SCHUNK OPR 048 User instructions

Original operating manual
Assembly and operating manual
OPR 048
Collision and Overload Protection Sensor

Imprint
2 03.00 | OPR 048 | Assembly and operating manual | en | 389630
Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights
reserved.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 389630
Version: 03.00|25/10/2022|en
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
Customer Management
Tel. [phone]
Fax [phone]
[email protected]
Please read the operating manual in full and keep it close to the product.

Table of Contents
Table of Contents
................................................................................................................................ 5
1 About this manual ................................................................................................... 6
1.1 Presentation of Warning Labels ........................................................................... 6
1.2 Applicable documents .......................................................................................... 7
1.3 Scope of delivery .................................................................................................. 7
2 Basic safety notes ................................................................................................... 8
2.1 Intended use......................................................................................................... 8
2.2 Not intended use.................................................................................................. 8
2.3 Constructional changes ........................................................................................ 8
2.4 Spare parts ........................................................................................................... 8
2.5 Environmental and operating conditions ............................................................. 8
2.6 Personnel qualification......................................................................................... 9
2.7 Personal protective equipment.......................................................................... 10
2.8 Notes on safe operation ..................................................................................... 10
2.9 Transport ............................................................................................................ 11
2.10 Malfunctions....................................................................................................... 11
2.11 Disposal .............................................................................................................. 11
2.12 Notes on particular risks..................................................................................... 12
3 Warranty ................................................................................................................13
4 Technical data.........................................................................................................14
5 Product Overview ...................................................................................................15
5.1 Introduction........................................................................................................ 15
5.2 Description ......................................................................................................... 16
6 Assembly ................................................................................................................17
6.1 Mechanical connection ...................................................................................... 17
6.2 Electrical connection .......................................................................................... 19
6.2.1 Switch Adjustment..................................................................................22
6.3 Pneumatic........................................................................................................... 23
6.3.1 Calculate Applied Loads..........................................................................23
6.3.2 Obtain required pressure setting ...........................................................25
6.3.3 Determining Exact Pressure Required ....................................................26
7 Operation ...............................................................................................................27
8 Troubleshooting .....................................................................................................28
9 Maintenance ..........................................................................................................29
9.1 General ............................................................................................................... 29
9.2 Cable Replacement............................................................................................. 30
9.3 Replacement of connector block assembly........................................................ 30
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Table of Contents
9.4 Periodic Lubrication Instructions........................................................................ 31
9.4.1 Cover and Stem Disassembly (only Version without integrated spring)
................................................................................................................31
9.4.2 Cover and Stem Re-assembly .................................................................33
9.5 Weld Splatter Shield Replacement..................................................................... 34
10 Assembly drawings .................................................................................................35
10.1 Assembly Drawing .............................................................................................. 36
10.2 Replacement Parts ............................................................................................. 37
11 Translation of the original declaration of incorporation ..........................................38
12 UKCA declaration of incorporation..........................................................................39
13 Annex to Declaration of Incorporation....................................................................40
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Adapter Plate
Optional component used to adapt the
OPR Body or Stem to the user’s robot
or tooling.
Body
Cylindrical aluminum housing and air
pressure chamber. An adap-ter plate to
the user’s robot is usually attached
here.
Cam
A hardened steel ring mounted inside
the cover on which the hardened steel
ball segments mounted to the stem are
nested.
Collision
The accidental impact between a tool
and some obstruction in its path.
Collision Sensing Switch
A switch that changes state to an
circuit when a crash is detected. It is
mounted in a threaded hole in the side
of the body under the connector block.
The steel target moves out of range in
the event of a crash.
Cover Plate
Disk-shaped aluminum cover for OPR
Body.
M8, 3-Pin Male Threaded Connector
8mm electrical connector mounted in a
block attached to the side of the Body.
Piston
The component which, together with
the Body, creates a pressure chamber.
Varying the pressure in this chamber
varies the load required to move the
piston.
Stem
Round, conical steel element with
threaded holes and dowel pin holes. An
adapter plate to the user’s tooling is
usually attached here.
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About this manual
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1 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.
In addition to these instructions, the documents listed
under }1.2 [/7] are applicable.
NOTE: The illustrations in this manual are intended to provide a
basic understanding and may deviate from the actual version.
1.1 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.

