Radial riveting machine RNE 281

Transcription

1 BalTec Maschinenbau AG Obermattstrasse 65 CH Pfäffikon ZH Phone: +41 (0) Fax: +41 (0) baltec@baltec.com OPERATING INSTRUCTIONS Radial riveting machine RNE 281 reduced force max. 9.5 kn /ENG Machine no. xxx.xxxx Power supply xxx /ENG

2 Introduction Radial riveting machine RNE /ENG

3 Radial riveting machine RNE 281 Introduction Contents 1 Introduction Safety regulations Term definitions Significance of the safety regulations Information and symbols Warning and safety notices Notes and symbols on the product Application limitations Intended use Riveting machine/riveting unit Form tool Workpiece holders Emissions Power supply General safety rules Declarations Product description RNE 281 details Dimensions drawing RNE Dimensions drawing RNE 281 for flange mounting Technical specifications riveting machine 281 reduced force Commissioning Introduction Personnel requirements Riveting unit Operation Safety regulations riveting machine Personal safety equipment Workplace Heating of riveting machine Basic settings Riveting stroke adjustment Riveting spindle advance speed adjustment Riveting force adjustment Setting up the riveting machine for a new workpiece Possible machine settings Form tools Form tool designs and closing head shapes Recommended form tool materials Form tool D = 20 with various lengths Replacing the form tool holder and pressure cup Replacing the pressure cup with the removal device Standard form tool Ø20 with flat profile ( ) Standard form tool Ø20 with conical profile ( ) Standard form tool Ø20 with crowned profile ( ) Options /ENG 3

4 Introduction Radial riveting machine RNE Pressure pad Pressure pad dimensions drawing Production of thrust piece and spring diagram Automatic lubrication riveting spindle head Foot switch Function Dimensions drawing Technical specifications Initiator upper end position Initiator lower end position (bridging initiator) Maintenance and repair work Introduction Safety regulations Personnel requirements Overview of maintenance work Riveting spindle head (form tool holder and pressure cup) Riveting spindle Automatic lubrication riveting spindle head (option) Air maintenance unit Mist oiler adjustment Polygon shaft Two-hand operating unit Piston and piston rod seals Riveting motor terminal box Maintenance and repair log Decommissioning, Storage Decommissioning Storage Re-commissioning Disposal Introduction Personnel requirements Disposal Replaced parts Mineral oils Riveting unit Appendix Schemata Pneumatic diagram with air maintenance unit 281 reduced force, Pneumatic diagram for automatic lubrication Spare parts lists Machine body 281 Standard/HPP reduced force a Riveting head k Electric motor h Pneumatics 270/281, Automatic lubrication u Foot switch d Two-hand operating unit d Pressure pad g Index /ENG

5 Radial riveting machine RNE 281 Introduction 1 Introduction We are certain that you have made the right choice with our product and thank you for your trust. For your personal safety Before carrying out any activities on or with the riveting machine, please carefully read these operating instructions first, in particular the chapter on "Safety regulations". Application area of these operating instructions These operating instructions describe the riveting machine and provide all information required for safe operation and maintenance of functionality. Please keep these operation instructions available at all times for all persons involved with the riveting machine. Questions or unclear points Please contact immediately if you have any questions or unclear points: - BalTec Maschinenbau AG, Obermattstrasse 65 CH 8330 Pfäffikon ZH - BalTec distributors (see representatives list in the appendix) Please provide them with the document and page numbers located in the footer and the machine number listed on the title page of operating instructions. Original language of assembly instructions These assembly instructions was originally written in German language. Copyright BalTec Maschinenbau AG Pfäffikon /ENG 5

6 Safety regulations Radial riveting machine RNE Safety regulations 2.1 Term definitions The following terms are used with regards to safety: Personnel qualification The work to be implemented with or on the product is described in the corresponding chapters in the operating instructions. The personnel qualifications listed in this chapter (in "Introduction") describes the minimum requirements for personnel regarding training and competences for implementing this work. Personnel Personnel are people who meet the personnel qualifications. Only such personnel are authorized to implement the work described in the applicable chapters. User Users are persons who cannot be identified as personnel but who still carry out activities with or on the product. Operator The operator is the owner of the product. This is irrespective of whether the product is: Operated as a stand-alone machine Operated as part of a system or Operated by a third party Product life phases 2.2 Significance of the safety regulations The product life phases are the state or usage phases of the product. These range from leaving the assembly hall to disassembly and disposal, and are divided into correspondingly logical sections (chapters) in these operating instructions. These safety regulations contain all behavior regulations and generally applicable danger information. The safety of the user and the personnel can only be ensured when these safety regulations and the safety information listed in the individual chapters are strictly complied with and followed. The operator is responsible for the enforcement /ENG

