Pneumatic Chuck ROTA TP / ROTA TP-LH

Transcription

1 Translation of the original manual Pneumatic Chuck ROTA TP / ROTA TP-LH Assembly and operating manual Superior Clamping and Gripping

2 Imprint Copyright: Imprint This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights reserved. Any reproduction, processing, distribution (making available to third parties), translation or other usage - even excerpts - of the manual is especially prohibited and requires our written approval. Technical changes: We reserve the right to make alterations for the purpose of technical improvement. Document number: en Version: /10/2017 en H.-D. SCHUNK GmbH & Co. All rights reserved. Dear Customer, thank you for trusting our products and our family-owned company, the leading 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. Spanntechnik KG Lothringer Str. 23 D Mengen Tel Fax info@de.schunk.com schunk.com ROTA TP en

3 Table of contents Table of contents 1 General About this manual Presentation of Warning Labels Applicable documents Sizes Warranty Scope of delivery Basic safety notes Intended use Not intended use Constructional changes Spare parts Chuck jaws Environmental and operating conditions Personnel qualification Personal protective equipment Notes on safe operation Transport Malfunctions Disposal Fundamental dangers Protection during handling and assembly Protection during commissioning and operation Protection against dangerous movements Notes on particular risks Technical data Chuck data Clamping force / speed diagrams Calculations for clamping force and speed Calculation of the required clamping force in case of a given rpm Calculation example: required initial clamping force for a given speed Calculation of the permissible speed in case of a given initial clamping force Grades of Accuracy Permissible imbalance Torques per screw ROTA TP en 3

4 Table of contents 4 Function Principle of Operation Functional testing Air transmission system Pilot controlled check valve Clamping or jaw actuation Power Chuck with extended and standard jaw stroke (LH) Transport Mounting Installing and connecting Inclusion Distributor ring Distributor ring: normal fastening Stationary mounting of the distributor ring Mounting with bracket Mounting with 2-part clamping ring (D.R.M.B.) Commissioning and maintenance Initial operation Maintenance Maintenance intervals Hardened Reversible Jaws and Soft Top Jaws Disassembly Assembly Spare parts Assembly drawings Translation of the original declaration of incorporation Appendix on Declaration of Incorporation, as per 2006/42/EC, Annex II, No. 1 B ROTA TP en

5 General General About this manual This manual contains important information for a safe and appropriate use of the product. This manual is an integral part of the product and must be kept accessible for the personnel at all times. Before starting work, the personnel must have read and understood this operating manual. Prerequisite for safe working is the observance of all 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 inevitably cause irreversible injury or death. WARNING Dangers for persons! Non-observance can lead to irreversible injury and even death. CAUTION Dangers for persons! Non-observance can cause minor injuries. NOTICE Material damage! Information about avoiding material damage ROTA TP en 5

6 General 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 schunk.com Sizes This operating manual applies to the following sizes: ROTA TP ; ; ; ; ; ; ROTA TP LH Warranty The warranty period is 24 months after delivery date from factory or cycles*, if it is used as intended, under the following conditions: Observe the applicable documents ( 1.1.2, Page 6) Observe the ambient conditions and operating conditions, ( 2.6, Page 9) Observe the specified maintenance and lubrication intervals, ( 7, Page 43) Parts touching the workpiece and wear parts are not included in the warranty. * A cycle consists of a complete clamping process ("Open" and "Close"). Scope of delivery 1 Power lathe chucks 6 T-nuts 2 Elbow connectors 2 Straight connectors 1 Spacer ring 1 Headless screw for fastening the distributor ring 1 Angle for eye bolt 1 Eye bolt Studs for assembling the chuck 1 Operating manual ROTA TP en

7 Basic safety notes Basic safety notes 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 17). The product is intended for industrial and industry-oriented use. Appropriate use of the product includes compliance with all instructions in this manual. 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 Technical data ). ( 3, Page 17) Not intended use A not intended use of the product is for example: It is used as a press, a punch, a toolholder, a load-handling device or as lifting equipment. the product is used for unintended machines or workpieces. the technical data is exceeded when using the product. ( 3, Page 17) if workpieces are not clamped properly, paying particular attention to the clamping forces specified by 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 approval of SCHUNK ROTA TP en 7

