: ...ce and screw strength 13 2 9 Transport 13 2 10 Malfunctions 13 2 11 Disposal 14 2 12 Fundamental dangers 14 2 12 1 Protection during handling and assembly 14 2 12 2 Protection during commissioning and operation 15 2 12 3 Protection against dangerous movements 15 2 12 4 Notes on particular risks 16 3 Technical data 19 3 1 Direct workpiece clamping modules 19 3 2 Pneumatic direct clamping module WDN...

Page 4: ...B SPD C 41 5 7 Clamping pin extensions SP VLK 50 42 5 8 Pneumatic circuit diagram 42 5 9 Compressed air supply 44 6 Functional description 45 6 1 Function of the connecting unit in the change components 45 6 2 Functions of the air routings in the change components 46 6 3 Function of the workpiece system control 47 6 4 WDA 99 79 32 48 7 Operation 49 8 Maintenance and care 50 8 1 Maintenance and car...

Page 5: ...tions 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: ...for VERO S clamping systems WDN M 99 70 For use as intended under the following conditions Observe the applicable documents 1 1 2 Page 6 Observe the ambient conditions and operating conditions 2 5 Page 10 Observance of the specified care and maintenance instructions 8 Page 50 Parts touching the workpiece and wear parts are not included in the warranty A cycle consists of a complete clamping proces...

Page 7: ...ers 6 mm WDG 99 60 1 set screw WDB 99 50 spare part 3 closing nip ple 2 locking screws 3 locking couplings 1 hexagonal socket screwdriver 6 mm WDR 99 60 1 sleeve 24 25 1 set screw WDB 99 50 spare part 3 closing nipples 3 locking couplings 1 hexagonal socket screwdrivers 6 mm WDS 99 30 1 set screw WDB 99 50 spare part WDS 99 50 1 set screw WDB 99 50 spare part WDS 99 80 1 set screw WDB 99 50 spare ...

Page 8: ...ts type PAL S PAL A clamping pin type SPA 40 SPB 40 SPC 40 SPG 40 Clamping pin for compensation module type WDA SPA 32 WDA SPC 36 Protective cover type SDE Alignment element ARE 25 for basic module Sleeve HUE 24 25 for basic module basic module clamping pin extensions Compressed air hoses Protection covers with shrink hoses Hexagonal screwdriver Torque wrench 1 3 1 ...

Page 9: ...e 19 The clamping systems are intended for industrial applications Appropriate use of the product includes compliance with all instructions in this manual Not intended use The VERO S WDB 99 is not being used as intended if for example It is used as a pressing tool a chuck a load handling device or as lifting equipment If tools or similar objects are picked up and clamped in the VERO S WDA 99 79 co...

Page 10: ...t surfaces of the interface are always clean Make absolutely sure that no chips of any kind can enter the interface and that the interface does not fill with cooling emul sion which is particularly possible with vertical positioning of the clamping pin axis The best way to ensure both of these is to use the SDE protection covers If the interface should fill with cooling emulsion initiate the unloc...

Page 11: ...knowledge and experience service personnel of the manufacturer is able to perform the delegated tasks and to recognize and avoid possible dangers Personal protective equipment Use of personal protective equipment Personal protective equipment serves to protect staff against danger which may interfere with their health or safety at work When working on and with the product observe the occupa tional...

Page 12: ... on a normal working environment If the product is to be operated in an environment with abrasive dusts or corrosive or aggressive fumes or fluids prior approval must be obtained from SCHUNK Safety during assembly and servicing During assembly connection adjustment commissioning and testing make sure that no accidental operation of the system by the fitter or other persons is possible Compensation...

Page 13: ...sport Incorrect handling during transport may impair the product s safe ty and cause serious injuries and considerable material damage When handling heavy weights use lifting equipment to lift the product and transport it by appropriate means Secure the product against falling during transportation and handling Stand clear of suspended loads Malfunctions Behavior in case of malfunctions Immediatel...

Page 14: ...ion Ensure that no residual energy remains in the system If the energy supply is connected do not move any parts by hand Do not reach into the open mechanism or movement area of the product during operation Protection during handling and assembly Incorrect handling and assembly Incorrect handling and assembly may impair the product s safety and cause serious injuries and considerable material dama...

Page 15: ...n the response of the monitoring function to avert danger Until the installed monitors become effective it must be assumed that the drive movement is faulty with its action being dependent on the control unit and the current operating condition of the drive Perform maintenance work modifications and attachments outside the danger zone defined by the movement range To avoid accidents and or materia...

