Hainbuch HYDROK User manual

Installation manual
HYDROK
HYDROK 40 SE
HYDROK 32 RD
Hydraulic stationary chuck SPANNTOP
orce operated

HYDROK
Table of contents
1 General....................................................................................................................5
1.1 In ormation about this manual........................................................................5
1.2 Explanation o symbols..................................................................................5
1.3 Limitations o liability.......................................................................................6
1.4 Max. RPM.......................................................................................................7
1.5 Copyright........................................................................................................7
1.6 Scope o delivery............................................................................................7
1.7 Spare parts.....................................................................................................8
1.8 Warranty terms...............................................................................................8
2 Sa ety......................................................................................................................9
2.1 Responsibility o the customer.......................................................................9
2.2 Personnel requirements...............................................................................10
2.3 Intended use.................................................................................................11
2.4 Personal protective equipment.....................................................................12
2.5 Special dangers............................................................................................13
2.6 Further warnings...........................................................................................16
2.7 Clamping orce.............................................................................................17
2.8 Screws..........................................................................................................18
2.9 Functionality.................................................................................................18
2.10 Implementation limits....................................................................................19
2.10.1Nomenclature.....................................................................................19
2.10.2First limit [workpiece length]...............................................................21
2.10.3Second limit [workpiece mass]...........................................................21
2.10.4Third limit [clamping length]...............................................................22
2.10.5Fourth limit [ orces].............................................................................23
2.10.6Sample calculation.............................................................................34
2.11 Selection o aggregate.................................................................................37
2.11.1Clamping and release low at HYDROK............................................37
2.11.2Clamping and release times at 2-liter hydraulic aggregate...............37
2.11.3Clamping and release times at 4-liter hydraulic aggregate...............37
2.11.4Clamping and release times at 8-liter hydraulic aggregate...............38
2.12 Environmental protection..............................................................................38
3 Technical data.......................................................................................................39
3.1 General in ormation HYDROK.....................................................................39
3.2 General in ormation stationary chuck...........................................................40
3.3 Clamping orces HYDROK and hydraulic stationary chuck SPANNTOP....41
3.3.1 Clamping orce diagram – HYDROK – size 32 RD............................43
3.3.2 Clamping orce diagram – hydraulic stationary chuck – size. 32 RD 44
3.3.3 Clamping orce diagram – HYDROK – size 40 SE............................45
3.3.4 Clamping orce diagram – HYDROK and hydraulic stationary chuck –
size 42/52 RD/SE...............................................................................46
3.3.5 Clamping orce diagram – HYDROK and hydraulic stationary chuck –
size 65 RD/SE....................................................................................47
3.3.6 Clamping orce diagram – HYDROK and hydraulic stationary chuck –
size 80 RD..........................................................................................48
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3.3.7 Clamping orce diagram – HYDROK and hydraulic stationary chuck –
size 100 RD/SE..................................................................................49
3.4 Operating conditions.....................................................................................50
3.5 Power speci ications.....................................................................................50
3.6 Type designation..........................................................................................50
4 Structure and unction...........................................................................................51
4.1 Overview HYDROK......................................................................................51
4.2 Overview HYDROK 32 RD / HYDROK 40 SE.............................................52
4.3 Brie description HYDROK / HYDROK32.....................................................53
4.4 Overview and brie description.....................................................................54
4.5 Brie description hydraulic stationary chuck SPANNTOP............................55
4.6 Designs hydraulic stationary chuck SPANNTOP.........................................56
4.6.1 Type 100x...........................................................................................56
4.6.2 Type 200x...........................................................................................56
4.7 Optional Accessories....................................................................................56
4.7.1 Changing ixture.................................................................................57
4.7.2 Clamping head...................................................................................57
4.7.3 Clamping head...................................................................................57
4.7.4 Grease................................................................................................58
4.7.5 Grease gun.........................................................................................58
4.7.6 Tandem cylinder.................................................................................58
4.7.7 Hydraulic base plate...........................................................................58
4.7.8 Multiple clamping pallet......................................................................59