7 Radial riveting machine RNE 281 Safety regulations 2.3 Information and symbols Warning and safety notices The warning and safety notices used in these operating instructions have the following significance: CAUTION Indicates a hazard with low risk which, if not avoided, could result in minor or moderate injury. WARNING Indicates a possible hazard with medium risk which, if not avoided, could result in death or serious injury. NOTICE DANGER Indicates an immediate hazard with high risk which, if not avoided, will result in death or serious injury. Indicates practical information and tips that permit the best use of machinery, system or equipment. CAUTION To warn of material damage only /ENG 7

8 Safety regulations Radial riveting machine RNE Notes and symbols on the product The following information and symbols are located on the riveting machine: Warning signs Danger of hand injuries Mandatory sign Wear safety goggles Mandatory sign Wear gloves 2.4 Application limitations The following technical operating instructions and ambient conditions must be complied with for the operation of the riveting machine. Environmental conditions Working temperature C Storage temperature C Relative humidity Max. 90%, non-condensing Mechanical power supply Operating pressure See technical specifications, label Rivet parameters Riveting force Rivet diameter See technical specifications, label See technical specifications Electrical power supply Rated voltage Rated current Frequency See title page, label See technical specifications, label See title page, label /ENG

9 Radial riveting machine RNE 281 Safety regulations 2.5 Intended use Riveting machine/riveting unit BalTec riveting machines are intended to form positive connections by cold forming of connection elements. The connection element (rivet) can either be a separate element or a specially shaped deformation zone on the workpiece itself. The connection is created in that a riveting tool (form tool) creates a closing head on the connection element. Following activation types are permitted to actuate the riveting process: a) Permanent activation with two-hand switching for: Manual charging Stroke H greater than 6 mm Stroke speed greater than 30 mm/s b) Pulse actuation with any command device (e.g. foot switch), where one of the following conditions is met: Workpiece charging with handling device Stroke H smaller than 6 mm Stroke speed smaller than 30 mm/s Form tool The riveting machines are laid out for use in commercial or industrial production; e.g. a) As machining station in a production line b) As stand-alone workplace or production cell The riveting units are laid out for installation in any spatial position: e.g. a) Vertical, with direction of action from top to bottom or bottom to top b) Horizontal WARNING Form tool breaks if an inappropriate material is used! Eye injuries, cutting damages! Form tool is to produce according to our specifications: material, heat treatment, geometry (see Chapter "Form tools") /ENG 9

10 Safety regulations Radial riveting machine RNE Workpiece holders WARNING Workpiece can be catapulted out! Eye injuries, cutting damages! Workpiece holders must be securely mounted on the machine table, e.g. with T-slots-screws, clamping shoes or other suitable and secure clamping equipment. 2.6 Emissions 2.7 Power supply Noise The sound pressure level of noise produced by BalTec riveting machines at the operator's workplace is less than 70 db(a) (measured according to SN EN ISO 3746). Vibrations Vibrations may be caused by the riveting machines dependent on the BalTec riveting process. Suitable vibration damping measures are required where other system parts may start oscillating due to resonance. DANGER Electrical hazard! Electric shock! Before the machine or their components are connected, isolate the electrical power supply and secure against being switched on again! /ENG

11 Radial riveting machine RNE 281 Safety regulations 2.8 General safety rules 2.9 Declarations Modifications Modifications to the riveting machine or control unit, in the sense of attachments and conversions are only permissible after prior consultation with and written authorization from the manufacturer. This also applies to welding on load-bearing components and the attachment of control, supply and transfer systems from third party suppliers. CE conformity declaration A CE-compliant riveting machine is marked with a CE rating plate. The standards used to check conformity are listed in the CE conformity declaration. The CE conformity declaration is included in the delivery documentation. Declaration of incorporation When being installed in other machines and/or for operation with a third party control unit, a non CE-compliant riveting machine cannot be commissioned until it is ensured that it meets the provisions of the machine directive 2006/42/EG. The declaration of incorporation is included in the delivery documentation /ENG 11

12 Product description Radial riveting machine RNE Product description 3.1 RNE 281 details Item Name Item Name 1 Riveting stroke adjustment 13 Oil sight glass 2 Clamping screw for riveting stroke adjustment 14 Water separator, sight glass 3 Lubricator nipple 15 Water separator, drain valve 4 Supply air 16 Restrictor valve for riveting spindle advance speed 5 Exhaust air 17 Initiator lower end position (option) 6 Riveting spindle head 18 Pressure regulator valve 7 Form tool 19 Manometer 12 Air connection 21 Initiator upper end position (option) /ENG

