Modulare machine vice KONTEC KSG

Transcription

1 Translation of original operating manual Modulare machine vice KONTEC KSG Assembly and Operating Manual Superior Clamping and Gripping

2 Imprint Imprint Copyright: This manual remains the copyrighted property of SCHUNK GmbH & Co. KG. It is solely supplied to our customers and operators of our products and forms part of the product. This documentation may not be duplicated or made accessible to third parties, in particular competitive companies, without our prior permission. Technical changes: We reserve the right to make alterations for the purpose of technical improvement. Document number: Edition: /11/2016 en SCHUNK GmbH & Co. KG All rights reserved. Dear customer, congratulations on choosing a SCHUNK product. By choosing SCHUNK, you have opted for the highest precision, top quality and best service. You are going to increase the process reliability of your production and achieve best machining results to the customer's complete satisfaction. SCHUNK products are inspiring. Our detailed assembly and operation manual will support you. Do you have further questions? You may contact us at any time even after purchase. Kindest Regards Your H.-D. SCHUNK GmbH & Co. Spanntechnik KG Lothringer Str. 23 D Mengen Tel Fax info@de.schunk.com KONTEC KSG en

3 Table of Contents Table of Contents 1 General About this manual Presentation of Warning Labels Applicable documents Sizes Variants Warranty Scope of delivery Basic safety instructions Intended use Not intended use Constructional changes Spare parts Environmental and operating conditions Operator and personnel obligations Personnel qualification Personal protective equipment Notes on safe operation Transport Malfunctions Disposal Residual risks Technical data Design and description Configuration Description Operation Mounting the base body Adjusting the clamping range Clamping and loosening the workpiece Exchanging the jaws Fastening the cover plates Troubleshooting Maintenance Maintaining the product KONTEC KSG en 3

4 Table of Contents 7.2 Disassembling and assembling the product Installing and removing the spindle assembly Installing and removing the mechanical force cassette Assembly drawing Accessories KSG R Function Assembly Troubleshooting Maintenance KSG 5A-VS Function Assembly Troubleshooting Maintenance KSG H Function Safety notes on the operation of KSG H Technical data Assembly Troubleshooting Maintenance Appendix Clamping forces Angularity Form and position tolerances Translation of the original EC declaration of incorporation KONTEC KSG 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 KONTEC KSG en 5

6 General Applicable documents General terms of business * Catalog data sheet of the purchased product * Assembly and Operating manuals of the accessories * The documents marked with an asterisk (*) can be downloaded on our homepage Sizes This operating manual applies to the following sizes: KSG 100 KSG 125 KSG Variants This operating manual applies to the following variations: KSG, Standard KSG VS, enlarged clamping range KSGR, adpater and pendulum plates KSG5A-VS, version with 5 axes, high support jaws and enlarged clamping range KSG2V, clamping towers with 2 KSG KSG4V, clamping towers with 4KSG 1.2 Warranty If the product is used as intended, the warranty is valid for 24 months from the ex-works delivery date under the following conditions: Observe the applicable documents ( 1.1.2, Page 6) Observe the ambient conditions and operating conditions ( 2.5, Page 9) Observe the specified maintenance and lubrication intervals ( 7, Page 25) Observe the maximum number of clamping cycles ( 3, Page 15) Parts touching the workpiece and wearing parts are not included in the warranty KONTEC KSG en

7 General 1.3 Scope of delivery The scope of delivery includes Clamps KSG in der bestellten Variante Clamping claws Clamping lever Cover plates SCHUNK offers a wide range of accessories for this product ( 8, Page 30) KONTEC KSG en 7

8 Basic safety instructions Basic safety instructions Improper handling, assembly and maintenance of this product may result in risk to persons and equipment if this operating manual is not observed. Report any failures and damage immediately and repair without delay to keep the extent of the damage to a minimum and prevent compromising the safety of the product. Only original SCHUNK spare parts may be used. Intended use The clamping device may only be used for clamping unmachined parts and processing workpieces. The product may only be used within the scope of its technical data, ( 3, Page 15). The product is intended for stationary usage on tool machines in an industrial environment. Appropriate use of the product includes compliance with all instructions in this manual. 2.2 Not intended use Any utilization that exceeds or differs from the appropriate use is regarded as misuse. Not intended use is, if the clamping device is used on rotating systems, far projecting workpieces are clamped, workpieces weighing more than 20 kg are clamped in vertical position without protection against falling out. 2.3 Constructional changes Making constructional changes Modifications, constructional changes and subsequent work, e.g. additional threads, drill holes and safety devices may impair the operation and safety or damage the product. Constructional changes may only be done with SCHUNK's permission KONTEC KSG en