About this manual
1.2 Applicable documents
• General terms of business *
• Catalog data sheet of the purchased product *
The documents labeled with an asterisk (*) can be downloaded
from schunk.com.
1.3 Scope of delivery
The scope of delivery includes:
• Collision and overload sensor OPR in the ordered variant
• Connection cable (5 m, straight connector, open wire strands)
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Basic safety notes
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2 Basic safety notes
2.1 Intended use
The OPR was designed as a device to protect industrial
components and machinery from damage resulting from collisions
and impacts.
The OPR has not been designed for, nor should it be used in,
situations involving the safety of humans or animals. In all
situations the user is responsible for insuring that applicable safety
practices are followed as outlined by the manufacturer of the
equipment on which the OPR will be used.
The module is intended for installation in a machine/system. The
requirements of the applicable guidelines must be observed and
complied with.
The module may be used only in the context of its defined
application parameters }4 [/14].
Any other use or use exceeding that specified is an infringement of
use for intended purpose. The manufacturer bears no liability for
damage resulting from such use.
2.2 Not intended use
It is not intended use if the product is used, for example, as a
pressing tool, stamping tool, lifting gear, guide for tools, cutting
tool, clamping device or a drilling tool.
• Any utilization that exceeds or differs from the appropriate use
is regarded as misuse.
2.3 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.
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 Environmental and operating conditions
Required ambient conditions and operating conditions

Basic safety notes
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 a sufficient size for the
application.
• Ensure that maintenance and lubrication intervals are observed,
Link Wartung.
• Make sure that the environment is free from splash water and
vapors as well as from abrasion or processing dust. Exceptions
are products that are designed especially for contaminated
environments.
2.6 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:
Trained electrician 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.
Qualified personnel 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 person Instructed persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behaviour.
Service personnel of
the manufacturer
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.
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Basic safety notes
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2.7 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.
2.8 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.

Basic safety notes
2.9 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.
2.10 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.
2.11 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.
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Basic safety notes
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2.12 Notes on particular risks
WARNING
Risk of injury from falling of the unit during transport, assembly
and operation!
•Secure gripper unit during transport and assembly with
adequately sized straps.
•Ensure careful cultivation of the collision and overload system
to the machine.
WARNING
Risk of injury from crushing fingers during deflection process!
WARNING
Risk of injury from overload signal of the sensor (eg electrical
short circuit) and in case of failure and reducing the supply of
compressed air! The function of the electrical signal
transmission is no longer guaranteed.

Warranty
3 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 specified maintenance and lubrication intervals
• Observe the ambient conditions and operating conditions
Parts touching the workpiece and wear parts are not included in
the warranty.
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Technical data
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4 Technical data
Standard for quality of the compressed air clean, dry, non-lubricated compressed air
from a self-relieving regulator
Pressure range min./max. [bar] OPR-048-P00: 1.4 / 6.2
OPR-048-P05: 1.4 / 5.9
OPR-048-P10: 1.4 / 5.5
OPR-048-P15: 1.4 / 5.2
Ambient temperature [°C] 5 to +50
Noise emission [dB(A)] ≤ 70
Connector Type Switch
Rating
M8-3-pin male
threaded connector
3-pole Nano
Connector
100 mA
10 - 30 VDC
Optional interated springs available corresponding to 0.3, 0.7, 1 bar
More technical data is included in the catalog data sheet.
Whichever is the latest version.

Product Overview
5 Product Overview
5.1 Introduction
The OPR is a pneumatically pressurized device offering protection
to industrial robots and tooling in the event of accidental impacts
and unanticipated loads. The unit works by “breaking away” from
its working geometry in the event of excessive torsional, moment,
or compressive axial forces, or any combination of these.
The OPR cannot respond to pure axial tension, which is an unlikely
mode of loading. Removal of the upsetting force or moment
allows the OPR to return to its initial position.
As a collision occurs, internal motion of the OPR components
cause a switch to change state (OPR-061: Change to an open
circuit / OPR-081-221: Cause a normally closed switch to open).
As a collision occurs, internal motion of the Protector components
cause a switch to change state to an open circuit.
The switch circuit may be monitored by robotic controllers to stop
operations before damage to the robot or tooling occurs. The load
threshold at which the OPR breaks away is adjustable by
controlling the air pressure supplied to the unit. The amount of
compliance (travel) provided by the OPR before the switch circuit
opens is adjustable by turning a switch adjustment screw.
All OPR devices provide axial (compression only), torsional, and
moment compliance.
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Product Overview
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5.2 Description
Optional Blank
Interface Plate
(Stem)
Stem Switch/Connector
Block Assembly
Electrical
connection 3-pin
Optional Blank
Interface Plate
(Body)
Cover Plate
Body
Pneumatic Port
The OPR consists of a piston housing (body) closed with a cover
plate assembly. A stem assembly protrudes through the cover
plate assembly. The cover plate assembly incorporates a cam to
accurately and repeatably position the stem assembly. The stem
assembly is forced into position against the cam by a piston. The
piston is supported by user supplied compressed air and an
optional assist spring. The stem provides a mounting surface for
customized interface plates. Tapped and through holes on the
back surface of the body allow direct bolting of the body to user
tooling. All load bearing components and those with wear surfaces
are made of hard-coat anodized aluminium, hardened bearing
steel, or hardened tool steel.
A Collision Sensing Switch is positioned in the side of the body. A
connector block assembly containing a M8, 3-pin male threaded
connector is mounted on the side of the OPR body. The user
connects to the switch using the M8 connector for which a variety
of cables are available. The user must also supply the OPR with
dry, regulated, compressed air through a port on the side of the
OPR body. The size and location of these connections are shown in
the drawing provided at the end of this manual.