Page 16: ...igence During operation erroneous or negligent loosening of the clamping pin must be prevented using suitable countermeas ures disconnecting the power supply after locking use of check valves or safety switches The machines and equipment must fulfill the minimum requirements of the EC Machinery Directive 2006 42 EC specifically they must have effective technical measures to protect against potenti...

Page 17: ...ically operated compensation module The machines and equipment must fulfill the minimum re quirements of the EC Machinery Directive 2006 42 EC specif ically they must have effective technical measures to protect against potential mechanical hazards Observe the technical data Observe the minimum clamping depth CAUTION Risk of injury due to impurities e g metal chips in the exhaust and air purge con...

Page 18: ...t is clean before starting assembly and installation work Wear suitable safety boots Follow the safety and accident prevention regulations when operating the quick change pallet system especially when working with machine tools and other technical equipment CAUTION Risk of burns due to workpieces with high temperatures There is a risk of burns due to workpieces with high tempera tures Wear protect...

Page 19: ...WDG 99 60 WDR 99 60 WDS 99 30 ID no 0471617 0471618 0471619 0471601 Height 60 mm 60 mm 60 mm 30 mm Change interface holding force 50 kN Change interface pull in force min 10 kN max 25 kN Actuation moment change interface min 20 Nm max 50 Nm weight 3 5 kg 3 1 kg 2 9 kg 1 7 kg Designation WDS 99 50 WDS 99 80 WDS 99 120 WDS 99 160 ID no 0471602 0471607 0471608 0471609 Height 50 mm 80 mm 120 mm 160 mm...

Page 20: ...uality according to ISO 8573 1 7 4 4 Tightness level IP IP 67 Holding force when fastening the clamping pin with cylindrical screw DIN EN ISO 4762 12 9 Manual direct clamping module WDN M 99 70 Designation WDN M 99 70 ID no 0471611 Height 70 mm Holding force M10 M12 M16 35 kN 50 kN 75 kN Actuation torque 20 Nm Maximum pull in force 15 kN Revolutions for full clamping stroke 6 Hexagon socket connec...

Page 21: ... 0 kN 15 kN Weight 3 0 kg Actuation pressure 6 bar Repeat accuracy 0 15 mm radially floating compensation Noise emission 70 dB A Pressure medium Compressed air compressed air quality according to ISO 8573 1 7 4 4 Tightness level IP IP 67 Hydraulic compensation module WDA 99 79 32 Designation WDA 99 79 32 ID no 0471605 Height 73 mm Ø clamping stem 32 mm Extraction length 22 mm max actuation torque ...

Page 22: ...ity 10 9 Screw size M10 M12 M16 Tightening torques MA Nm 52 92 224 Screw tightening torques for the attachments screws of the change interface for connecting two joined workpiece direct clamping modules screw quality 12 9 Clamping screw of the change interface screw tightening torques MA Nm 20 25 30 35 40 42 50 Achievable pull in force at the change interface kN 7 5 10 10 8 13 20 21 5 25 4 ...

Page 23: ...rt damage Assembly dismantling and modification work on the workpiece direct clamping module may only be carried out by specialist personnel Disconnect the power supply lines and ensure that there is no residual energy in the system before performing assembly modification maintenance or adjustment work Until the workpiece direct clamping module is assembled access to the side attachment screw of t...

Page 24: ... compensation module WDA 99 70 36 can be used also refer to chapter Clamping pins 5 4 Page 35 An indi vidual height compensation on the Z axis can be achieved at the same time as the longitudinal distance between two shifted clamping pillars using the compensation module WDA 99 70 36 NOTE When connecting the WDB 99 60 base module or the WDG 99 60 basic module or the WDR 99 60 raster module for sup...

Page 25: ...und the raster plate Four M12 screws and 2 M16 screws with 2 washers are included in the scope of delivery The nuts for T slots are not included in the scope of delivery of the clamping system For machine tables with T slots various center hole distances are available Alternatively the clamping system can be secured using two or four BRR 50 clamping pin blanks see chapter Accessories 1 3 1 Page 8 ...

Page 26: ...unlocking connection and the turbo con nection can be found on the front side The turbo connection serves to amplify the pull in force on the quick change pallet system On the back there is an air connection for the air control to the WDN 99 70 Via the integrated air forwarding to the change interfaces a VERO S NSE plus quick change pallet system plus or a WDA 99 70 direct clamping module can be c...

Page 27: ...Assembly 02 00 WDB 99 en 27 Mounting the WDB 99 60 on grid plates Mounting the WDB 99 60 on T groove table ...