13 Radial riveting machine RNE 281 Product description 3.2 Dimensions drawing RNE 281 Drawing no Free height H see chapter Form tool D=20 with various lengths /ENG 13

14 Product description Radial riveting machine RNE Dimensions drawing RNE 281 for flange mounting Drawing no Free height H see chapter Form tool D=20 with various lengths /ENG

15 Radial riveting machine RNE 281 Product description 3.4 Technical specifications riveting machine 281 reduced force Maximum rivet shaft diameter (solid shaft rivet, steel 370 N/mm 2 ) Ø 7.5 Riveting unit motor, driving power at 50Hz kw 0.55 Riveting unit motor, driving power at 60Hz kw 0.55 Riveting unit motor, rpm at 50Hz min Riveting unit motor, rpm at 60Hz min Rated current at 1 x 220V A 6.3 Rated current at 3 x 220V A 3.5 Rated current at 3 x 400V A 1.8 Rated current at 3 x 440V A 1.6 Pneumatics operating pressure bar 2 6 Thread size compressed air connection (air maintenance unit STF) Thread size compressed air connection (air maintenance unit) G ⅜ G ¼ Max. riveting force at 6 bar kn 9.52 Max. permissible riveting time per cycle sec 10 Tool stroke (stroke limiting stop-adjustment range) mm 5 40 Cylinder volume at maximum stroke cm Weight of riveting machine without control unit kg 155 Weight of riveting machine with control unit kg 165 Weight of riveting unit kg /ENG 15

16 Commissioning Radial riveting machine RNE Commissioning 4.1 Introduction Personnel requirements Commissioning work must be implemented by persons who have mechanical and electrical training. The connection of electrical component has to be made only by a trained authorised electrician. 4.2 Riveting unit The necessary information for commissioning are indicated in the assembly instructions /ENG

17 Radial riveting machine RNE 281 Operation 5 Operation 5.1 Safety regulations riveting machine Personal safety equipment Workplace All user are obliged to wear the following personal safety equipment for all work: Tightly fitting working clothes Safety goggles Gloves The riveting machine may only be operated by one person. CAUTION Third party can hold fingers between form tool and workpiece! Danger of hand injuries! Configure workplace with rivet holder so that third parties do not have access (e.g. three-sided enclosure) Heating of riveting machine Forming procedures can lead to heating. CAUTION Riveting head, tool and workpiece could be hot! Light burns! Do not touch with unprotected hand! /ENG 17

18 Operation Radial riveting machine RNE Basic settings Riveting stroke adjustment The maximum possible riveting stroke can be set with the riveting stroke adjustment. Item Name 1 Clamping screw (UK) / Clamping bolt (US) 2 Adjustment ring Procedure: 1. Undo the clamping screw 2. Adjust stroke by turning the adjustment ring: Rotate to the right: Stroke is reduced Rotate to the left: Stroke is increased 3. Value on the scale roughly represents the stroke up to the stop 4. Retighten clamping screw NOTICE Only tighten the clamping screw lightly to avoid damaging the clamping band! /ENG

19 Radial riveting machine RNE 281 Operation Riveting spindle advance speed adjustment The advance speed of the riveting spindle can be adjusted with the restrictor valve HPP a) Reducing the advance speed and force build-up Rotate the level control of the restrictor valve clockwise. b) Increasing the advance speed and force build-up Rotate the level control of the restrictor valve counter-clockwise. NOTICE To have easy access to the restrictor valve, move the riveting unit up to the top position! /ENG 19

20 P [bar] Operation Radial riveting machine RNE Riveting force adjustment The riveting force (operating pressure) is adjusted at the pressure regulator of the air maintenance unit. Procedure: 1. Pull the turning handle up out of the detent 2. Set the required operating pressure 3. The value set is displayed by the manometer The operating pressure set determines the riveting force at the form tool (see pressure/force diagram). Pressure/force diagram F [kn] P = operating pressure F = riveting force NOTICE The operating pressure can be set between 1-6 bar. To ensure good functionality, we recommend that the minimum operating pressure of 2 bar is not undershot. The maximum operating pressure is 6 bar and must not be exceeded! /ENG