9 Basic safety instructions 2.4 Spare parts Use of unauthorised spare parts Using unauthorised spare parts can endanger personnel and damage the product or cause it to malfunction. Use only original spare parts or spares authorised by SCHUNK. 2.5 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 15). 2.6 Operator Operator obligations Operator and personnel obligations The operator is the person that operates the product for commercial or economical purposes or makes it available to third parties for usage. During operation the operator is legally responsible for the protection of the user, the personnel and third parties using the product. The operator commits himself to only let persons work with the machine that are familiar with the basic regulations on work safety and accident protection, have been instructed in working with the machine and have read and understood the operating manual The operator commits himself to meet the requirements of the EC guideline for the use of work equipment 2007/30/EC KONTEC KSG en 9

10 Basic safety instructions Personnel obligations 2.7 Qualified personnel Instructed person All persons instructed in working with the machine commit themselves to observe the basic regulations on work safety and accident prevention and have read and understood the chapter on safety and the safety notes in this operating manual and to observe the aforementioned notes. 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 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 KONTEC KSG en

11 Basic safety instructions 2.8 Personal protective equipment Using personal protective equipment Not wearing personal protective equipment while working with the product, may result in dangers that impact the personnel's safety and health. While working with the product, observe the health and safety regulations and wear the required personal safety equipment. Observe the valid safety and accident prevention regulations. In case of sharp edges and corners and rough surfaces, wear protection gloves. In case of hot surfaces, wear heat-resistant protection gloves. When dealing with hazardous substances, wear protection gloves and goggles. In case of moving parts, wear tight protection clothes. 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 KONTEC KSG en 11

12 Basic safety instructions 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 KONTEC KSG en

13 Basic safety instructions 2.13 Residual risks The clamping device is assembled according to the state of the art and the acknowledged safety-related rules. WARNING Risk of injury due to hot flying chips. Hot flying chips may cause serious eye injuries and skin burns. For all works at the machine, wear personal safety equipment. NOTICE Material damage due to inappropriate jaw change. Unsufficiently tightened base jaws lead to material damage. Do only use screws approved by SCHUNK. Observe tightening torques. The operator is responsible for correct workpiece clamping. New clamping methods must be checked by qualified personnel with an appropriate vocational training. Due to different geometries, supporting surfaces, coefficients of friction, machining forces, faulty manipulations of the processing machine etc., there is also in case of correctly functioning clamps the danger that a workpiece is moving or pulled out. Attach protection devices to the processing machine in order to protect the operator against ejected tool and workpiece parts. Wear safety goggles in the closer sorrounding of the processing machine. Avoid working methods that impair the function and operation safety of the clamping device KONTEC KSG en 13

14 Basic safety instructions Notes on clamping technology The operator ensures that the clamping geometry and the clamping forces correspond to the chosen processing method. The clamping forces are only reached if the clamping device functions properly and if the workpiece is clamped correctly. Regular maintenance and cleaning according to the data in this manual is essential to guarantee a correct functioning. In case of elastic thin-walled workpieces, e.g. pipes or package clampings, the clamping force may be substantially reduced due to deflection of the workpiece. In case of high clampings, the clamping force is substantially reduced by increased friction forces in the slide. In case of a clamping height of 100 mm above the base body, there is a clamping force loss of approx. 40 % KONTEC KSG en

15 Technical data 3 Technical data Type Min. clamping force [kn] Max. clamping force [kn] KSG KSG KSG Type Weight [kg] KSG KSG KSG Warranty and maximum clamping cycles Duration of warranty 24 Months Maximum clamping cycles More technical data are included in the catalog data sheet. Whichever is the latest version KONTEC KSG en 15