Page 28: ...aused by the machining forces The integrated change interface of the clamping system has a central connection screw for clamping an adaptable WDS 99 stack ing module or a WDN 99 70 workpiece direct clamping or a WDA 99 79 D32 or WDA 99 70 D36 compensation module The WDG 99 60 basic module has three air supply connections G 1 8 The air supply is intended to supply a VERO S workpiece direct clamping...

Page 29: ... change interface with central fastening screw and centering sleeve HUE 24 25 This makes it compatible with conventional thread bore hole plates with center ing bores Ø 24 H6 H7 mm and tapped hole M16 in bore hole grid spacing 50 mm x 50 mm The technical equipment features and the functions are identical to the basic module WDG 99 60 5 3 2 Page 28 The mounting scheme on grid plates corresponds to ...

Page 30: ... the taper interface and at the same time clamps and positions it against the flat surface of the pre assembled module The shaft connection allows a torque load on the clamping pillars which for instance is exercised through machining forces For orientation of the installation position a cylindrical pin grips into the interface to be inserted The stacking module has integrated routing air for the ...

Page 31: ...llars via the change interface The clamping system has a VERO S NSE plus 99 quick change pallet module which is supplied with compressed air via the integrated air routing of the change components assembled on top of each other The quick change pallet module is a system secured by a spring The unlocking of the VERO S change interface takes place via the air routing of a WDB 99 60 WDG 99 60 or WDR ...

Page 32: ...stem on the WDB 99 clamping pillars via the change interface The drive for the clamping function of the clamping system is manual as standard using a rotary movement on the actuator screw which is on the side of the housing The clamping system can be operated by means of a hexagonal screwdriver angled pin wrench The clamping force is initiated after precise torque speci fication using a torque wre...

Page 33: ...of the remaining clamping pillars should be equipped with clamping systems for a VERO S SPB 40RF clamping pin with compensation function in longitudinal direction sword pin All other clamping pillars may be loaded with SPC 40RF clamping bolts The compensation module can be positioned as the top clamping system on the WDB 99 clamping pillars via the change interface The clamping system has a hydrau...

Page 34: ... module can be used several times in the entire clamping structure unlike the WDA 99 79 D32 compensation module Several clamping pillars can be loaded with this compensation module At least two clamping pil lars in the system structure must be fitted with a clamping pin with centering function such as VERO S SPA 40RF centering pin and a VERO S SPB 40RF clamping pin with sword function Mounting and...

Page 35: ... for compensation modules are used see chapter Work piece direct clamping pins for compensation modules 5 5 Page 38 NOTICE Notes on clamping pins and mounting screws The holding force of the quick change pallet system is limited essentially by the tightness of the screw connection which connects the clamping pin to the pallet or the device This is why only screws of strength class 12 9 may be used...

Page 36: ... system Type designation ID no Min outer diameter on the support of the part WDN 99 70 0471603 75 mm WDN M 99 70 0471611 75 mm Clamping pins installation Tolerances and installation conditions Type ID no A B C D E F G H SPA 40 RF 0471151 12 17 M12 15 20 M10 15 12 SPB 40 RF 0471152 12 17 M12 15 20 M10 15 12 SPC 40 RF 0471153 12 17 M12 15 20 M10 15 12 SPG 40 RF 0471154 12 17 M12 15 20 M10 25 22 SPA ...

Page 37: ...O S clamping pins type SPA SPB SPC Screw quality 12 9 Screw size M10 M12 M14 M16 Tightening torque Nm 62 108 170 262 Clamping pins without bore hole SPA 40 OB SPB 40 OB The clamping pins without bore holes only require a slim fitting bore Ø 10 H7 in the installation space For the SPC 40 OB design no fit seating is required Clamping pins installation SPA 40 OB 5 4 1 ...

Page 38: ... individual height adjustment to the workpiece can be achieved with this clamping pin The WDA SPA 32 fulfills the function of the centering pin similar to a SPA 40RF clamping pin In the WDA 99 79 D32 compensation module the clamping pin can be clamped in a limited extraction area up to the marking slot This enables height tolerances on the workpiece or also height off sets to the additional clampi...

Page 39: ... 108 Using the WDA SPA 32 workpiece direct clamping pin in combi nation with a VERO S clamping pin in a workpiece application WDA SPC 36 The WDA SPC 36 clamping pin is compatible with the WDA 99 70 D36 compensation module Individual height adjustment to the workpiece can be achieved with this clamping pin The WDA SPC 36 fulfills the function of the clamping pin with centering play simi lar to a SP...

Page 40: ...VERO S SPA 40RF centering pin and SPB 40RF sword pin clamping pins WDA SPC 36 installation Tolerances and installation conditions Type ID no A W C D E F G H WDA SPC 36 0471616 12 17 M12 15 20 M10 20 12 The length of the screwed thread must not exceed the dimension G under any circumstances Tightening torques for mounting VERO S clamping pins type WDA SPC 36 Screw quality 12 9 Screw size M10 M12 Ti...