8 Basic safety notes 2.4 Spare parts Use of unauthorized spare parts Using unauthorized spare parts can endanger personnel and damage the product or cause it to malfunction. Use only original spare parts or spares authorized by SCHUNK. 2.5 Chuck jaws Requirements of the chuck jaws Stored energy can make the product unsafe and risk the danger of serious injuries and considerable material damage. Only replace chuck jaws if no residual energy can be released. Do not use welded jaws. The jaws should be designed 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 greater surface pressure in the jaw guidance and can significantly reduce the clamping force). If for constructional reasons the special chuck jaws are heavier than the top jaws assigned to the lathe chuck, greater centrifugal forces must be accounted for when defining the required clamping force and the recommended speed. The maximum recommended speed may only be operated in conjunction with maximum actuating force and only with the lathe chuck in optimal, fully functioning condition. After a collision, the lathe chuck and the chuck jaws must be subjected to a crack test before being used again. Damaged parts must be replaced with original SCHUNK spare parts. Screw the jaw mounting screws into the bore holes furthest apart. The jaw fastening screws must be replaced if they show any signs of wear or damage. Only use screws with a quality of ROTA TP en

9 Basic safety notes Trained electrician Qualified personnel Instructed person Service personnel of the manufacturer Environmental and operating conditions Required ambient conditions and operating conditions Incorrect ambient and operating conditions can make the product unsafe, leading to the risk of serious injuries, considerable material damage and/or a significant reduction to the product's life span. Make sure that the product is used only in the context of its defined application parameters, ( 3, Page 17). Make sure that the product is a sufficient size for the application. Only use high-quality cooling emulsions with anti-corrosive additives during processing. Lubricating intervals must be adhered to ( 7.3, Page 47). Personnel qualification Inadequate qualifications of the personnel If the personnel working with the product is not sufficiently qualified, the result may be serious injuries and significant property damage. All work may only be performed by qualified personnel. Before working with the product, the personnel must have 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 dangers and know the relevant standards and regulations. Due to its technical training, knowledge and experience, qualified personnel is able to perform the delegated tasks, recognize and avoid possible dangers and knows the relevant standards and regulations. Instructed persons were instructed by the operator about the delegated tasks and possible dangers due to improper behaviour. Due to its technical training, knowledge and experience, service personnel of the manufacturer is able to perform the delegated tasks and to recognize and avoid possible dangers ROTA TP en 9

10 Basic safety notes 2.8 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 occupational health and safety regulations and wear the required personal protective equipment. Observe the valid safety and accident prevention regulations. Wear protective gloves to guard 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. 2.9 Notes on safe operation Incorrect handling of the personnel Incorrect handling and assembly may impair the product's safety and cause serious injuries and considerable material damage. Avoid any manner of working that may interfere with the function and operational safety of the product. Use the product as intended. Observe the safety notes and assembly instructions. Do not expose the product to any corrosive media. This does not apply to products that are designed for special environments. Eliminate any malfunction immediately. Observe the care and maintenance instructions. Observe the current safety, accident prevention and environmental protection regulations regarding the product's application field ROTA TP en

11 Basic safety notes 2.10 Transport Handling during transport Incorrect handling during transport may impair the product's safety 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 Immediately remove the product from operation and report the malfunction to the responsible departments/persons. Order appropriately trained personnel to rectify the malfunction. Do not recommission the product until the malfunction has been rectified. Test the product after a malfunction to establish whether it still functions properly and no increased risks have arisen Disposal Handling of disposal The incorrect 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 ROTA TP en 11

12 Basic safety notes 2.13 Fundamental dangers General Observe safety distances. Never deactivate safety devices. Before commissioning the product, take appropriate protective measures to secure the danger zone. Disconnect power sources before installation, modification, maintenance, or calibration. 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 damage. Have all work carried out by appropriately qualified personnel. For all work, secure the product against accidental operation. Observe the relevant accident prevention rules. Use suitable assembly and transport equipment and take precautions to prevent jamming and crushing. Incorrect lifting of loads Falling loads may cause serious injuries and even death. Stand clear of suspended loads and do not step into their swiveling range. Never move loads without supervision. 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 ROTA TP en