16 Design and description Design and description Configuration Configuration 1 Quick-release levers 2 Moveable standard reversible jaws 3 Spindle assembly group 4 Fixed standard reversible jaw 5 Knurled pin 6 Base body 4.2 Description The KSG is a clamping device for exactly clamping unmachined and machined parts. The force generation is purely mechanical. The force is generated via a mechanical force cassette and a hermetically sealed spindle assembly. The force (from 4 to 30 or 40 kn) is adjusted via an adjustment ring at the spindle assembly. The workpiece is clamped by swiveling a clamping lever. The clamps can be assembled and disassemled in just a few simple steps. Extensive accessories (e.g. the jaw assortment) increase the versatile applications of the clamps. The clamping range depends on the used jaw assortment and the size KONTEC KSG en

17 Operation Operation Mounting the base body The KSG can be adjusted on T-slot tables using precision slot nuts. For the adjustment there are longitudinal and transverse slots (10 H7) in the base body. Furthermore, the base body can be mounted on grid plates using fitting screws. For this purpose, there are bore holes (Ø 12 F7 or Ø 16 F7) in the base body. The clamping bolts of the quick-change pallet system VERO-S can be mounted thanks to interfaces at the base body. Adjustment possibilities Mounting options KONTEC KSG en 17

18 Operation Mounting on a T-slot table 1 Adjust the clamps with the precision slot nuts. 2 For particularly precise adjustment, use a dial gauge for the fixed jaw. 3 Mount the base body on the T-slot table using clamping claws (1) and fastening screws. Mounting on a grid plate 1 Adjust the clamps with two fitting screws. 2 In order to adjust the base body particularly precise, use a dial gauge for the fixed jaw. Mounting with VERO-S interface For the sizes 125 and 160, the base body is equipped with an interface for mounting the clamping bolts (2) of the quick-change pallet system VERO-S. For size 100, an additional base plate is required to mount the base body to the quick-change pallet system VERO-S. The base plate is available as accessory at SCHUNK. Customer-specific mounting The KSGcan also be supplied with customer-specific positioning and mounting bore holes as well as with mounts for different quickchange pallet systems of competitors KONTEC KSG en

19 Operation 5.2 Adjusting the clamping range 1 Adjust the hexagon (2) of the spindle at left stop using the clamping lever. 2 Adjust the clamping range with the knurled handle (1). 3 Position the moveable jaw backlash-free at the workpiece. 4 Serial production: Set the knurled handle (1) three or four steps backwards to create a gap of max. 2 mm to the workpiece. In this way, the jaw opening lies within the maximal approach stroke. 5 Single production: A gap is not necessarily needed for a single production. The preclamping force and thus also the end force is increased by manually pre-clamping the workpiece at the knurled handle KONTEC KSG en 19

20 Operation 5.3 Clamping Clamping and loosening the workpiece Note: Always hold on the handle of the clamping lever during operation. The clamps are fixed and the clamping range is adjusted correctly. 1 Adjust the desired clamping force (3) at the adjustment ring. 2 Set the clamping lever at the 12 o'clock position. 3 Turn the clamping lever by maximal 90 to the right. The moveable jaw is approached to the workpiece (approach stroke). 4 Turn the clamping lever by 70 further to the right. The clamping force is generated (clamping stroke). The effort at the clamping lever is increasing. The clamping process ends at the striking end stop of the clamping lever and the clamping force is secured mechanically. Loosening 1 Turn the clamping lever to the left until it stops. The clamping force is decreasing. The approach stroke is opened again. 2 Ensure the clamping lever is at the left stop KONTEC KSG en

21 Operation 5.4 Exchanging the jaws The correct selection of the jaws significantly influences the reliable function of the clamping device. The KSG is delivered with reversible jaws by default. SCHUNK offers a wide range of jaws as accessory. 1 Loosen the screws and remove the jaws. 2 Clean and oil support surfaces, e.g. with slideway oil MOTOREX Supergliss 68 K according to ISO VG Position the jaws and tighten them crosswise using original screws. Tightening torques: Size 100 and 125 = 60 Nm Size 160 = 150 Nm 5.5 Fastening the cover plates A cover is not necessarily needed, since the spindle is not turning during the clamping process. For addtional protection, a set of cover plates is contained in the scope of delivery. 1 Choose the correct plate size depending on the clamping range. 2 For KSG 100, 125: Click the cover plate into the V-slot of the base body. For KSG 160: Insert the cover plate from behind and engage it in the nut. Multiple plates can be combined for larger clamping ranges. Cover plates can be removed by reaching under the plate and pulling it out upwards or by removing the spindle assembly KONTEC KSG en 21