Page 41: ... function of a sword pin and allows a position balancing in the longitudinal direction of 1 mm For the use of the SPD B a fit seating in the installation space is required With the SPD C clamping bolt concentric positioning tolerances can be compensated These clamping pins can be combined with all other VERO S clamping pins within a workpiece interface By using these clamping bolts the workpiece c...

Page 42: ...50 1318565 SPB VLK 50 1317936 SPC VLK 50 1317937 Pneumatic circuit diagram The displayed pneumatic circuit diagram serves as an example for the function illustration for the WDN 99 70 direct clamping mod ule clamping systems and WDA 99 70 D36 compensation module The air supply lines can be branched over several clamping pillars Depending on the system structure the recommended minimum line diamete...

Page 43: ...air supply against the upcoming system pressure to the base module When controlling the NSE plus 99 quick change pallet systems and the WDA 99 70 D36 compensation module the following must be observed unlocking function turbo function Max pressure 6 bar Workpiece system control only with WDN 99 70 direct clamping module see chapter Function of the workpiece system control 6 3 Page 47 Max pressure ...

Page 44: ...inters The tube protection sleeves are available in three prepared lengths and can be cut to length With the enclosed heat shrink tube the tube protection sleeve is fixed and stuck for connection coupling see Preparing the air connector plug illustration To make a heat resistant air connection plug a metal cutter and a hot air blower are required Preparing the air connection plug Type ID no Length...

Page 45: ... intended for fine height adjustments to the workpiece interface Function of the connecting unit in the change components The clamping systems of the WDB 99 modular system have a special connecting mechanism which contains a quick change function The connection is transferred to a connection shaft by a tapered screw At the same time a pre tension force is applied at the clamping point on the flat ...

Page 46: ... A cylindrical pin is intended as a guide The clamping systems can be fixed using the T handle hexagonal socket screw driver included For clamping the precise screw tightening torque must be initiated at the clamping area The connection point is hereby fixed and positioned A tapered screw is included in the scope of delivery as a spare part Sequence when substituting a stacking module into the cha...

Page 47: ...ng in the change components Function of the workpiece system control Max pressure 2 bar Limit volumetric flow to 15 l min In order to guarantee reliable evaluation the pressure and air volume must be held constant Pressure fluctuations can affect the settings of the pressure switch and lead to incorrect measurement results The length and cross section of the line can affect the switching time of t...

Page 48: ...ping depth into the clamping mounting of the hydraulic compen sation module The marking slot on the clamping pin is consid ered the maximum permissible extraction height in relation to the front of the clamping device The hydraulic clamping system may not be clamped over 25 C without joined clamping pins Only original SCHUNK clamping pins may be used The actuating screw may not be actuated with a ...

Page 49: ...portation In the case of overhead application or if the system is in a horizontal position secure the pallets or workpieces so that they do not fall when releasing the clamping module WARNING Risk of injury due to losing pallets or workpieces if the supply of compressed air drops or fails and due to the clamping pins immediately closing Do not reach into the clamping module Use pressure maintenanc...

Page 50: ...clamping module has to be disassembled send the module to SCHUNK for repair The covers of the clamping modules are spring preloaded and must only be removed by trained specialist personnel The cover of the NSE plus 99 quick change pallet module and the WDA 99 70 compensation module may also only be assembled and disassembled in compliance with the corresponding assembly and disassembly instruction...

Page 51: ...rk is only allowed to be carried out at a SCHUNK site Ambient conditions and operating conditions Make sure that the contact surfaces of the interface are always clean Always ensure that no chips of any kind enter the interface of the change components Only use high quality cooling emulsions with anti corrosive additives during processing Check the pneumatic clamping systems and the workpiece dire...

Page 52: ...nge pallet system or pneumatic compensation module does not unlock Possible cause Remedial measures Defective air connections Check air supply 5 8 Page 42 Defective sealing elements for air routing Replace sealing elements at the affected change components Pressure below minimum Check operating pressure min 5 bar A component is broken e g due to over loading Replace the module or send it to SCHUNK...

Page 53: ... and on the clamping pin The manual quick change pallet module NSE M plus 99 ZL WDN M 99 70 no longer works flawlessly Possible cause Remedial measures A component is broken e g due to over loading Replace the module or send it to SCHUNK for repair Hexagon socket of the actuator screw is defective Replace actuator screw or send module to SCHUNK for repair The WDA 99 79 D32 compensation module no l...