13 Basic safety notes Protection against dangerous movements Unexpected movements Residual energy in the system may cause serious injuries while working with the product. Switch off the energy supply, ensure that no residual energy remains and secure against inadvertent reactivation. Never rely solely on 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 material damage, human access to the movement range of the machine must be restricted. Restrict unintentional access by persons to this range e.g. via a protective cover, protective fence or photoelectric barrier. The protective cover and protective fence must be rigid enough to withstand the maximum possible movement energy. EMERGENCY STOP switches must be easily and quickly accessible. Check the function of the EMREGENCY STOP before starting up the machine or system. If this protective equipment is not working properly, prevent the operation of the machine Notes on particular risks DANGER Risk of fatal injury from suspended loads! Falling loads can cause serious injuries and even death. Stand clear of suspended loads and do not step within their swiveling range. Never move loads without supervision. Do not leave suspended loads unattended. Wear suitable protective equipment ROTA TP en 13

14 Basic safety notes DANGER Risk 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 automated system. The machine manufacturer and the operator of the machine must carry out and document a hazard assessment and risk analysis to ensure that suitable measures are taken to maintain 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 requirements of the EC Machinery Directive; specifically, they must have effective technical measures to protect against potential mechanical hazards. DANGER Possible risk of fatal injury to operating personnel if a jaw breaks or if the lathe chuck fails because the technical data have been exceeded and a workpiece is released or parts fly off The technical data specified by the manufacturer for using the lathe chuck must never be exceeded. The lathe chuck may only be used on machines and facilities that fulfill the minimum requirements of the EC Machinery Directive; specifically, they must have effective technical measures to protect against possible mechanical hazards ROTA TP en

15 DANGER Basic safety notes Possible risk of fatal injury to operating 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 potential mechanical hazards. Always wear tight-fitting clothing and a hairnet when working on the machine and the lathe chuck. CAUTION Danger of slipping and falling in case of dirty environment where the chuck is used (e.g. by cooling lubricants or oil). Ensure that the working environment is clean before starting assembly and installation work. Wear suitable safety shoes. Follow the safety and accident-prevention regulations when operating the chuck, especially when working with machine tools and other technical equipment. CAUTION Danger of limbs being crushed by opening and closing of the chuck jaws during manual loading and unloading or when replacing moving parts. Do not reach between the chuck jaws. Automatic loading is preferred. If manual loading is used, adjust the jaw position so that the opening gap between the jaw and the workpiece is less than 4 mm. Wear protective gloves. Observe the safety and accident prevention regulations during operation of the chuck, especially in connection with machining centers and other technical equipment ROTA TP en 15

16 Basic safety notes CAUTION Risk of burns due to workpieces with high temperatures. Wear protective gloves when removing the workpieces. Automatic loading is preferred. CAUTION Risk of damages due to incorrect choice of clamping position for chuck jaws on workpiece. If an incorrect clamping position is chosen for the chuck jaws on workpiece, the base and the top jaws may be damaged. The T-nuts combine the top jaws with the base jaws and they should never protude over the base jaws in radial direction. The outer diameter of the screwed top jaws must not exceed the outer diameter of the chuck by more than 10%. CAUTION Hazard from vibration due to imbalanced rotating parts and noise generation. Physical and mental strains due to imbalanced workpieces and noise during the machining process on the clamped and rotating workpiece. Ensure the chuck's axial and concentric runout. Check options for remedying imbalances on special top jaws and workpieces. Reduce the speed. Wear hearing protection ROTA TP en

17 Technical data Technical data Chuck data Size LH Chuck through bore [mm] Max. clamping force [kn] Max. rotation speed [min-1] Stroke per jaw [mm] Serration of the jaws [mm] 1/16"x90 Chuck diameter [mm] Distributor ring Ø [mm] Centrifugal torque of base jaw [kgm] McGB Max. jaw eccentricity of center of gravity in axial direction [mm] amax The specified maximum speed of rotation stated only applies when using the maximum clamping force and the SHB-type, soft, 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. Ensure minimal weight for all jaws. For unhardened top jaws or chuck jaws in special design, the permissible RPM according to VDI 3106 must be calculated for the respective machining job. Whereby the recommended maximum speed must not be exceeded. The values calculated must be checked by means of dynamic measurement using a clamping force tester ROTA TP en 17

18 Technical data 3.2 Clamping force / speed diagrams The diagrams refer to 3-jaw-chuck. Clamping force/rpm curves have been calculated using hard jaws. The chucks were operated with the max. permissable force and the jaws were located exactly on line with the chuck O.D. The chuck is in perfect condition and lubricated with SCHUNK LINOMAX 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 center of gravity in axial direction Fmax Max. actuating force Clamping force / speed diagram ROTA TP ROTA TP en