22 Troubleshooting 6 Troubleshooting Loosening the adjustment ring Oiling the sealing area KONTEC KSG en

23 Troubleshooting Possible malfunction Corrective action The adjustment ring (1) is stuck. Variant A: The adjustment ring (1) is screwed in too far. Gap A = ca. 0 mm. Loosen the adjustment ring (1) by turning it counterclockwise. Variant B: The adjustment ring (1) is unscrewed too far. Gap A = ca. 2 mm. In order to loosen the adjustment ring (1), turn it in clockwise direction. Workpiece is insufficiently clamped. Remove the spindle assembly, ( 7.2.1, Page 25). Clean the guides at the base body and spindle nut. Insert the spindle assembly. Clamp the workpiece. If neccessary, replace mechanical force cassette or spindle assembly, ( 7.2.2, Page 27) and ( 7.2.1, Page 25). Attention: Do not disassemble the mechanical force cassette and spindle assembly otherwise the guarantee is becoming void. Clamps are too sluggish. Disassemble, clean and oil the KSG. Carefully pull off possibly bashed in parts. The clamping force setting is readjusting automatically. There is an increased seal friction at the knurled handle during clamping or loosening. Cooling liquid, dirt or the like caused the sealing ring under the adjustment ring to swell up. Remove the spindle assembly, ( 7.2.1, Page 25). Hold the spindle with the knurled handle vertically to the top. Lubricate the sealing area between adjustment ring and collar bearing with low viscosity oil (arrow 1). Turn the adjustment ring back and forth for several times. If necessary, replace the spindle assembly KONTEC KSG en 23

24 Troubleshooting Possible malfunction The approach stroke of the mechanical force cassette is readjusting automatically. Corrective action When adjusting the clamping range, there is an increased seal friction at the knurled handle between drawbar and spindle. Cooling liquid, dirt or the like caused the sealing ring under the adjustment ring to swell up. Remove the spindle assembly, ( 7.2.1, Page 25). Hold the spindle with the knurled handle vertically to the top. Lubricate the sealing area between adjustment ring and collar bearing with low viscosity oil (arrow 1). Turn the spindle assembly and lubricate the gap between drawbar and spindle end with low viscosity oil (arrow 2). Hold the spindle assembly at the spindle and turn the drawbar back and forth for several times. If necessary, replace the spindle assembly, ( 7.2.1, Page 25) KONTEC KSG en

25 Maintenance Maintenance Maintaining the product The KSG requires no special maintenance, since highly stressed parts are already protected against dirt on site. Maintenance interval Maintenance works for KSG 100, 125, 160 once a week, twice a week in case of heavy wear If required 1 Remove the spindle assembly, ( 7.2.1, Page 25). 2 Clean the base body and the spindle assembly. 3 Clean and oil running surfaces, e.g. with slideway oil MOTOREX Supergliss 68 K according to ISO VG 68. replace mechanical force cassette, ( 7.2.2, Page 27). 7.2 Disassembling and assembling the product Installing and removing the spindle assembly Removal 1 Adjust the hexagon (7) of the spindle with the clamping lever to the left stop and the clamping range at least to 30 mm. 2 Unscrew the knurled pin (3) from the clamping lever KONTEC KSG en 25

26 Maintenance 3 Screw the knurled pin (3) through the bore (1) of the base body into the thread of the coupling bolt (2). 4 Pull out the coupling bolt (2). 5 Pull out the spindle assembly (5). Note: The coupling bolt (2) can also be removed vertically. Remove the fixed jaw (8). Turn the spindle with the clamping lever by 90 to the right. Afterwards, the coupling bolt can be removed (to the top). Installation 1 Insert the spindle assembly (5) into the base body. 2 Turn the knurled handle (6) until the bores of the mechanical force cassette (4) and the spindle assembly (5) for the installation of the coupling bolt (2) are positioned above each other. 3 Insert the coupling bolt (2) through the bore (1) using the knurled pin (3). 4 Engage the coupling bolt (2) in the drawbar. 5 The marking at the knurled pin (3) must line up precisely with the lateral surface of the base body (varies depending on the size). Visually check the position from above. 6 Remove the knurled pin (3) and screw it in at the clamping lever KONTEC KSG en