Page 54: ...ion Quantity 4 O ring 1 6 O ring 2 7 SWK seal M5 3 WDA 99 79 D32 ID no 0471624 Item Designation Quantity 3 O ring 2 5 SWK seal M5 3 VERO S NSE plus 99 ZL ID no 0471122 Item Designation Quantity 20 O ring Ø 71 5 x 1 5 1 21 O ring Ø 62 x 3 1 22 O ring Ø 26 x 1 5 1 23 O ring Ø 20 x 1 5 4 24 O ring Ø 4 5 x 1 5 2 25 O ring Ø 18 x 2 1 26 O ring Ø 71 5 x 1 5 2 27 O ring Ø 18 x 1 5 1 40 Slide washer 1 WDA...

Page 55: ...en maintenance is performed Part lists WDB 99 60 ID no 0471617 Item Designation Quantity 1 Base plate 1 2 Support bushing 1 3 Set screw 1 4 Sealing ring 3 5 Sealing nipple 3 6 Locking screw 3 8 Screw DIN EN 4762 4 9 Screw DIN EN 4762 2 11 Metal washer 2 12 Locking coupling 3 13 Allen key 6 mm 1 WDG 99 60 ID no 0471618 Item Designation Quantity 1 Holder 1 2 Support bushing 1 3 Set screw 1 4 SPA 40 ...

Page 56: ...Holder 1 2 Support bushing 1 3 Set screw 1 4 Sleeve HUE 24 25 1 5 Sealing ring 3 6 Sealing nipple 3 7 Locking screw 3 WDS 99 30 ID no 0471601 Item Designation Quantity 1 Holder 1 2 Shaft 1 3 Support bushing 1 4 Set screw 1 5 Cylindrical pin 1 6 O ring 2 7 SWK seal M5 3 WDS 99 50 ID no 0471602 Item Designation Quantity 1 Holder 1 2 Shaft 1 3 Support bushing 1 4 Set screw 1 5 Cylindrical pin 1 6 O r...

Page 57: ...9 120 ID no 0471608 Item Designation Quantity 1 Holder 1 2 Shaft 1 3 Support bushing 1 4 Set screw 1 5 Cylindrical pin 1 6 O ring 2 7 SWK seal M5 3 WDS 99 160 ID no 0471609 Item Designation Quantity 1 Holder 1 2 Shaft 1 3 Support bushing 1 4 Set screw 1 5 Cylindrical pin 1 6 O ring 2 7 SWK seal M5 3 WDN 99 70 ID no 0471603 Item Designation Quantity 1 Holder 1 2 Shaft 1 4 O ring 1 5 Cylindrical pin...

Page 58: ...ing 2 7 SWK seal M5 3 8 Cylindrical pin 1 10 VERO S NSE M plus 99 ZL 1 WDA 99 79 D32 ID no 0471605 Item Designation Quantity 1 Hydraulic expansion toolholder 1 2 Shaft 1 3 O ring 2 4 Cylindrical pin 1 5 SWK seal M5 3 WDA SPA 32 ID no 0471606 Item Designation Quantity 1 WDA SPA 32 clamping pin 1 2 Screw 1 3 Compression spring 1 WDA 99 70 D36 ID no 0471615 Item Designation Quantity 1 Holder 1 2 Shaf...

Page 59: ...esignation Quantity 1 SP VLK 50 1 2 HUE 24 25 1 3 Screw DIN 4762 1 4 SPA 40 16RF clamping pin 1 5 Set screw M16 x 43 5 SPL 1 SPB VLK 50 ID no 1317936 Item Designation Quantity 1 SP VLK 50 1 2 HUE 24 25 1 3 Screw DIN 4762 1 4 SPB 40 16RF clamping pin 1 5 Set screw M16 x 43 5 SPL 1 SPC VLK 50 ID no 1317937 Item Designation Quantity 1 SP VLK 50 1 2 HUE 24 25 1 3 Screw DIN 4762 1 4 SPC 40 16RF clampin...

Page 60: ...Assembly Drawings 60 02 00 WDB 99 en Assembly Drawings X Included with NSE plus 99 ZL Illustration back up for sizes 30 50 80 120 160 11 ...

Page 61: ...Assembly Drawings 02 00 WDB 99 en 61 X Clamping pin WDA SPA 32 accessories X Clamping pin WDA SPC 36 accessories Y Marking slot for minimum clamping depth in WDA 99 79 D32 Y Included with WDA 99 ...

Page 62: ...completed machine may not be put into operation 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 EN ISO 12100 2010 Safety of machinery General principles for design Risk assessment and risk reduction EN ISO 4414 2010 Pneumatic fluid power General ...