5 Transporting, packaging and storing....................................................................60
5.1 Sa ety instructions or transporting...............................................................60
5.2 Symbols on the packaging...........................................................................60
5.3 Transport inspection.....................................................................................61
5.4 Unpacking and inner-company transportation.............................................61
5.5 Packaging.....................................................................................................62
5.6 Storing..........................................................................................................63
6 Assembly...............................................................................................................64
6.1 Pre-consideration.........................................................................................64
6.2 Preparations.................................................................................................65
6.3 Installation....................................................................................................66
6.3.1 Installation o the HYDROK and the hydraulic stationary chuck
SPANNTOP........................................................................................68
6.3.2 Installation o the HYDROK 32 RD and the HYDROK 40 SE............69
6.3.3 Installation o the clamping head.......................................................71
6.4 Workpiece.....................................................................................................72
6.5 Inspections...................................................................................................73
6.6 Control o the stroke position........................................................................74
6.7 Activities a ter production is concluded........................................................74
7 Disassembly..........................................................................................................75
7.1 Sa ety............................................................................................................75
7.2 Disassembling the clamping device.............................................................77
7.2.1 Disassembly o the clamping head....................................................77
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7.2.2 Disassembly o the HYDROK............................................................77
7.2.3 Disassembly o the HYDROK 32 RD / HYDROK 40 SE...................78
7.2.4 Disassembly o the hydraulic stationary chuck SPANNTOP.............79
7.3 Subsequent storage o the clamping device................................................79
7.4 Disposal........................................................................................................80
8 Maintenance..........................................................................................................81
8.1 General.........................................................................................................81
8.2 Cleaning........................................................................................................83
8.2.1 Cleaning HYDROK 32 RD and HYDROK 40 SE...............................84
8.3 Preservation.................................................................................................85
8.4 Use o lubricant.............................................................................................85
8.5 Maintenance schedule.................................................................................86
8.6 Bolt torque....................................................................................................87
9 Trouble shooting...................................................................................................88
9.1 Sa ety............................................................................................................88
9.2 Trouble shooting table..................................................................................89
9.3 Start-up a ter corrected ault.........................................................................90
10 Appendix...............................................................................................................91
10.1 Service Hotline.............................................................................................91
10.2 Representatives............................................................................................91
10.2.1Europe................................................................................................91
10.2.2North america.....................................................................................94
10.2.3South america....................................................................................94
10.2.4Asia....................................................................................................94
10.2.5Australia.............................................................................................95
10.2.6A rica..................................................................................................95
Index..............................................................................................................................96
EC Declaration o con ormity.........................................................................................99
»Translation of original installation manual«
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HYDROK – General
1 General
1.1 Information about this manual
This manual enables sa e and e icient handling o the
clamping device.
The manual is a component o the clamping device and
must be kept in the immediate vicinity o the clamping
device where it is accessible or personnel at all times.
Personnel must have care ully read and understood
this manual prior to starting all tasks. The basic prereq-
uisite or sa e work is compliance with all the sa ety in-
structions and handling instructions in this manual.
Illustrations in this manual are provided or a basic un-
derstanding and may deviate rom the actual model o
the clamping device.
It is assumed that the reader is amiliar with standard
procedures, such as cleaning the mounting sur aces.
1. Explanation of symbols
Safety instructions Sa ety instructions are indicated by symbols in this
operating manual. The sa ety instructions are intro-
duced by signal words that express the scope o the
hazard.
The sa ety instructions must be strictly adhered to.
You must act prudently to prevent accidents, personal
injury, and material damage.
DANGER
… indicates an imminent dangerous situation
than can result in death or serious injury i it is
not avoided.
WARNING
… indicates a possible dangerous situation
that can result in death or serious injury i it is
not avoided.
CAUTION
… indicates a possible dangerous situation
that can result in minor or light injury i it es not
avoided.
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NOTE
… indicates a possible dangerous situation
that can result in material damage i it is not
avoided.