19 Technical data Clamping force / speed diagram ROTA TP Clamping force / speed diagram ROTA TP Clamping force / speed diagram ROTA TP ROTA TP en 19

20 Technical data Clamping force / speed diagram ROTA TP Clamping force / speed diagram ROTA TP Clamping force / speed diagram ROTA TP ROTA TP en

21 Clamping force / speed diagram ROTA TP-LH Technical data Legend 3.3 Calculations for clamping force and speed Missing information or specifications can be requested from the manufacturer. Fc Total centrifugal force [N] McAB Centrifugal torque of top jaws [Nm] Fsp Effective clamping force [N] McGB Centrifugal torque of base jaws [Nm] Fspmin Minimum required clamping force [N] n Speed [rpm] Fsp0 Initial clamping force [N] rs Center of gravity radius [mm] Fspz Cutting force [N] rsab Center of gravity radius of top jaw [mm] mab Mass of one top jaw [kg] ssp Safety factor for clamping force mb Mass of chuck jaw set [kg] sz Safety factor for machining Mc Centrifugal force torque [Nm] Σs Max. clamping force of 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 generates an additional centrifugal force. The centrifugal force reduces or increases the initial clamping force depending on whether gripping is from the outside inwards or from the inside outwards. The sum of the initial clamping force Fsp0 and the total centrifugal force Fc is the effective clamping force Fsp. ( ) for gripping from the outside inwards (+) for gripping from the inside outwards ROTA TP en 21

22 Technical data DANGER Risk to life and limb of the operating personnel and significant property damage when the RPM limit is exceeded! With gripping from the outside inwards, and with increasing RPM, the effective clamping force is reduced by the magnitude of the increasing centrifugal force (the forces are opposed). When the RPM limit is exceeded, the clamping force drops below the required minimum clamping force Fspmin. Consequently, 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 factor takes into account uncertainties in the calculation of the machining force. According to VDI 3106: Sz 1.5. From this we can derive the calculation of the initial clamping force during shutdown: (+) for gripping from the outside inwards ( ) for gripping from the inside outwards ROTA TP en

23 NOTICE Technical data This calculated force must not be larger than the maximum clamping force ΣS engraved on the chuck. See also "Chuck data" table ( 3.1, Page 17) From the above formula it is evident that the sum of the effective clamping force Fsp and the total centrifugal force Fc is multiplied by the safety factor for the clamping force Ssp. According to VDI 3106, the following also applies here: Ssp 1.5. The total centrifugal force Fc is dependent on both the sum of the masses of all jaws and on the center of gravity radius and the rpm. NOTICE For safety reasons, in accordance with DIN EN 1550, the centrifugal force may be a maximum of 67% 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 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 base jaws McGB and the centrifugal torque of the top jaws McAB need to be added: The centrifugal torque of the base jaws McGB can be found in the table "Chuck data"( 3.1, Page 17). The centrifugal torque of the top jaws McAB is calculated as per: ROTA TP en 23

24 Technical data Calculation example: required initial clamping force for a given speed Required initial clamping force Fsp0 for a given speed n The following data is known for the machining job: Gripping from the outside in (application-specific) Machining force Fspz = 3000 N (application-specific) max. speed of rotation nmax = 3200 rpm ("Chuck data" table) RPM n = 1200 rpm (application-specific) Mass of one (!) top jaw mab = 5.33 kg (applicationspecific) Center of gravity radius of top jaw rsab = m (applicationspecific) Safety factor Sz = 1.5 (according to VDI 3106) Safety factor Ssp = 1.5 (according to VDI 3106) Note: Masses of the jaw mounting screws and T-nuts are not taken into account. First the required effective clamping force Fsp is 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 data" table: For the centrifugal torque of the top jaw, the following applies: Centrifugal torque for one jaw: The chuck has 3 jaws, the total centrifugal torque is: ROTA TP en

