SCHUNK ROTA FSW Series User instructions

Translation of Original Operating Manual
Chuck quick-change
ROTA FSW
Assembly and Operating Manual
Superior Clamping and Gripping

Imprint
2 04.00|ROTA FSW |en
Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights
reserved. Any reproduction, processing, distribution (making available to third parties),
translation or other usage - even excerpts - of the manual is especially prohibited and
requires our written approval.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 0889133
Version: 04.00 |05/06/2018|en
© H.-D. SCHUNK GmbH & Co.
All rights reserved.
Dear Customer,
thank you for trusting our products and our family-owned company, the leading
technology supplier of robots and production machines.
Our team is always available to answer any questions on this product and other solutions.
Ask us questions and challenge us. We will find a solution!
Best regards,
Your SCHUNK team
H.-D. SCHUNK GmbH & Co.
Spanntechnik KG
Lothringer Str. 23
D-88512 Mengen
Tel. [phone]
Fax [phone]
[email protected]
schunk.com

Table of Contents
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3
Table of Contents
1
General .................................................................................................................... 5
1.1
About this manual .................................................................................................... 5
1.1.1
Presentation of Warning Labels.................................................................... 5
1.1.2
Applicable documents................................................................................... 6
1.1.3
Sizes............................................................................................................... 6
1.2
Warranty................................................................................................................... 6
1.3
Scope of delivery ...................................................................................................... 6
2
Basic safety notes .................................................................................................... 7
2.1
Intended use............................................................................................................. 7
2.2
Not intended use ...................................................................................................... 7
2.3
Constructional changes ............................................................................................ 7
2.4
Spare parts................................................................................................................ 8
2.5
Environmental and operating conditions................................................................. 8
2.6
Personnel qualification............................................................................................. 8
2.7
Personal protective equipment................................................................................ 9
2.8
Notes on safe operation........................................................................................... 9
2.9
Transport ................................................................................................................ 10
2.10
Malfunctions........................................................................................................... 10
2.11
Disposal................................................................................................................... 10
2.12
Fundamental dangers............................................................................................. 11
2.12.1
Protection during handling and assembly .................................................. 11
2.12.2
Protection during commissioning and operation ....................................... 11
2.12.3
Protection against dangerous movements................................................. 12
2.12.4
Notes on particular risks ............................................................................. 13
3
Technical data ......................................................................................................... 17
3.1
Precision classes ..................................................................................................... 17
3.2
Permissible imbalance............................................................................................ 17
4
Torques per screw ................................................................................................... 18
5
Mounting ................................................................................................................ 19
5.1
Installing and connecting ....................................................................................... 19
5.2
Checking the spindle nose for mounting the chuck quick-change ........................ 19
5.3
Assembly of the ROTA FSW Chuck quick-change................................................... 20
5.3.1
Assembly of the ROTA FSW Chuck quick-changes with a reducing or exten-
sion flange ................................................................................................... 20
5.3.2
Assembly of the ROTA FSW Chuck quick-change with a direct mount ...... 22
5.4
Assembly of the flexible adapter to the draw tube/drawbar ................................ 23

Table of Contents
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5.4.1
Assembling the retainer ring and draw tube adapter to the clamping device
..................................................................................................................... 24
5.5
Assembly of the clamping device and the ROTA FSW chuck quick-change........... 25
6
Function .................................................................................................................. 27
6.1
Function of the ROTA FSW Chuck quick-change.................................................... 27
6.2
Handling the ROTA FSW Chuck quick-change........................................................ 27
6.3
Functional testing ................................................................................................... 29
7
Commissioning ........................................................................................................ 30
8
Maintenance ........................................................................................................... 32
8.1
Lubrication.............................................................................................................. 32
8.2
Maintenance instructions ...................................................................................... 33
8.3
Period of maintenance ........................................................................................... 34
8.4
Storing the ROTA FSW Chuck quick-change........................................................... 35
8.5
Disassembling and assembling the ROTA FSW Chuck quick-change ..................... 35
9
Spare parts.............................................................................................................. 37
10
Assembly drawing ................................................................................................... 38
11
Translation of original EC declaration of incorporation ............................................ 39
12
Appendix on Declaration of Incorporation, as per 2006/42/EC, Annex II, No. 1 B ..... 40

General
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5
General
About this manual
This manual contains important information for a safe and appro-
priate 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 under-
stood 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.
1
1.1
1.1.1