Tips and recommen-
dations
… indicates use ul tips and recommendations,
as well as in ormation or e icient and trou-
ble- ree operation.
1.3 Limitations of liability
All in ormation and instructions in this operating manual
have been provided under due consideration o appli-
cable standards and regulations, the current state o
technology, as well as our many years o experience.
The manu acturer assumes no liability or damage due
to:
Failure to ollow the instructions in the manual
Non-intended use
Deployment o untrained personnel
Unauthorized conversions
Technical changes
Use o non-approved spare parts
The actual scope o delivery can vary rom the expla-
nations and graphic representations provided in this
manual in the case o special versions, i supplemental
order options are desired, or on the basis o the latest
technical changes.
The agreed obligations in the delivery contract, the
general terms and conditions, as well as delivery condi-
tions o the manu acturer, and the statutory regulations
valid at the time the contract was concluded, apply.
CAUTION!
Our clamping devices are balanced with bal-
ance quality G = 4, in one level n = 1.
The data on the rotation balance re ers to rota-
tionally symmetrical workpieces.
The clamping o not rotationally symmetrical
workpieces may not be clamped and/or only be
clamped a ter consultation with the manu ac-
turer.
Balancing bolts and balancing weights at the
clamping devices may not be removed / disas-
sembled!
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1.4 Max. RPM
CAUTION!
The maximum permissible speed is marked on
the product.
By the combination o a clamping device and
an add on clamping device a reduction o the
maximum permissible speed may be neces-
sary.
O all RPMs o the groups speci ied, the low-
est given RPM must always be used.
Note that the clamping orce is in luenced by
the centri ugal orce o the clamping elements.
I necessary, adjust the machining orce!
1.5 Copyright
This manual is protected by copyright and is provided
exclusively or internal purposes.
Delivery o the operating manual to third parties, dupli-
cation in any orm – including excerpts – as well as ex-
ploitation and/or communication o the content, are not
permitted [except or internal use] without written ap-
proval rom the manu acturer.
Actions to the contrary make damage compensation
mandatory. We reserve the right to en orce additional
claims.
1.6 Scope of delivery
All tools and accessories that are not included
in the scope o delivery are marked as option-
al.
In scope o delivery o the clamping device:
1 HYDROK
Optionally the scope o delivery o the clamping de-
vice HYDROK includes:
2 Koenig expander
Clamping head
Multiple clamping pallet [only or size 65]
Optionally the scope o delivery o the clamping de-
vice HYDROK 32 includes:
Clamping head
Tandem cylinder
Hydraulic base plate
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1.7 Spare parts
WARNING!
Safety risk if the wrong spare parts are
used!
Incorrect or de ective spare parts can cause
damage, mal unction, or total ailure; they can
also impair sa ety.
Only use manu acturer's original spare parts.
Only purchase spare parts rom authorized dealers or
direct rom the manu acturer. Addresses are in the ap-
pendix.
1.8 Warranty terms
The warranty terms are included in the manu acturer's
terms and conditions.
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HYDROK – Safety
Safety
This section provides an overview o all the important
sa ety aspects or optimal protection o personnel, as
well as or sa e and trouble- ree operation.
.1 Responsibility of the customer
The product is used in industrial applications. Conse-
quently the owner o the product is subject to legal in-
dustrial sa ety obligations.
In addition to the sa ety instruction in this manual,
generally valid sa ety and accident protection guide-
lines, and environmental protection guidelines as well
as the machines' manual must be adhered to and
complied with or the area o implementation o the
device.
Note in particular that the status scans o the machine
must be adjusted to the respective product.
DANGER!
Risk of injury due to thrown out parts!
Incorrect machine settings may lead to the
throwing out o parts.
The status scans the machine must be set to
the respective clamping device.
Regularly check the status scans o the ma-
chine, see chapter »Maintenance Schedule«.
I the end position can not be reached the
product may no longer be used.
Observe the operating instructions o the ma-
chine.
WARNING!
Risk of injury!
Declining operating orce, or example by de-
clining energy supply, may cause serious per-
sonal injury.