25 Technical data The total centrifugal force can now be calculated: Initial clamping force during shutdown that was sought: Calculation of the permissible speed in case of a given initial clamping force Calculation of the permissible speed nperm in case of a given initial clamping force Fsp0 The following formula can be used to calculate the permissible RPM for a given initial clamping force during shutdown: NOTICE The calculated permissible RPM may not exceed the maximum RPM inscribed on the chuck for safety reasons! Example of calculation: Permissible RPM for a given effective clamping force The following data is known from previous calculations: Initial clamping force during shutdown Fsp0 = N Machining force for machining job Fspz 3000 N (applicationspecific) Total centrifugal torque of all jaws Mc = 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 smaller than the maximum permissible RPM of the chuck nmax = 3200 rpm (see "Chuck data" table ( 3.1, Page 17)). This calculated RPM may be used ROTA TP en 25

26 Technical data 3.4 Grades of Accuracy Tolerances for run-out accuracy and axial run-out accuracy correspond to the Technical Supply Terms for lathe chucks as per DIN ISO Permissible imbalance The ROTA TP in ungreased state without T-nuts and top jaws corresponds to the balancing quality class 6.3 (according to DIN ISO ). Risks of residual unbalance may arise due to insufficient rotation compensation being achieved (see DIN EN e). This applies particularly to high speeds, 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 Torques per screw Tightening torques for mounting screws used to clamp the chuck on lathes or other suitable technical equipment (screw quality 10.9) Screw size M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 Admissible torque MA (Nm) 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) ROTA TP en

27 Function Function The item numbers specified for the corresponding individual components relate to chapter drawings.( 9, Page 52) Principle of Operation The problem of air supply was solved by a stationary distributor ring with profile ring seals arranged therein. Openings in the two elastic radially deformable profile seals allow the compressed air to flow through a non-return valve to one of the two pressure chambers. The pilot controlled non-return valve controls the feeding to one pressure chamber and the simultaneous forced ventilation of the second pressure chamber. This triggers the piston stroke and the base jaws are moved by the wedge hook. The valve system blocks and stores the pressure in the chuck body while the profile seals, due to their elasticity, are raised from the chuck body by the ventilation of the supply lines and therefore are not subject to wear from the rotating chuck. 4.2 Functional testing 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. operating force/pressure. Stroke control! The stroke of the clamping piston must allow a safety zone at the front and rear end position. The machine spindle may only be started when the clamping piston has passed through the safety zone. Only limit switches that meet the requirements for safety limit switches specified in DIN EN may be used. When determining the necessary clamping force to machine a workpiece, take the centrifugal force acting on the chuck jaws into account (according to VDI 3106). If the chuck jaws are changed, adjust the stroke control to the new situation ROTA TP en 27

28 Function DANGER Risk of fatal injury to operating personnel if the top speed is exceeded, resulting in workpiece loss and parts flying off! A reliable speed limiter must be installed in the machine tool or technical equipment and proof must be provided that the speed limiter is effective! 4.3 Air transmission system Air transfer takes place only when the headstock spindle is at a standstill, via profile seals provided radially in the distributor ring. The profile seal is designed so that the outer upper section of the surface is larger than the surface of the openings. Upon pressurization the difference in surface area exerts a radial force on the profile seal in the ring-shaped chamber of the distributor ring, resulting in optimal static sealing of the profile seal at the air transfer point. This allows low-loss flow of the air through the openings in the profile seal into the cylinder chamber of the chuck. If the supply of compressed air is stopped, the double check valve closes and the pre-tensioned profile seal raises from the chuck body due to its elasticity and is not subjected to wear during rotation of the chuck. The off- and return air out of the opposit cylinder chamber leaves for the most part directly below the associated profile sealing ROTA TP en

29 NOTICE Function During actuation of the clamping device (clamping or releasing) it must be ensured that a short ventilation time is maintained between the switching processes. This ventilation time must last at least 0.5 seconds, depending on the hose length. For this purpose we recommend the use of a 4/3- or 5/3- way valve (central position depressurized). 4.4 Pilot controlled check valve The pilot-controlled check valve is an intrinsically sealed unit, and comprises a valve body plus two locking pistons. Light maintenance can be performed on it from the face side of the chuck via a locking screw. The locking pistons of the valve unit control the rate of the air that flows to and from the profile seals through two air ducts. By changing the pressure of the air at the profile seals, the air duct is vented into a cylinder chamber (relief chamber) on one side. During this process, the compressed air is rerouted from one cylinder chamber due to the valve housing moving axially while the two individual locking/check pistons execute only one stroke when locking their respective cylinder chambers. As a result of this process, both O.D. and I.D. clamping are possible throughout the valve system ROTA TP en 29