General
6 04.00|ROTA FSW |en
Applicable documents
• General terms of business*
• Catalog data sheet of the purchased product *
• Calculation of the jaw centrifugal forces, "Technology" chapter
in the lathe chuck catalog *
• Quick guide
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
Sizes
This operating manual applies to the following sizes:
• FSW 220-A8
• FSW 290-A11
• FSW 400-A15
Warranty
The warranty period is 24 months from works delivery, 250 000
clamping cycles* of the flexible adapter and the draw tube adapter
when used as intended under the following conditions:
• Observe the applicable documents (1.1.2, Page 6)
• Observe the ambient conditions and operating conditions,
(2.5, Page 8)
• Observe the specified maintenance and lubrication intervals,
(8, Page 32)
Parts touching the workpiece and wear parts are not included in
the warranty.
* A cycle consists of a complete clamping process ("Open" and
"Close").
Scope of delivery
1
ROTA FSW Chuck Quick-change
1
Clamping device and machine-specific attachment
1
Actuation key
1
Eye bolt
1
Assembly and Operating Manual
1
Short operating manual
1.1.2
1.1.3
1.2
1.3

Basic safety notes
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7
Basic safety notes
Intended use
The product acts exclusively as an interface between the machine
spindle and clamping device in the machine tool.
• The product may only be used within the scope of its technical
data, (3, Page 17).
• The product is intended for industrial and industry-oriented
use.
• Appropriate use of the product includes compliance with all
instructions in this manual.
The maximum speed of the design and the maximum actuating
force of the clamped clamping device must be determined by the
operator for each clamping task in accordance with the valid
standards or technical specifications of the manufacturer.
Not intended use
The product is not being used as intended if, for example,
• the clamping device is not positioned and clamped properly in
the chuck quick-change.
• the intended use of the clamping device is ignored. (See the
Assembly and Operating Manual of the respective clamping
device.)
• it is used under working environment conditions that are not
permissible.
• The technical data for use of the product specified are
exceeded. (3, Page 17)
• if the product is used for machines or clamping devices for
which it was not intended.
• if the product is operated without protective equipment.
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 ap-
proval of SCHUNK.
2
2.1
2.2
2.3

Basic safety notes
8 04.00|ROTA FSW |en
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.
Environmental and operating conditions
Required ambient conditions and operating conditions
Incorrect ambient and operating conditions can make the product
unsafe, leading to the risk of serious injuries, considerable material
damage and/or a significant reduction to the product's life span.
• Make sure that the product is used only in the context of its
defined application parameters, (3, Page 17).
• Make sure that the product is a sufficient size for the applica-
tion.
• Only use high-quality cooling emulsions with anti-corrosive ad-
ditives during processing.
See also
Maintenance (8, Page 32)
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 proper-
ty 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:
2.4
2.5
2.6

Basic safety notes
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9
Due to their technical training, knowledge and experience, trained
electricians are able to work on electrical systems, recognize and
avoid possible dangers and know the relevant standards and
regulations.
Due to its technical training, knowledge and experience, qualified
personnel is able to perform the delegated tasks, recognize and
avoid possible dangers and knows the relevant standards and
regulations.
Instructed persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behaviour.
Due to its technical training, knowledge and experience, service
personnel of the manufacturer is able to perform the delegated
tasks and to recognize and avoid possible dangers.
Personal protective equipment
Use of personal protective equipment
Personal protective equipment serves to protect staff against d
anger which may interfere with their health or safety at work.
• When working on and with the product, observe the occupa-
tional 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.
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.
Trained electrician
Qualified personnel
Instructed person
Service personnel of
the manufacturer
2.7
2.8

Basic safety notes
10 04.00|ROTA FSW |en
• 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 environ-
mental protection regulations regarding the product's
application field.
Transport
Handling during transport
Incorrect handling during transport may impair the product's safe-
ty 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.
2.9
2.10
2.11

Basic safety notes
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11
Fundamental dangers
General
• Observe safety distances.
• Never deactivate safety devices.
• Before commissioning the product, take appropriate protective
measures to secure the danger zone.
• Disconnect power sources before installation, modification,
maintenance, or calibration. Ensure that no residual energy
remains in the system.
• If the energy supply is connected, do not move any parts by
hand.
• Do not reach into the open mechanism or movement area of
the product during operation.
Protection during handling and assembly
Incorrect handling and assembly
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Have all work carried out by appropriately qualified personnel.
• For all work, secure the product against accidental operation.
• Observe the relevant accident prevention rules.
• Use suitable assembly and transport equipment and take
precautions to prevent jamming and crushing.
Incorrect lifting of loads
Falling loads may cause serious injuries and even death.
• Stand clear of suspended loads and do not step into their
swiveling range.
• Never move loads without supervision.
• Do not leave suspended loads unattended.
Protection during commissioning and operation
Falling or violently ejected components
Falling and violently ejected components can cause serious injuries
and even death.
• Take appropriate protective measures to secure the danger
zone.
• Never step into the danger zone during operation.
2.12
2.12.1
2.12.2