21 Radial riveting machine RNE 281 Operation 5.3 Setting up the riveting machine for a new workpiece Before setting up for a new riveting job, the following requirements must be met: 1. Suitable form tool for the rivet and closing head to be produced 2. Form tool length suitable for calotte radius of pressure cup (Rp) in the currently installed form tool holder NOTICE The form tool length Ls must be selected so that the form-shaping form tool profile cuts directly in the radius centerpoint (see Chapter "Form tools"). 3. Rivet holder or workpiece carrier must be set up centrically to the riveting spindle axis and fixed onto the machine table The following settings must always be made in the control unit "Setup operation" so that the procedure can be interrupted at any time: 1. Insert workpiece 2. Adjust the height of the riveting machine in the stand so that the distance of the form tool to the rivet is smaller than the maximum achievable spindle stroke. If a short cycle time is desired, this distance to the workpiece can be reduced as long as the necessary distance required to insert the workpiece is maintained. 3. Set the required dimension for the rivet path with the stroke limiting stop NOTICE Incrementally lower the stroke limiting ring to determine the correct setting using a test workpiece. 4. At the same time, incrementally adjust the riveting force setting (via pressure regulator) and riveting spindle advance speed (via restrictor valve) to obtain the required results If the workpieces evidence spreading over the height, the stroke limitation may be an obstacle. In this case, the stroke limiting stop should be set slightly lower than necessary. The actual riveting path is then only limited by the termination of the specified riveting time. NOTICE If other system parts may start oscillating due to resonance by the riveting process, check that the tool is in perfect condition and that the workpiece holder is fastened without any play /ENG 21

22 Operation Radial riveting machine RNE Possible machine settings Riveting to stroke limiting stop Suitable for workpieces with constant thickness. The necessary riveting path can be finely set by adjusting the stroke limiting stop. The height of the closing head then only spreads by the workpiece height spread value. The riveting time must therefore be sufficient that the stroke limiting stop is also securely reached. During the "riveting out" on the stroke limiting stop, stress is removed and the closing head is cleanly smoothed. Riveting without stroke limiting stop Suitable for parts with differing heights. Instead of a limiting stop, the stroke is limited by the set riveting time. The closing head is then only influenced by the pressure, stroke speed (exhaust valve throttle) and the riveting time. The stroke limitation must be set so that the form tool cannot move into the workpiece carrier when a workpiece is not present. Riveting under high pressure Suitable for rivets where a high hole intrados pressure is required. If a higher pressure is selected for a specific riveting, the riveting time is reduced. The permissible pressure limit is set by the workpiece itself. The opening of the restrictor valve means both a faster advance of the riveting spindle (centre sleeve) and a steeper rise in force. Riveting under low pressure Suitable for joint riveting. A longer riveting time, but lower pressure. The stress on the workpiece is reduced. Possible bending of a rivet pin can be prevented. The partial closing of the restrictor valve also works in the same direction. Advance speed and rise in force takes place slowly. Less material is pressed into the bore, the closing head therefore has more material volume available and will tend to be larger, the intrados remains small /ENG

23 Radial riveting machine RNE 281 Form tools 6 Form tools 6.1 Form tool designs and closing head shapes The shape of the closing head being produced depends on the design of the form tool. Dimensions for D S and L S, see the lists "Standard form tools" /ENG 23

24 Form tools Radial riveting machine RNE Recommended form tool materials Table 1 Material DIN Name Material no. Max. hardness heat treatment Hardening Annealing 90 Mn V HRC C C Analysis C Si Mn P S Cr V % % % % % % % Application Form tool designs Preparation commercial rivet materials Normal and special designs Table 2 Material DIN Name Material no. Max. hardness heat treatment Hardening Annealing S HRC C C Analysis C Si Mn P S Cr Mon. V W % % % % % % % % % Application Form tool designs Preparation tempered materials Normal and special designs /ENG

25 Radial riveting machine RNE 281 Form tools 6.3 Form tool D = 20 with various lengths Standard form tools with shaft diameter Ds = 20mm must be removed using the removal tool (BalTec order no ) that is supplied with the machine accessories (see instructions below) but they can be reinserted manually. They are held with 3 suspension thrust pieces. Procedure: 1. Form tool in installed condition 2. Undoing the form tool: Insert removal device in groove Lever removal device upwards until the form tool loosens 3. Pull form tool downwards CAUTION Longer form tools require the replacement of the form tool holder and pressure cup. Form tool length must always be in combination with pressure cup and form tool holder as shown in the table below. Non-compliance can lead to the destruction of the machine! /ENG 25

26 Form tools Radial riveting machine RNE 281 Item Name 1 Form tool axis 2 Pressure cup 3 Form tool holder 4 3 thrust pieces 5 Form tool Machines Type Radius Rp [mm] Form tool length Ls [mm ± 0.1] Shaft Ds [mm] Angle Free height H [mm] g /ENG