The product may be used only on machines
where it is ensured, that during use, the oper-
ating orce does not drop.
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WARNING!
Risk of injury!
An incorrect media supply [hydraulic, pneumat-
ic], e.g. by damaged or missing seals or pipes,
can cause serious personal injury.
Hydraulic and / or pneumatic tubes must be
secured by the machine by check valves and
a permanent pressure monitoring!
. Personnel requirements
WARNING!
Danger of injury due to insufficient qualifi-
cation!
Improper handling o the clamping device can
cause serious injury or material damage.
Only have activities per ormed by personnel
who are quali ied to per orm these activities.
The ollowing quali ications are cited in the operating
manual or the various activity areas.
Specialized personnel
are personnel who due to their specialized training,
skills, and experience, as well as knowledge o the
applicable regulations, are capable o executing the
tasks assigned to them and o recognizing and
avoiding possible hazards on their own.
Hydraulic specialist
The hydraulic specialist has been trained or the
particular task area in which he is active and is a-
miliar with the relevant standards and regulations.
Due to his specialized training and experience the
hydraulic specialist can per orm tasks on hydraulic
equipment and recognize and avoid possible dan-
gers on his own.
Electric specialist
The electric specialist has been trained or the par-
ticular task area in which he is active and is amiliar
with the relevant standards and regulations.
Due to his specialized training and experience the
electric specialist can per orm tasks on electric
equipment and recognize and avoid possible dan-
gers on his own.
Only persons rom whom it can be expected that they
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HYDROK – Safety
reliably execute their work are considered as person-
nel. Persons whose capability to react is impaired, or
instance through drugs, alcohol, or medication, are
not approved.
Comply with age-speci ic and job-speci ic regula-
tions that are applicable at the installation site when
selecting personnel.
.3 Intended use
The clamping device is designed or installation in a ma-
chine tool according to CE compliant. Within the machine
tool the clamping device is designed exclusively as a
through-bore chuck or bar work and / or as an end-stop
chuck or chuck work.
The clamping device should only be mounted, operated,
maintained, and cleaned by instructed, specialized per-
sonnel.
Intended use also includes compliance with all the in-
structions in this manual.
The clamping device is to be used or the case o applica-
tion contractually agreed between the producer/deliverer
and the user, as well as such cases o application de-
scribed in the product description which are also in accor-
dance with the technical values.
The sa e unction o the clamping device is, as ar as it
can be oreseen, guaranteed when it is used or the in-
tended purpose in accordance with the appropriate sa ety
regulations.
Any use that extends beyond the intended use, or any
other use o the clamping device is considered to be mis-
use and can cause dangerous situations.
WARNING!
Danger due to misuse!
Misuse o the clamping device can cause danger-
ous situations.
Particularly re rain rom the ollowing uses o the
clamping device:
Use in machines other than machine tools.
Use in machine tools with technical data other
than that speci ied on the clamping device.
Claims o any type due to damage arising rom non-in-
tended use are excluded.
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Unintended and improper use o the Power Chuck is or
example
I workpieces are not clamped properly
I sa ety regulations are disregarded and persons are
working at the clamping device without additional pro-
tective devices e.g. or machining.
I the clamping device is used or machines or tools or
which it is not intended.
.4 Personal protective equipment
Wearing o personal protective equipment is required
to minimize health hazards when working with the de-
vice.
Always wear the protective equipment necessary or
the respective task when working with the device.
Follow the instructions that have been posted in the
work area.
Always wear For all tasks always wear:
Protective work clothing
is tight- itting work clothing with low resistance to tear-
ing, with tight sleeves, and without projecting parts. It
is primarily used to protect against entanglement by
moving machine parts.
Do not wear rings, chains, or other jewelry.
Safety footwear
or protection against heavy alling parts and slipping
on slippery substrates.
For special tasks
wear
Special protective equipment is required when exe-
cuting special tasks. Separate re erence is made to
this equipment in the speci ic sections o this manual.
This special protective equipment is explained below:
Hard hat
to protect against alling and lying parts and materi-
als.