27 Maintenance Installing and removing the mechanical force cassette Removal 1 Remove the spindle assembly, ( 7.2.1, Page 25). 2 Remove the left and right threaded pins (2) from the base body (3). 3 Push the mechanical force cassette (1) backwards out of the module. WARNING Risk of injury due to spring-tensioned parts. The mechanical force cassette is under spring tension. During assembly parts may move unexpectedly and cause seious injuries. In addition, the warranty becomes void. Do not disassemble the mechanical force cassette. Order the exchange force cassette as accessory at SCHUNK and insert it. Installation 1 Insert the mechanical force cassette (1) and horizontally adjust the bore for the coupling bolt. Adjust the position of the safety screw for the bolt to the top. 2 Adjust the lateral bore in the mechanical force cassette housing (1) through the left or right thread in the base body (3) using a drift punch or the like. 3 Screw in the threaded pin (2) on the opposite side until the pin is securely engaged in the bore of the housing. 4 Screw in the second threaded pin (2) until the pin is securely engaged to the bore of the housing KONTEC KSG en 27

28 Maintenance 5 Install the spindle assembly and perform a test clamping, ( 7.2.1, Page 25). 6 Tighten the threaded pins (2) again and afterwards loosen them by approx. 1/4 turn to avoid a lateral stress of the base body KONTEC KSG en

29 Maintenance 7.3 Assembly drawing 10 Base body 90 Brand plate 20 Fixed standard reversible jaw 100 Cover plate 30 Moveable standard reversible jaws 110 Clamping lever 40 Spindle nut 120 Knurled pin 50 Mechanical force cassette 130 Cylinder screw 60 Spindle assembly group 140 Threaded pin 70 Coupling bolt 150 Springy pressure piece 80 Protective plate KONTEC KSG en 29

30 Accessories Accessories A wide range of accessories are available for this product For information on which accessories can be used with the appropriate product version, see catalog. KSG R Function When using the pendulum plate system, inclined or curved surfaces are securely clamped at 4 points. Due to the conic positioning of the pendulum plate, the plate is pulled down during the clamping process and therefore lifting of the pendulum plate is largely excluded. Sixfold reversible jaws cover a wide range of clamping solutions. On the whole there are six different clamping sides: at the four sides of the jaw and at the two spots with convex "grip" profile. Thanks to the side coated with tungsten carbide, parts can be machined on two sides. Machining the first side: There are five different clamping sides with a clamping depth of 3.8 and 18 mm for raw part clamping with the sixfold reversible jaw. Machining the second side: Clamping with the tungsten carbide coated side of the sixfold reversible jaw. Bear in mind that the sixfold reversible jaws may slightly move during the first clamping cycle until there is no clearance in the studmounting hole left. Measure the workpiece position after 3-5 power clamping cycles and set the zero point. Handling the disassembled pendulum plate: The conic pivot can be pulled out, since in opposite direction it is only held in position by a O-ring. When handling the pendulum plate, do not turn it upside done, since the pivot may fall out KONTEC KSG en

31 Accessories Assembly KSG R with adapter and pendulum plates The KSG R is delivered with the following components: 1 x pendulum plate with 6 cover screws 1 x fixed adapter plate with 6 cover plates (without sixfold reversible jaws) The plates are designed for the use of sixfold reversible jaws. Standardly workpieces are clamped with four sixfold reversible jaws. Mounting the pendulum and adapter plates (in case of conversion) 1 Disassemble the standard reversible jaws, ( 5.4, Page 21). 2 Position the adapter plate (1) and the pendulum plate (2) and tighten the cylinder screws crosswise. Tightening torque: ( 5.4, Page 21) Mounting the sixfold reversible jaws NOTICE Material damage due to incorrect assembly. If the clamping surfaces of the jaws are not adjusted parallel to the workpiece surface, the sixfold reversible jaw may be loosened by the clamping force. Do always adjust the sixfold reversible jaws parallel to the clamping surface. 1 Define the mounting position of the sixfold reversible jaw. Note: The best clamping results are received, if the workpiece is clamped as far at the side as possible KONTEC KSG en 31