27 Radial riveting machine RNE 281 Form tools 6.4 Replacing the form tool holder and pressure cup Item Name 1 Internal ring gear 2 Pressure cup 3 Form tool holder 4 Connection piece 5 Screw M4x12 6 Pressure spring 7 Cap 8 Form tool Procedure: 1. Pull form tool out of riveting head 2. Undo the screws with which the cap is fastened CAUTION The cap is under spring pressure! Cap and form tool holder fall on the fingers! Gloves are mandatory! /ENG 27

28 Form tools Radial riveting machine RNE Once the cap is removed, pull the form tool holder and pressure spring out of the riveting head 4. Pull the pressure cup out of the centring in the connection piece using the screws M5x70 provided in the machine accessories and insert a new pressure cup CAUTION The screws M5x70 must not be used to push the pressure cup off the internal ring gear. Contact surface of internal ring gear will be damaged! 5. Grease the form tool holder with Klübersynt GE (also see Chapter "Maintenance and repair work") 6. Once the new pressure cup is inserted, hold the cap with the form tool holder and pressure spring pressed against the pressure cup. Screw cap back on /ENG

29 Radial riveting machine RNE 281 Form tools 6.5 Replacing the pressure cup with the removal device The form tool holder and pressure cup can be most easily removed using the removal device shown below. This is available as an option from BalTec (order no ). Item Name 1 Removal device 2 Internal ring gear 3 Pressure cup 4 Special screws M5x120 5 Connection piece CAUTION The special screws M5x120 must not be used to push the pressure cup off the internal ring gear. Contact surface of internal ring gear will be damaged! /ENG 29

30 Form tools Radial riveting machine RNE Standard form tool Ø20 with flat profile ( ) Ls = 68 ± 0.1 Ls = 84 ± 0.1 Ls = 100 ± 0.1 Articleno. ± 0.1 no. ± 0.1 no. ± 0.1 Øds Article- α L2 L3 Øds Article- α L2 L3 Øds α L2 L ** ** ** * * * * * * * * * * * * * * * * * * * * = available from stock (α = 15 ) ** = available from stock (α = 25 ) * * /ENG

31 Radial riveting machine RNE 281 Form tools 6.7 Standard form tool Ø20 with conical profile ( ) Ls = 68 ± 0.1 Ls = 84 ± 0.1 Ls = 100 ± 0.1 Article Øds α β Article Rs L2 L3 Øds α β Article Rs L2 L3 Øds α β no. ± 0.1 ± 30 no. ± 0.1 ± 30 no. ± 0.1 ± 30 Rs ** ** ** * * * * * * * * * * * * * * * * * * * = available from stock (α = 15 ) * ** = available from stock (α = 25 ) * * L2 L /ENG 31

32 Form tools Radial riveting machine RNE Standard form tool Ø20 with crowned profile ( ) Article no. Øds ± 0.1 Ls = 68 ± 0.1 Ls = 84 ± 0.1 Ls = 100 ± 0.1 α Ro ± 0.1 Bt ± 0.05 L2 L3 Article no. Øds ± 0.1 α Ro ± 0.1 Bt ± 0.05 L2 L * * * * * * * * * * * * * * * * * CAUTION * * * * Article no. Øds ± 0.1 Bt and Ro dimensions must be complied with! α Ro ± 0.1 Bt ± 0.05 If Ro is calculated smaller or Bt larger than the corresponding form tool diameter, this will lead to overstressing of the form tool holder, pressure cup and riveting spindle guide! * = available from stock (α = 15 ), + = available from stock (α = 25 ) L2 L /ENG

33 Radial riveting machine RNE 281 Options 7 Options 7.1 Pressure pad Use For parts that must be held together before the form tool touches down or parts that need to be pressed together with force for a press fit. Pre-stress force The necessary pre-stress force must be determined through experience or empirically. Pressure pad components (springs, thrust piece) The design of the pressure pad components can be seen in the diagram (series ) or (series ). The thrust piece must be made to match the workpiece. The thrust piece influences the pre-stress force, the pretravel with regards to the form tool and the spring rate. In normal cases, the pressure pad is produced specifically for the customer. NOTICE When using a pressure pad following minimum dimensions for form tool and form tool holder are required: Series : Form tool length Ls = 54, form tool holder radius Rp = 80 Series : Form tool length Ls = 84, form tool holder radius Rp = /ENG 33