30 Function 4.5 Clamping or jaw actuation All three base jaws are centrically driven by a piston with a collar. The force is transmitted on the two-sided, extended and selflocking (10 wedge slant standard) wedge hook or base jaw. The clamping forces are absorbed by the diameter of the piston collar and braced against by the chuck body. Both sides of a piston cover screwed onto the piston neck for clamping and unclamping are pressurized, thus causing the piston cover to trigger the axial motion of the piston ROTA TP en

31 Function 4.6 Power Chuck with extended and standard jaw stroke (LH) Lathe chucks with dual stroke system (LH-serie) are not allowed to be used for I.D. clamping. Moreover, no workpieces are allowed to be clamped on the fast jaw stroke, since due to the long jaw strokes the resulting clamping forces are lower (1). Please make sure that the entire fast stroke plus at least 1/3 of the clamping stroke (corresponding to the basic covering) of the TB-LH lathe chuck is executed during workpiece clamping (2) ROTA TP en 31

32 Transport 5 Transport DANGER Risk of fatal injury from suspended loads! Falling loads can cause serious injuries and even death. Use suitable lifting equipment. Secure the product to prevent it from falling. Stand clear of suspended loads and do not step within their swiveling range. Only move loads when supervised and do not leave unattended. Wear suitable protective equipment. CAUTION Risk of injury due to sharp edges and rough or slippery surfaces Wear personal protective equipment, particularly protective gloves. An eye bolt and an angle are included in the scope of delivery for transporting lathe chucks with a size of 160 and above. These chucks are only allowed to be transported on this eye bolt. Place the angle under the eye bolt on the distributor ring. Screw the eye bolt into the thread provided. Using the angle prevents the distributor ring from slipping backwards out of the chuck ROTA TP en

33 Mounting Mounting Installing and connecting WARNING Risk of injury due to unexpected movements! If the power supply is switched on or residual energy remains in the system, components can move unexpectedly and cause serious injuries. Before starting any work on the product: Switch off the power supply and secure against restarting. Ensure that no residual energy remains in the system. CAUTION Danger of injury due to sharp edges and rough or slippery surfaces Wear personal protective equipment, particularly protective gloves. NOTICE Always use the correct length of mounting screws when mounting the chuck and flange. Screws that are too long may protrude from the tapping drill hole or damage the machine spindle. 1 Preparing the mount ( 6.2, Page 34) 2 Chuck assembly ( 6, Page 33) 3 Performing a functional check ( 4.2, Page 27) ROTA TP en 33

34 Mounting 6.2 Inclusion For ROTA TP 125 / Z up to 350 / Z lathe chuck types, a normal intermediate flange must be placed on the spindle head. Using 6 pin screws M12 x 40 (sizes ), the rear flange side of the front of the power chuck which has been turned free is screwed»across corners«into the intermediate flange which has been screwed into the spindle head. The cylindrical precisely turned centering shoulder on the flange must be screwed on 6 2 mm deep so as to ensure contact with the outer chuck edge. In order to avoid a large reach of the chuck, the chuck terminating cover having a centering mount can be replaced with one having a short cover for corresponding direct mounting on the spindle nose as per DIN or Camlock (DIN 55029). Of course, this also applies to a conversion of the chuck from one direct mount to another, in which case attention must be paid to the inner and outer O-ring for static sealing ROTA TP en

35 Mounting 6.3 Distributor ring The distributor ring of the front-mounted power chuck model RO- TA TP and TP-LH is supplied with 2 possible means of fastening as standard Distributor ring: normal fastening The distributor ring is automatically centered with the chuck body by a plastic centering sleeve (Hostaform C). The following maximum speeds are possible with this mounting: ROTA TP ROTA TP ROTA TP ROTA TP ROTA TP min min min min min -1 ROTA TP ROTA TP ROTA TP-LH ROTA TP LH min min min min -1 Two threaded holes are arranged on the circumference at less than 120 from each other and at a distance from the pneumatic connection so that the distributor ring can be secured against turning by means of a set-screw belonging to the equipment. The set-screw is screwed into the threaded hole that brings the pneumatic connections into a suitable position so that the pneumatic supply lines can be routed to the control unit over the shortest possible distance. The set-screw must be able to move back and forth freely in both directions, but no more than 3 mm, in a fork rigidly mounted in the headstock or lathe bed. And the fork must be produced and installed in such a way that it does not apply pressure to the distributor ring axially or radially. Note Therefore, ONLY flexible connection cables may be used ROTA TP en 35