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HYDROK – Safety
Protective goggles
to protect eyes rom lying parts and liquid splashes.
Protective gloves
to protect hands rom riction, abrasion, puncture
wounds, or deeper injuries, as well as rom contact
with hot sur aces.
.5 Special dangers
In the ollowing section residual risks are cited that
occur due to installation o the clamping device in a
machine tool. In each case the residual risks that
have been determined based on a risk analysis o the
machine must be speci ied by the customer.
Follow the sa ety instructions listed here and the
warnings in the other sections o this manual to re-
duce health hazards and to avoid dangerous situa-
tions.
Horizontal / lying
parts
WARNING!
Danger of injury due to horizontal parts!
Be ore transporting the clamping device in hor-
izontal condition:
Put the clamping device on a non-slip pad
Screw in the eye bolts
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Suspended loads WARNING!
Life-threatening danger due to suspended
loads!
Some clamping devices must be li ted with a
crane. When li ting the clamping device there
is a li e-threatening hazard due to alling parts
or parts swinging out o control.
Never step under suspended loads.
Comply with the instructions concerning the
intended attachment points. Ensure that the
sling gear is securely seated!
Do not attach li ting gear in projecting compo-
nents.
Only use approved hoists and sling gear with
su icient bearing capacity.
Do not use rope and belts that are torn or
rayed.
Moving parts WARNING!
Danger of injury due to moving parts!
Rotating parts o the clamping device can
cause serious injuries.
Do not reach into moving parts or handle
moving parts during operation.
Note the gap dimensions o moving parts.
Do not open covers when the device is in op-
eration.
Be aware o a terrun time:
Prior to opening the covers ensure that all
parts have come to a standstill.
Wear tight- itting protective work clothing in
the danger zone.
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Wrong clamping of
the work piece
WARNING!
Danger of injury due to incorrect clamping
of the work piece!
Incorrect work piece clamping may lead to the
ejection o the work piece and result in serious
injuries.
Under dimensioned [tolerance] parts can lead
to incorrect clamping!
Check the unmachined work pieces at ran-
dom on dimensional accuracy.
Too low supply pressure can lead to the reduc-
tion o clamping orce!
Too high supply pressure can lead to damage
o the components o the clamping device!
Check and adjust, i necessary, the supply
pressure regularly.
Do random checks o the unmachined work
pieces on dimensional accuracy.
Missing changing
parts
WARNING!
Danger of injury due to missing changing
parts!
When operating the clamping device without
changing parts [segmented clamping bushing,
clamping heads, work piece end-stops] there is
a higher danger o crushing injuries due to the
stroke o movable components o the clamping
device.
The clamping process may not be initiated
without assembled segmented clamping
bushing and/or work piece end-stop.
Parts with sharp
edges
WARNING!
Risk of injury!
When screwing in individual components such
as or example work piece end-stops, threaded
adapters and similar devices that are equipped
with an external thread or wear caused by
burrs, there is risk o cutting.
The operation must be done only by quali ied
personnel.
Wearing o gloves / [PSA] is required!
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CAUTION!
Risk of injury!
A special use-dependent or job-based design
can result in variations in the clamping strokes
and thus the clamping orce.
The notes on the associated clamping situa-
tions or product drawing must always be ob-
served
.6 Further warnings
WARNING!
Risk of injury!
Never reach or the clamping device while the
spindle is rotating. Be ore starting to work on
the mandrel, make sure the machine spindle
cannot be put in motion.
WARNING!
Risk of injury!
Falling down o the clamping device or its parts
can cause severe bruises and ractures.
The dead weight o the clamping device or its
parts can lead to high physical stress.
WARNING!
Risk of injury!
By repeated reworking or wear and tear o the
clamping sur aces sharp edges and burrs may
appear and lead to severe cutting damages.
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HYDROK – Safety
WARNING!
Risk of injury!
Missing o-rings or seals may cause severe
injuries!
Due to missing / allen out O-rings and seals
compressed air or hydraulic luids which are
under high pressure may expel!