34 Options Radial riveting machine RNE Pressure pad dimensions drawing Machine type / / / /431 A max. 30 max. 30 max. 30 max. 30 max. 62 max. 62 max. 62 B C D 7.5 (R80) 27.5 (R100) 7.5 (R80) 27.5 (R100) 7.5 (R80) 27.5 (R100) 7.5 (R80) 27.5 (R100) 4 (R116) 20 (R132) 36 (R148) 4 (R116) 20 (R132) 36 (R148) 4 (R116) 20 (R132) 36 (R148) E b Applicationspecific Applicationspecific Applicationspecific Applicationspecific Applicationspecific Applicationspecific Applicationspecific G Thrust piece production As per drawing no "Production of thrust piece and spring diagram As per drawing no "Production of thrust piece and spring diagram /ENG

35 Radial riveting machine RNE 281 Options Production of thrust piece and spring diagram Spring diagram F (dan) spring force Fmax dan Fmax dan Fmax. 670 dan f (mm) travel * Travel f = 0.75h do not exceed if possible I II III 6 disk springs 80x41x2.25 (simple) 6 disk springs 80x41x3 (simple) 5 disk springs 80x41x4 (simple) /ENG 35

36 Options Radial riveting machine RNE 281 Example: a and b sought for pre-stress force Fv = 470 dan for I Fv = 380 dan for II Fv = 1250 dan for III Spring combination Force at 0.75h I II III a = 12 A travel of 7 (until f = 0.75h) remains for b a = 8 A travel of 7.4 (until f = 0.75h) remains for b a = 10 A travel of 4.1 (until f = 0.75h) remains for b -> F 660 dan -> F 1050 dan -> F 2250 dan Thrust piece production Material thrust piece: Case-hardened steel Ra = 3.2 b = depends on application Case-hardened ± 20 HV /ENG

37 Radial riveting machine RNE 281 Options 7.2 Automatic lubrication riveting spindle head The automatic lubrication is recommended mainly for machines and units that are installed in automatic systems and are operated in multi-shifts. It is however also suitable for manual workplaces to ensure regular relubrication of form tool holders and pressure cups. Two machines or units (e.g. RND) can be lubricated simultaneously with a second metering valve. The distance between both machines or units should however not exceed more than 1 meter. A constant air pressure of 6 bar is necessary to operate the device. Setting the grease volume The riveting spindle head is default supplied with approx. 6mm 3 grease. For extremely high loading, this volume can be increased by rotating the level control of the injection lubricator (metering valve) in the "+" direction. One level increases the volume by approx. 1mm 3. Monitoring The level monitoring in the grease container is implemented with an initiator whose control state is shown on the control unit display when the grease volume is too low. Lubrication interval The lubrication interval is specified with the setup parameter in the control unit. The default lubrication interval in the control unit is set to 5h. The default lubrication interval of 5h can be adapted if necessary to the operating requirements. A shorter interval can be set for hard permanent operation in the upper riveting force range or a longer interval for manual insertion operation (see setup table in operating instructions Control ). Topping up the grease container See Chapter "Maintenance and repair work" /ENG 37

38 Options Radial riveting machine RNE Foot switch Function If for instance large and/or bulky parts cannot be riveted using a two-hand operating unit, a safety foot switch can be used. When the safety foot switch is actuated, the make contact is closed and the riveting procedure initiated. When the pedal is released, the riveting spindle automatically returns to the start position. CAUTION Foot switch is activated unintentionally! Contusions, scrapes! Set the riveting machine to the smallest possible stroke for the processing Dimensions drawing /ENG

39 Radial riveting machine RNE 281 Options Technical specifications Type F1-U1Z UN Type F1-U2ZD UN Part number Wiring diagram Additional safety pressure point to interrupt the operating process No Yes Creep switching element Yes Yes Jump switching element No No Voltage 500 VAC 500 VAC Permanent current 10A 10A Start-up current as per IEC AC 15/DC 13 Yes Yes Switching frequency max. 50/min. 50/min. Mech. service life - number of cycles 10 x x 10 6 Ambient temperature, min..max. 30 C/+80 C 22 F/+176 F 30 C/+80 C 22 F/+176 F Approvals CSA, UL CSA, UL, BG Cable entry 1 x M20 x x M20 x 1.5 Weight 1.5kg / 3.3lb 1.6kg / 3.5lb /ENG 39