36 Mounting If the plastic centering sleeve of the distributor ring becomes worn slightly at the weight-loaded upper point of contact with the chuck body over time, it can be turned further by one third by removing the three hexagon socket screws. The three hexagon socket screws hold the two parts of the distributor ring and the plastic centering sleeve together. The plastic centering sleeve must be inserted in such a way that the slotted location is on one of the three bore holes of the distributor ring. The flat surface of the chuck body which is raised in the area of the distributor ring prevents the penetration of dirt and chips between the distributor ring and the chuck body. The hexagon socket screws of the distributor ring should be lightly tightened. The two parts of the distributor ring can be realigned with each other only by light knocking. Retighten the screws. The profile seals only begin to wear if the chuck is actuated by the control unit during the rotation, which is generally prevented by the connection of the electrical interlock to the machine ROTA TP en

37 Mounting Stationary mounting of the distributor ring If the distributor ring is mounted in a stationary position, the speed can be increased to the value provided in the table below. ROTA TP TP TP TP TP Max. rotation speed [min-1] a ROTA TP TP TP-LH TP-LH Max. rotation speed [min-1] a ROTA TP en 37

38 Mounting In this case, the distributor ring is a component that is completely separate from the chuck and is centered and retained on the headstock of the lathe axially and radially by means of spacing consoles. The stationary mounting can be accomplished by using M6 threaded holes on the rear face side of the distributor ring. It must be ensured that the distributor ring is aligned with the chuck body without contact. For this mounting type, the distributor ring must be equipped with a spacer ring instead of the plastic centering sleeve. This spacer ring is loosely enclosed with each ROTA TP / TP-LH front-end power chuck. If the distributor ring is to be fastened but is equipped standard with the centering sleeve, the centering sleeve must be replaced with the enclosed spacer ring ROTA TP en

39 Mounting Mounting with bracket First, the lathe chuck is installed onto the machine spindle with the loosely attached distributor ring and the distributor ring is aligned flush with the stepped front side of the chuck. The height dimension of the spacing consoles can only be determined by measuring between the face side of the headstock and the rear face side of the distributor ring. The determined dimension is the height dimension of the spacing consoles. In this case, the distance dimension a (see table above) is subtracted. If the face side of the headstock is not machined, a mean must be determined and any height differences must be compensated by means of a positioning screw or positioning sleeve. Incidentally, the spacing consoles can be customized, but they should achieve the stability of the presented design ROTA TP en 39

40 Mounting Mounting with 2-part clamping ring (D.R.M.B.) The distributor ring can be clamped onto a rigid collar on the machine (at least 8 mm wide) using a two-piece clamping ring. The distributor ring is clamped onto this collar by two screws. The height of the clamping ring is designed according to the "Bracket Mounting" chapter. ( 6.3.2, Page 37). During assembly, this two-piece clamping ring is first screwed to the threads of the distributor ring. Then they entire assembly group is clamped onto the rigid collar of the machine. When mounting the chuck with a bayonet or Camlock, the clamping ring should have a cut-out to allow access to the collar nuts or clamping cams using the corresponding wrench. NOTE The distributor ring must be aligned with the outer chuck diameter in such a way that at least a radial and axial run-out tolerance of 0.1 mm is achieved. During the assembly, as mentioned at the start, it must be ensured that the distributor ring is axially and radially aligned with the chuck body without contact and fixed. Note Therefore, ONLY flexible connection cables may be used ROTA TP en

41 Mounting The radial alignment of the distributor ring is correct if the distance between the distributor ring cover and the distributor ring equals a (see the "Conventional Mounting of the Distributor Ring" chapter) ( 6.3.2, Page 37). The ring can be aligned radially with a feeler gauge. The air gap between the chuck body and the distributor ring at the front and rear should be uniform over the entire circumference (approx. 1 mm). Additional measurement and alignment can be performed by using a magnetic dial indicator stand, which is placed on the face side of the chuck. The dial indicator is placed radially against the distributor ring and the distributor ring is aligned until the dial indicator no longer indicates a significant deviation (approx. 0.2 mm) ROTA TP en 41