Basic safety notes
12 04.00|ROTA FSW |en
Protection against dangerous movements
Unexpected movements
Residual energy in the system may cause serious injuries while
working with the product.
• Switch off the energy supply, ensure that no residual energy
remains and secure against inadvertent reactivation.
• Never rely solely on the response of the monitoring function to
avert danger. Until the installed monitors become effective, it
must be assumed that the drive movement is faulty, with its
action being dependent on the control unit and the current
operating condition of the drive. Perform maintenance work,
modifications, and attachments outside the danger zone
defined by the movement range.
• To avoid accidents and/or material damage, human access to
the movement range of the machine must be restricted. Lim-
it/prevent accidental access for people in this area due through
technical safety measures. The protective cover and protective
fence must be rigid enough to withstand the maximum possible
movement energy. EMERGENCY STOP switches must be easily
and quickly accessible. Before starting up the machine or
automated system, check that the EMERGENCY STOP system is
working. Prevent operation of the machine if this protective
equipment does not function correctly.
2.12.3

Basic safety notes
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13
Notes on particular risks
DANGER
Possible risk of fatal injury to operating personnel if a jaw
breaks or if the ROTA FSW chuck quick-change or the clamping
device fails because the technical data has been exceeded and a
workpiece is released or parts fly off.
• The technical data specified by the manufacturer for using the
ROTA FSW chuck quick-change must never be exceeded.
• The ROTA FSW chuck quick-change may only be used on ma-
chines and equipment that fulfill the minimum requirements
of the EC Machinery Directive; specifically, they must have
effective technical measures to protect against possible me-
chanical hazards.
DANGER
Possible risk of fatal injury to operating personnel due to ROTA
FSW chuck quick-
change failure if the maintenance and servicing
instructions for the ROTA FSW chuck quick-change and the tool-
holder are disregarded!
• The servicing instructions specified by the manufacturer must
be complied with to ensure safe operation of the ROTA FSW
chuck quick-change.
• Work must be carried out by qualified specialist personnel
with the relevant safety training.
2.12.4

Basic safety notes
14 04.00|ROTA FSW |en
DANGER
Possible risk of fatal injury to operating personnel from clothing
or hair being caught on the ROTA FSW chuck quick-change
and/or clamping device and being dragged into the machine.
Loose clothing or long hair may become caught on projecting
parts of the ROTA FSW chuck quick-change or clamping device
and be drawn into the machine.
• The machines and equipment must fulfill the minimum re-
quirements of the EC Machinery Directive; specifically, they
must have effective technical measures to protect against
potential mechanical hazards.
• Always wear tight-fitting clothing and a hairnet when working
on the machine and the ROTA FSW chuck quick-change or
clamping device.
WARNING
Risk of injury due to dropping the ROTA FSW chuck quick-
change during transport, installation or removal
• Take special care in the danger zone when transporting, in-
stalling or removing the ROTA FSW chuck quick-change or
clamping device.
• Note the relevant load securing regulations for working safely
with cranes, ground conveyors, lifting gear and load-handling
equipment.
CAUTION
Risk of slipping or falling if the ROTA FSW chuck quick-change's
operational environment is not clean (e.g. contaminated with
cooling lubricants or oil).
• Ensure that the working environment is clean before starting
assembly and installation work.
• Wear suitable safety boots.
• Follow the safety and accident-prevention regulations when
operating the ROTA FSW chuck quick-change, especially when
working with machine tools and other technical equipment.

Basic safety notes
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15
CAUTION
Danger of limbs being crushed when manually attaching the
ROTA FSW chuck quick-change and assembling and dismantling
the clamping device.
• Use a crane to install the ROTA FSW chuck quick-change and
clamping device.
• Wear personal protective equipment.
• Do not reach between the spindle nose and the ROTA FSW
chuck quick-change.
• Do not reach between the ROTA FSW chuck quick-change and
clamping device.
• Follow the safety and accident-prevention regulations when
operating the ROTA FSW chuck quick-change, especially when
working with machine tools and other technical equipment.
CAUTION
Risk of burns due to workpieces with high temperatures.
• Wear protective gloves when removing the workpieces and
the clamping device.
• Automatic loading of workpieces and clamping devices is to be
preferred.
CAUTION
Danger of damage due to incorrectly set clamping positions of
the clamping slides when changing the clamping devices.
If an incorrect clamping position is chosen for the clamping slides
relative to the clamping device, the ROTA FSW chuck quick-
change and clamping device may be damaged.
• Ensure that the clamping slides are locked/unlocked securely
before or after changing the clamping devices with the ROTA
FSW chuck quick-change.