40 Options Radial riveting machine RNE Initiator upper end position The upper end position of the riveting spindle is monitored by an initiator and can send the control unit the required pulse for an upstream or downstream machine (e.g. rotary indexing table, pneumatic sliding table, etc.). For further information, such as settings and connection diagrams refer to the operating instructions of the control unit. without path-measuring system HPP with path-measuring system HPP 7.5 Initiator lower end position (bridging initiator) The lower end position initiator is used for self-holding the two-hand operating unit. For further information, such as settings and connection diagrams, refer to the operating instructions of the control unit /ENG

41 Radial riveting machine RNE 281 Maintenance and repair work 8 Maintenance and repair work 8.1 Introduction Safety regulations Personnel requirements The maintenance and repair work on the machine comprises periodic cleaning, lubrication, inspection and upkeep work. All completed maintenance and repair work must be entered in the maintenance and repair log by the persons responsible for the work (example form see chapter Maintenance and repair log ). If, during maintenance, it is noted that a machine part is defective or damaged, it must be correctly repaired or replaced. Only use original spare and wear parts. Inform operating personnel before starting any maintenance and repair work. Implement specified adjustment, maintenance and inspection work according to the schedule. For safety reasons, maintenance and repair work may only be carried out by trained specialist personnel /ENG 41

42 Check Relubrication Removal Cleaning New lubrication Topping up Emptying Replacement Every 40h or weekly Every 1000h or annually Every 5000h or 2 years Each time riveting unit is dismantled Maintenance and repair work Radial riveting machine RNE Overview of maintenance work Assembly Type of maintenance Maintenance interval (whichever is reached first) Riveting spindle head (form tool holder and pressure cup) X X X Riveting spindle X X X X X Automatic lubrication riveting spindle head (option) X When the corresponding indication appears on the control unit display Air maintenance unit X X X X Polygon shaft X X X Two-hand operating unit X X Piston and piston rod seals X X Riveting motor terminal box X X /ENG

43 Radial riveting machine RNE 281 Maintenance and repair work Riveting spindle head (form tool holder and pressure cup) 7 Item Name 1 Form tool holder spherical plain bearing 2 Pressure cup 3 Form tool holder 4 Lubricator nipple 5 Red cap 6 Screwed connection for automatic lubrication 7 Grease gun (Article No ) Riveting spindle head (form tool holder and pressure cup) maintenance schedule Name Maintenance activity Grease type Interval Pressure cup/form tool holder Form tool holder spherical plain bearing Lubricate with one shot of the grease gun via the lubricator nipple Clean, check for wear, relubricate Clean and check for wear, relubricate, replace if necessary Klübersynth GE Every 40 h or weekly. Lubrication intervals should be reduced for extremely high stresses (temperature at red cap over 40 C) or during shift operation. Every 1000 h or after every replacement of pressure cup/form tool holder Every 1000 h or after every replacement of pressure cup/form tool holder /ENG 43

44 Maintenance and repair work Radial riveting machine RNE Riveting spindle /ENG

45 Clean and check for wear, replace if necessary Dismantle Replacement Lubricate Klüber-Staburags NBU 8 EP Mobil DTE 24 Radial riveting machine RNE 281 Maintenance and repair work Riveting spindle maintenance schedule Maintenance activity Grease type Item Name Comments 4 Guide sleeve X X 7 Eccentric sleeve X 16 Internal ring gear X X X 17 Eccentric shaft X X X 18 Washer X 25 Needle ring X X 38 Axial ball bearing X X 39 Needle ring X X 40 Needle bearing X X 42 Washer X 43 I.D. seal X X 44 I.D. seal X X 45 I.D. seal X X 46 O.D. seal X X 47 Damping sealing ring X X 49 O-Ring X X 51 O-Ring X X 53 O-Ring X X 88 Compensating washer X X 89 Compensating washer X X 90 Buffer disc X 91 Buffer disc X 92 Axial needle ring X X 93 Shaft & housing locating wash. X Item 88 must be centered on the damping piston item 3 during assembly (grease item 88 with Klüber-Staburags NBU 8 EP to make it easier) The riveting unit must be completed disassembled every 2 years or 5000 operating hours for maintenance lubrication. All parts must be cleaned and the bearing surfaces must be checked for wear or burnt areas. The needle rings and axial needle bearings of the eccentric shaft must be replaced (see maintenance list). All parts must be carefully reassembled after being newly lubricated. NOTICE This revision interval should be shorted appropriately if high stresses are involved (higher material stressing)! /ENG 45