42 Mounting A Spacer ring,( 6.3.3, Page 39) B Centering ring, ( 6.3.2, Page 37) ROTA TP en

43 Commissioning and maintenance Commissioning and maintenance Initial operation Check that the jaw guides and the piston of the ROTA TP-type power chuck are sufficiently lubricated at the lubrication nipples set into the base jaws; if not, relubricate the base jaws in the retracted position with LINOMAX acid-free grease. When the chuck is dried out, the clamping force is significantly reduced. A locking screw with a hexagon socket is located on the front face side of the chuck. Behind the locking screw, the pilot controlled non-return valve controls the charging and exhausting of the two pressure chambers and blocks the pressure toward the outside. It is very important that the bore hole of the valve system is lightly lubricated with oil so that the valve system can move easily. Too much grease lubrication and dirt in the valve bore hole significantly impair the function of the chuck and should be avoided. NOTICE When actuating the clamping device (clamping or releasing), allow a short pause for ventilation between each shifting operation. This ventilation pause must be at least 0.5 seconds, depending on the length of the hose. We recommend using a 4/3 or 5/3 directional control valve for this (center position depressurized). Note Facing or skimming of the front-end power chuck is not permitted. Drilling of the chuck on the front face side may be performed only in accordance with the drilling patterns on the SCHUNK dimension sheets ROTA TP en 43

44 Commissioning and maintenance 7.2 Maintenance A type WEH maintenance unit, consisting of filter, water separator, and oiler, must be connected upstream of the power chuck. The air enriched with 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 opened occasionally. 2-part maintenance unit, type WEH with filter, oiler, and pressure control valve Type WEH-1 ID number Technical Data Oil type Shell Tellus S2 MA 32 Esso Febis Connection G 1/4" Nominal pressure 10 bar ROTA TP en

45 Commissioning and maintenance 1 Mounted directly from front: 2 bore holes Ø L, depth C4 2 Lateral mounting with two retaining brackets (accessories) 3 Protective metal cage with container made of transparent polycarbonate 4 Fill level indication for condensate (small inspection port) 5 Fill level indication for oil min./max. (large inspection port) 6 Semi-automatic condensate drain, G 1/8 connection 7 Required distance for removing the container 8 Automatic condensate drain can be connected by means of a hose with Ø 6 inside 9 Pressure gauge, Ø Protective cage lock 11 Distributor module as accessory: with two connections (Ø T) at front and rear and one already mounted seal plug Ø W G 1/4 D 84 K 10 Container 7 cl D1 42 K1 28 A 125 E 89 Ø L 4.1 B 213 E1 65 Ø L1 4.5 B1 - F 21 M 3 C 42 F1 40 Ø T G 1/8 C1 76 H 215 V G 1/8 C2 61 H1 - Weight [kg] C3 95 J 74 C4 38 J (weight without pressure gauge) Chuck type ROTA TP 125 ROTA TP 160 ROTA TP 200 ROTA TP ROTA TP 250 ROTA TP ROTA TP ROTA TP-LH ROTA TP-LH Basic setting for oiler Air consumption/jaw stroke at 6 bar Clamping strokes Number of oil drops Oil quantity 1 3 liters 100 approx. 1 approx. 6 mm liters 100 approx. 2 approx. 12 mm liters 100 approx. 2-3 approx. 18 mm ROTA TP en 45

46 Commissioning and maintenance Flow rate characteristic curves and pressure drops Cleaning and lubrication 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. As such, the chuck must be lubricated with LINOMAX special grease paste from a grease gun at the three base jaw lubrication nipples every operating hours. The chuck must be actuated two to three times without a workpiece to achieve grease distribution by means of the completely extended jaw stroke. The valve system of the chuck must be occasionally lightly lubricated with oil after the locking screw has been removed on the face side of the chuck. The non-return valve is removed from the bore hole, and the bore hole and the valve are cleaned to remove dirt and any foreign bodies. The fine serration of the base jaws and top jaws must be cleaned when the hardened reversible jaws or soft top jaws are adjusted, because otherwise the true running accuracy will be reduced. Foreign matter, such as dust, scale, casting dust, and fine chips, penetrates into almost every chuck, even though there is optimal sealing provided by the hardened guide bushing in the throughhole 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 clamping frequency. As such, it is not possible to specify a generally applicable rule for this ROTA TP en