Basic safety notes
16 04.00|ROTA FSW |en
CAUTION
Hazard from vibration due to imbalanced rotating parts and
noise generation.
Physical and mental strains due to imbalanced workpieces and
noise during the machining process on the clamped and rotating
workpiece.
• Ensure that the ROTA FSW chuck quick-change and the
clamped clamping device run true, both radially and axially.
• Check options for remedying imbalances on special top jaws
on the clamping device and workpieces.
• Reduce the speed.
• Wear hearing protection.

Technical data
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FSW |en
17
Technical data
Type ROTA FSW
220-A8
290-A11
400-A15
ID no.
0824200
0824300
0824400
Tightening torque [Nm]
100
150
200
Max. actuating force [kN]
70
133
140
Max. speed of rotation [rpm]
6000
4200
3500
Weight without adapter [kg]
10
20
51
Operating temperature [°C]
15 - 60
Maximum number of clamping cycles of the flexi-
ble adapter and the draw tube adapter.
250.000
Maximum number of clamping equipment chang-
es of the flexible adapter and the draw tube
adapter
5,000
The maximum permissible actuating force and the maximum per-
missible RPM for special machining must be calculated by the user
based on the permitted data of the ROTA FSW chuck quick-change
and the mounted clamping device or toolholder.
Precision classes
Tolerances for axial and radial run-out accuracy correspond to the
Technical Supply Terms per DIN ISO 3089.
Permissible imbalance
The ROTA FSW/bayonet in ungreased state without a substituted-
in lathe chuck corresponds to the balancing quality class 6.3
(according to DIN ISO 21940-11). Residual imbalance risks may
arise due to insufficient rotation compensation being achieved
(see DIN EN 1550 6.2 e). This applies particularly to high speeds,
asymmetrical workpieces or the use of lathe chucks that do not
correspond to balancing grade 6.3, as well as uneven application
of lubricants. In order to prevent damage resulting from these
residual risks, the entire rotor is to be dynamically balanced in ac-
cordance with DIN ISO 21940-11.
3
3.1
3.2

Torques per screw
18 04.00|ROTA FSW |en
Torques per screw
Tightening torques for mounting screws used to clamp the ROTA
FSW Chuck quick-change on lathes or other suitable technical
equipment (screw quality 10.9)
Screw size
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
Admissible torque
MA(Nm)
13
28
50
88
120
160
200
290
400
500
1050
1500
4

Mounting
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19
Mounting
Installing and connecting
WARNING
Risk of injury due to unexpected movements!
If the power supply is switched on or residual energy remains in
the system, components can move unexpectedly and cause seri-
ous injuries.
• Before starting any work on the product: Switch off the power
supply and secure against restarting.
• Ensure that no residual energy remains in the system.
CAUTION
Danger of injury due to sharp edges and rough or slippery sur-
faces
• Wear personal protective equipment, particularly protective
gloves.
1 Checking the holder of the ROTA FSW or the intermediate
flange (5.2, Page 19)
2 Assembly of the ROTA FSW chuck quick-change (5, Page 19)
3 Performing a functional check (6.3, Page 29)
Checking the spindle nose for mounting the chuck quick-
change
For high run-out accuracy of the ROTA FSW chuck quick-change or
the substituted-in clamping device, the machine side must be
aligned before assembly of the ROTA FSW chuck quick-change or
the intermediate flange. To do this, check the contact surfaces on
the spindle for axial and concentric run-out using a dial indicator
(see Fig. "Assembly of the chuck quick-change or intermediate
flange" - A).
There should be a maximum concentricity error in the centering
of the mount of 0.005 mm and a maximum axial run-out error in
the contact surfaces of 0.005 mm. The flat surface of the spindle
must also be checked for flatness using a straight edge.
Make sure that the surface area of the flat surface is chamfered at
the bore holes and is clean.
5
5.1
5.2

Mounting
20 04.00|ROTA FSW |en
Assembly of the chuck quick-change or intermediate flange
Assembly of the ROTA FSW Chuck quick-change
Assembly of the ROTA FSW Chuck quick-changes with a reducing
or extension flange
(Figure "Assembly of the chuck quick-change or intermediate
flange" see chapter "Checking the spindle nose of the holder of the
chuck quick-change" (5.2, Page 19))
If the ROTA FSW chuck quick-change is screwed on with an inter-
mediate flange, the following points must be observed:
• To mount the ROTA FSW chuck quick-change with a reducing or
extension flange on the machine spindle with a short taper, a
corresponding intermediate flange is fastened to the spindle
nose.
• Before assembly of the intermediate flange, remove any dirt or
chips from the machine spindle and from the centering mount
and contact surface of the flange.
5.3
5.3.1