32 Accessories 2 Reposition the cover screws that the chosen mounting position is free. 3 Position the sixfold reversible jaws and slightly tighten the M12 cylinder screws. 4 Turn the sixfold reversible jaws to the desired clamping surface, slightly pre-clamp the workpiece with the clamping jaws that the clamping surfaces are parallel to the workpiece. 5 Fasten the sixfold reversible jaws using M12 cylinder screws. Tightening torque: 80 Nm Troubleshooting Possible malfunction Pendulum plate is turning very sluggishly. Corrective action Unscrew the pendulum plate and press the pendulum stud from the bottom out of the pendulum plate. Check vise guide and surface of the pendulum plate for indentations and deformations. If necessary, remove the plate or the vise guide. Check stud for dirt. Check O-rings for correct fitting. The upper O-ring must fit closely. Lubricate the whole system with grease and assemble it. For further notes on troubleshooting, see ( 6, Page 22) KONTEC KSG en

33 Accessories Maintenance Oil the upper collar of the pendulum stud on a regular basis. The pendulum bearing is protected by O-rings. Turn the pendulum plate around the whole axis once a week that the lubricating film can be rebuilt and the highly stressed areas remain lubricated well. Relubricate the complete stud once a year. For further notes on maintenance, see ( 7, Page 25) 8.2 KSG 5A-VS Function Special jaws with 5 axes guarantee an optimal access of the machine spindle to the workpiece and an enlarged clamping range. Due to the increased clamping force, the workpiece can be processed better on machines with 5 axes. The clamping range depends on the used jaw assortment and the size. In case of high clampings, the nominal clamping force is decreased by ca. 40 % due to increased friction forces in the spindle nut. The reduced adhesion can mostly be compensated by using "grip" stepped jaws KONTEC KSG en 33

34 Accessories Assembly KSG 5A-VS with elevated 5A-VS support jaws The KSG5A-VS is delivered with the following components: 1 x moveable 5A-VS support jaw with "grip" stepped jaw 5mm 1 x fixed 5A-VS support jaw with "grip" stepped jaw 5mm Mounting the 5A-VS support jaw (in case of conversion) 1 Disassemble the standard reversible jaws, ( 5.4, Page 21). 2 Remove the spindle assembly, ( 7.2.1, Page 25). 3 Unscrew the spindle assembly from the spindle nut. 4 Turn the 5A-VS support jaw (3) into the spindle assembly (2). 5 Install the spindle assembly (2), ( 7.2.1, Page 25). 6 Position the 5A support jaw (1) and tighten the cylinder screws crosswise. Tightening torque: ( 5.4, Page 21) Note: The spindle nut is required for converting the KSG5A-VS to the standard variant Troubleshooting For further notes on troubleshooting, see ( 7, Page 25) Maintenance For further notes on maintenance, see ( 7, Page 25) KONTEC KSG en

35 Accessories 8.3 KSG H Function Instead of the mechanical force cassette and the spindle assembly, a single-acting hydraulic cylinder with spring reset is installed. The cylinder is fed via a hydraulic aggegate with pressure controller provided by the customer. The adapted spindle assembly serves for adjusting the clamping opening and for transfering the force to the clamping jaw. The clamping force is adjusted by regulating the hydraulic pressure. For more information, see diagram ( 8.3.3, Page 37) Safety notes on the operation of KSG H Hydraulic systems are under high pressure. Omit manipulations at the system under pressure. WARNING Risk of injury due to hydraulic energies! Hydraulically driven parts may move unexpectedly. If parts are damaged, hydraulic luiquid may leak out under high pressure and causes serious injuries. Only qualified workers are allowed to work at hydraulic parts. Check the hose lines for damage after each use. If necessary, have the damage repaired. Do not adjust the pressure above the maximum value. Prevent the hydraulic liquid from getting in contact with your skin. Wear safety equipment KONTEC KSG en 35

36 Accessories WARNING Risk of crushing due to hydraulic clamping Fingers may be crushed between the clamps due to incorrect settings or unfavorable jaw geometry. Only correctly set clamping ranges ensure a safe operation. Adjust the jaw opening that the opening is approx. 1-2 mm bigger than the workpiece. In this way fingers can't get caught in the gap. Do not operate the clamps in an opening area with a fingerbreadth gap between two jaws or the workpiece and a jaw to avoid that the finger is getting caught inbetween. When manufacturing own jaws or using aluminium form jaws, avoid gaps which could lead to risks of crushing. Pressure maintenance during operation Hydraulic cylinders may leak. During milling the clamps must always be supplied by the hydraulic aggregate to avoid pressure loss caused by leakage. Protect hydraulic lines from hot chips. Check hydraulic lines regularly for wear. In case of pressure drop in the hydraulic system or a ruptured hose, the clamping force is decreasing. Therfore SCHUNK recommend attaching a check valve directly in front of the clamping device to guarantee increased safety. Check clamps regularly for leakage KONTEC KSG en