Make sure that all O-rings / seals or the hy-
draulic / pneumatic connections are available
and undamaged!
I necessary lubricate them be ore assembly
and/or during service.
Risk of injury!
Leaking [sprayed out] hydraulic oil can cause
serious injury.
Make sure that all O-rings / seals or the hy-
draulic and/or pneumatic connections are
available and undamaged
WARNING!
Damage of clamping device!
The clamping device may be released exclu-
sively in the standing condition!
.7 Clamping force
The achieved clamping orce can vary due to the main-
tenance condition o the clamping device [state o lubri-
cation and degree o contamination] [see chapter
»Maintenance«].
The clamping orce must be checked at regular inter-
vals. This requires the use o static clamping orce
measuring devices.
CAUTION!
Damages due to excessive draw and com-
pressive force!
An excessive draw orce and/or compressive
orce may damage the clamping device.
The max. draw orce and compressive orce
may not be exceeded.
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.8 Screws
Moving parts WARNING!
Danger of injury due to screws and stud
screws being accelerated out of the device!!
Screws and stud screws radially attached to
the product can be accelerated out o the de-
vice and cause severe injuries.
At the product radially mounted screws and
stud screws which were loosened or assem-
bly and maintenance must be re-tightened
with the correct tightening torque!
The tightening torque is given at the product
itsel , near the screw or threaded pin, and/or
given in chapter »Bolt torque«.
All screws or stud screws that are not
marked with a tightening torque speci ication
are tightened with the prescribed tightening
torque and locked [medium-strength bonding]
in the actory and should only be unscrewed
a ter consultation with the manu acturer. I in
doubt you must contact the manu acturer im-
mediately do determine the subsequent pro-
cedure.
.9 Functionality
NOTICE!
With high contamination o the clamping device
the unctionality is no longer guaranteed.
The cleaning and maintenance intervals must
be observed.
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.10 Implementation limits
Clamping head chucks are designed and developed
or location o workpieces or machining o rotational-
ly-symmetric workpieces. Other ields o application
require an explicit approval by the manu acturer.
The chucks are also subject to limits in the area o
machining o workpieces.
Speci ically, prior to using the chucks, our limits that
are independent o each other must be checked.
.10.1 Nomenclature
Short description Unit Explanation
apmm Depth o cut, turning operation
c - Contact actor
DBmm Drill bit diameter
dsp mm Clamping diameter
dzmm Machining ø turning operation
mm Feed / turn turning operation
Feed / cutting edge drilling operation
FBN Feed orce, drilling operation
FcN Cutting orce, turning operation
Fc max N Max. cutting orce, turning operation
Fz N Clamping orce contingency or rotation compensation
FGN Weight orce, workpiece
nmm Feed / turn drilling operation
FqN Transverse orce
Fq max N Max. permissible transverse orce
Frad N Radial clamping orce
Frader N Required radial clamping orce
Fsk N Clamping orce or preventing the workpiece rom levering out
Fsz N Clamping orce or location o the machining orces and
machining moments when turning or drilling in the direction o
the chuck axis
Ft kN Tailstock orce
Ft max. kN Max. tailstock orce
kc N/mm² Speci ic cutting orce
Lamm Unclamping length
Lgmm Distance, center o gravity - workpiece - clamping position
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Short description Unit Explanation
Lqmm Distance: "radial drilling – clamping position"
Lsp mm Clamping length
Lspmin mm Minimum required clamping length
Lwmm Workpiece length
Lzmm Distance: »machining point – clamping position« when turning
m kg Mass o the clamping head
mwkg Workpiece mass
MBNmm Torque, drilling operation
Mq Nm Moment due transverse orce relative to the chuck axis
Mqmax Nm Max. moment due to transverse orce relative to the chuck
axis
n 1/min Speed
p - Machining code
rs mm Distance center o mass SK segment relative to the axis o
rotation o the chuck
S - Clamping orce spread actor
μa- Coe icient o riction in the axial direction
μt- Coe icient o riction in the radial direction
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