46 Maintenance and repair work Radial riveting machine RNE Automatic lubrication riveting spindle head (option) Item Name Item Name 1 Injection lubricator (metering valve) 7 Initiator 2 Lubricant line 8 Container cover 3 Solenoid valve 9 Pistons 4 Screwed connection 10 Pressure control valve 5 Plug screw 11 Compressed air hose 6 Grease container (27.6 cm 3 ) Topping up the grease container ATTENTION Container is under pressure! Grease squirts out of container! To topping up stop the compressed air supply! The grease level in the grease container can be determined from the position of the piston. When the end protrudes less than 4 mm out of the container cover or when a corresponding indication appears on the control unit display, the grease container must be topped up as follows: 1. Stop compressed air supply to riveting machine 2. Disconnect compressed air hose at connection 3. Remove the lubricant line and the aperture plug screw on the grease container 4. Push the piston through the aperture down to the stop. Slowly top up with grease (Klübersynth GE ) until it starts to come back out of the same aperture. 5. The grease must leak through the screw connection when the plug screw is mounted again. 6. Reconnect the lubricant line. Manually actuate the injection lubricator several times --> there must not be any air in the lubricant line! /ENG

47 Radial riveting machine RNE 281 Maintenance and repair work Air maintenance unit 081, 181, 231, STF, 231 STF, 281 STF, 331, 331 STF 331, 331 STF Item Name Item Name 1 Filter / water separator 4 Exhaust air filter 2 Oil tank 5 Filter element 3 Drain valve 6 Oil filler screw Air maintenance unit maintenance schedule Item Maintenance activity Oil type Interval 1 Check water level, drain water via drain valve when necessary. Notice: The condensate level must never exceed the maximum mark otherwise water with compressed air would be entrained to the control elements! Every 40h or weekly Check oil level, top up if necessary Oil filler air maintenance unit : 2 Stop compressed air supply to air maintenance unit (oil filler under pressure not possible!) Unscrew oil tank Top up oil to the mark Oil filler air maintenance unit 331, STF: Possible during operation, system has not to be unpressurized Undo slowly oil filler screw (pressure decrease in oil tank) Top up oil to the mark Retighten oil filler screw See table for recommended oils Every 40h or weekly 4 Replace filter element Annually /ENG 47

48 Maintenance and repair work Radial riveting machine RNE 281 Oils recommended for the air maintenance unit Manufacturer BP Name ENERGOL RD-E 46 (ISO) CHEVRON (only available in USA) ARIES ISO-VG 46 ESSO NUTO H32 MOBIL MOBIL DTE 24 SHELL TORCULA Oil 32 (ISO) TEXACO (only available in Europe) ARIES ISO-VG 32 VALVOLINE ATO 46 or ATO 22 SYNTH Mist oiler adjustment Item Name 1 Adjustment screw 2 Mist oiler Use the adjustment screw to set the desired oil quantity. At delivery the oiler is opened by 1½ turn clockwise. Increasing the oil quantity = turn the adjustment screw counterclockwise Decreasing the oil quantity = turn the adjustment screw clockwise If oil escapes out of the pneumatic valve the quantity of oil could be reduced /ENG

49 Radial riveting machine RNE 281 Maintenance and repair work Polygon shaft It is strongly recommended, for preventative maintenance regarding machines subject to high stresses and multiple shift work, that the polygon profile is cleaned every 1000 operating hours or at least annually and lubricated again with Interflon Grease LS1/2. NOTICE This point applies in particular to riveting machines that are equipped with the Process-Controller /ENG 49

50 Maintenance and repair work Radial riveting machine RNE Two-hand operating unit The two-hand operating unit must be checked regularly, at least once a year, by an expert provided by the operator. This check must cover: 1. The secure function of the two-hand operating unit 2. The condition of the two-hand operating unit components 3. The interaction of the two-hand operating unit with the riveting machine control unit The test results must be documented in a report to be signed by the tester. The report must be retained. Safety inspection After every change in working procedures, e.g tool change, change to activation type "Two-hand operating unit", additions of further safety equipment, the following must be checked: 1. That the two-hand operating unit required for safety is switched on and functional 2. That the two-hand operating unit and exposed connection lines are visually undamaged 3. That the necessary safety distance is complied with Check list for two-hand operating unit check Yes No Does the riveting machine start after actuation of the two-hand button at an interval of < 0.5 sec.? X Does the riveting machine start after actuation of the two-hand button at an interval of > 0.5 sec.? Two-hand button and exposed lines damaged? X X Safety distance complied with? Is the start lifting movement interrupted if one button is released? X X Piston and piston rod seals NOTICE The piston and piston rod seals must always be replaced when the riveting machine is disassembled (seals may be damaged during inappropriate removal of riveting unit). Seals must be carefully reassembled after being newly lubricated (see riveting spindle maintenance schedule) /ENG