Assembly
6 Assembly
Protect electrical cables and compressed air lines as much as
possible against tensile strain, kinking, breakage etc. when laying.
NOTICE
Prior to establishing or branching the compressed air line to the
OPR, ensure that the compressed air supply is switched off and
that enclosed compressed air has been discharged.
NOTICE
The level of desired or required air pressure will vary according
to the weight, loading, and motion of the user’s tooling.
When the pneumatically-supplied force is sufficient to re-seat the
OPR, the tooling will move to its working position.
•Exercise caution while increasing the air pressure supplied to
the OPR.
6.1 Mechanical connection
The OPR is usually installed with the housing facing the robot and
the broach facing the insert tool, yet users can decide this for
themselves.
The OPR can be attached directly to a robot or insert tool with the
help of the alignment pin and through-hole / thread bores. Where
this is not possible, please use an adapter plate.
NOTICE
The surface to which the OPR body is mounted must be flat and
smooth and provide support for the entire surface of the body.
A second interface plate is often required for mounting to the OPR
stem. Such adapterplates may be ordered from SCHUNK as blank
plates or machined as necessary for specific applications. Another
option is for the user to fabricate their own interface plates. Once
any required machining of the adapter plates is complete, mount
the OPR using hardware appropriately sized for the application.
Connect an appropriately sized air line and fitting to the OPR.
Do not supply air pressure at this time.
All mounting hardware should be tightened. The use of an
industrial thread-locking compound is recommended for all
fasteners.
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Assembly
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CAUTION
unexpected movement of the OPR
Personal injury or damage to equipment is possible
•Before connecting or uncoupling the air supply to the OPR,
ensure that the air supply is turned off and that all trapped air
has been vented
Fastener Torque Specifications
Screw [mm] Tightening torque [Nm]
M3 - 12.70 mm 2.2 Nm
M4 - 17.78 mm 4.6 Nm
M5 - 20.32 mm 9.6 Nm
M6 - 25.40 mm 7.9 Nm
Fastener Torque Specifications
Type Screw [mm] Tightening torque [Nm]
OPR-061 M4 - 40 mm 4.4 - 5.1 Nm
OPR-081 M5 - 45 mm 5.0 - 6.8 Nm
OPR-101 M5 - 50 mm 5.0 - 6.8 Nm
OPR-131 M6 - 69 mm 9.0 - 11.9 Nm
OPR-176 M8 - 80 mm 21.5 - 28.2 Nm
OPR-221 M10 - 100 mm 44.0 - 58.8 Nm

Assembly
6.2 Electrical connection
For connection to the user’s controls, the OPR is equipped with a
collision sensing switch. When the OPR is in the collision mode or
the electrical cable to the switch is disconnected an open circuit is
generated.
Following you can find the connections between the internal
switch and the pins in the Connector Block Assembly. Optional
mating cables, available from SCHUNK }6.1 [/17], utilize the
brown-black-blue color code indicated.
Blue Brown
Black
Break switch
in the OPR
Switch wiring as a normaly-closed , dry contact switch
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Assembly
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OPR-061
PNP Switch (standard)
NPN Switch (optional)
switch wiring:
switch wiring:
switch test circuit:
switch test circuit:
Inside OPR Inside OPR
Inside OPR Inside OPR
PNP proximity switch PNP proximity switch
NPN proximity switch NPN proximity switch
Brown Brown
Brown Brown
Blue
Blue
Blue
Blue
Black
Black
Black
Black
RL
RL
(+ V) (+ V)
(+ V)
(+ V)
(0 V) (0 V)
(0 V) (0 V)
switch rating:
switch rating: 100 mA (Max.)
at 10-30 VDC
100 mA (Max.)
at 10-30 VDC LED test light with current limiting
resistor 100 mA (Max.) at 10-30 VDC
LED test light with current limiting
resistor 100 mA (Max.) at 10-30 VDC
* Provided by customer
* Provided by customer
Switch wiring as a normaly-open PNP or NPN proximity switch
OPR-081-221
NC Switch
Inside OPR
Blue
Black
Brown
Switch wiring as a normaly-closed , dry contact switch