37 Accessories Technical data Type Max. clamping force [kn] Max. clamping stroke [mm] Clamping time [s] e.g. performance of pump 3.6 l/min 1 clamps 2 clamps KSG 125 H 40 5 ca ca KSG 160 H 70 6 ca ca Clamping force and pressure Clamping force and pressure for KSG H KONTEC KSG en 37

38 Accessories Hydraulic connections Connections for KSG H Recommended operating medium: Hydraulic oil 15 HLP Attention: Before connecting the hydraulic supply at the clamps, vent the supply line. Perform clamping cycles without workpiece after the connection KONTEC KSG en

39 Accessories Assembly Mounting KSG H The KSG H is delivered with the following components: 1 x hydraulic cylinder 1 x spindle assembly for the hydraulic cylinder Mounting the KSG H (in case of conversion) 1 Disassemble the fixed standard reversible jaw (4). 2 Pull out coupling bolt (2) and remove spindle assembly, ( 7.2.1, Page 25) 3 Unscrew the spindle assembly from the spindle nut (5). 4 Remove the mechanical force cassette, ( 7.2.2, Page 27). 5 Install hydraulic cylinder (1), ( 7.2.2, Page 27). 6 Screw the spindle assembly (6) into the spindle nut (5). 7 Install the spindle assembly (6), ( 7.2.1, Page 25). 8 Insert the coupling bolt (2) from above using a M5 screw (3). 9 Mounting the standard reversible jaw (4). Tightening torque: ( 5.4, Page 21) 10 Connect hydraulic lines and adjust the clamping force, ( 8.3.3, Page 37) KONTEC KSG en 39

40 Accessories Troubleshooting For further notes on troubleshooting, see ( 7, Page 25) Maintenance For further notes on maintenance, see ( 7, Page 25) KONTEC KSG en

41 Appendix Appendix Clamping forces The angle of rotation of the clamping lever for the clamping is approximately 160 (Positioning and clamping stroke) Type Max. clamping force F max. [kn] KSG ± 2 KSG ± 2 KSG ± 2 KSG 100 5A-VS 18 ± 2 * KSG 125 5A-VS 24 ± 2 * KSG 160 5A-VS 24 ± 2 * *) Approx. 40% clamping force loss due to too high support jaws KONTEC KSG en 41

42 Appendix 9.2 Angularity In case of maximal clamping force, the angularity of the clamping surface to the base surface is checked. Jaw type Angular deviation [mm] Standard reversible jaws 0.02 Combined reversible jaws 0.04 Support jaws with 5 axes 0.04 Workpiece deviation after decrease of the clamping force of the support jaw Maximal workpiece deviation [mm] Vertical 0.1 Horizontal KONTEC KSG en

43 Appendix 9.3 Form and position tolerances KONTEC KSG en 43

44 10 Translation of the original EC declaration of incorporation In terms of the EC Machinery Directive 2006/42/EG, Annex II, Part B manufacturer/ distributor H.-D. SCHUNK GmbH & Co. Spanntechnik KG. Lothringer Str. 23 D Mengen We hereby declare that the following product: Product designation: Single clamps, hydraulic KSG H 125, KSG H 160 ID number ; ; meets the applicable basic requirements of the Machinery Directive (2006/42/EC). The incomplete machine may not be put into operation until conformity of the machine into which the incomplete machine is to be installed with the provisions of the Machinery Directive (2006/42/EC) is confirmed. Applied harmonized standards, especially: DIN EN ISO 12100: Safety of machinery - General principles for design - Risk assessment and risk reduction The manufacturer agrees to forward on demand the relevant technical documentation for the partly completed machinery in electronic form to national authorities. The relevant technical documentation according to Annex VII, Part B, belonging to the partly completed machinery, has been created. Person authorized to compile the technical documentation: Alexander Koch, Address: see manufacturer's address Mengen, June 2016 p.p. Philipp Schräder; Head of Engineering Design KONTEC KSG en