SCHUNK ROTA-M flex 2+2 Series User instructions

Translation of Original Operating Manual
Manual Lathe Chucks
ROTA-M flex 2+2
Assembly and Operating Manual
Superior Clamping and Gripping

Imprint
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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: 1416054
Version: 01.00 |23/04/2020|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
Reasonably foreseeable misuse ............................................................................... 7
2.3
Constructional changes ............................................................................................ 8
2.4
Spare parts................................................................................................................ 9
2.5
Chuck jaws ................................................................................................................ 9
2.6
Environmental and operating conditions............................................................... 10
2.7
Personnel qualification........................................................................................... 11
2.8
Personal protective equipment.............................................................................. 12
2.9
Notes on safe operation......................................................................................... 12
2.10
Transport ................................................................................................................ 13
2.11
Malfunctions........................................................................................................... 13
2.12
Disposal................................................................................................................... 13
2.13
Fundamental dangers............................................................................................. 14
2.13.1
Protection during handling and assembly .................................................. 14
2.13.2
Protection during commissioning and operation ....................................... 14
2.13.3
Protection against dangerous movements................................................. 15
2.13.4
Notes on particular risks ............................................................................. 15
3
Technical data ......................................................................................................... 18
3.1
Lathe chuck data..................................................................................................... 18
3.2
Dimensions ............................................................................................................. 19
3.3
Clamping force / speed diagrams........................................................................... 21
3.4
Calculations for clamping force and speed ............................................................ 23
3.4.1
Calculation of the required clamping force in case of a given rpm............ 23
3.4.2
Calculation example: required initial clamping force for a given speed .... 26
3.4.3
Calculation of the permissible speed in case of a given initial clamping
force ............................................................................................................ 27
3.5
Grades of Accuracy................................................................................................. 28
3.6
Permissible imbalance DIN ISO 21940-11 .............................................................. 28

Table of Contents
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4
Torques per screw ................................................................................................... 28
5
Assembly................................................................................................................. 29
5.1
Installing and connecting ....................................................................................... 29
5.2
Testing the spindle nose......................................................................................... 30
5.3
Assembly................................................................................................................. 30
5.3.1
Assembly of the lathe chuck (with cylindrical recess) ................................ 31
5.3.2
Assembly preparation for lathe chuck with reduction or expansion adapter
plate ............................................................................................................ 32
5.3.3
Assembly preparation for lathe chuck with direct mounting..................... 33
6
Function .................................................................................................................. 34
6.1
Function and handling............................................................................................ 34
6.2
Function test before use ........................................................................................ 34
6.3
Replacement or renewal of jaws............................................................................ 35
6.4
Clamping the workpiece......................................................................................... 36
6.5
Compensation / workpiece dimensions................................................................. 37
7
Maintenance ........................................................................................................... 38
7.1
Lubrication.............................................................................................................. 38
7.2
Maintenance intervals............................................................................................ 38
7.3
Disassembling and assembling the chuck .............................................................. 38
7.4
Assembling the lathe chuck.................................................................................... 40
8
Remedies for faults ................................................................................................. 43
9
Storage.................................................................................................................... 45
10
Disposal .................................................................................................................. 45
11
Spare parts .............................................................................................................. 46
12
Drawing................................................................................................................... 48
13
Translation of the original declaration of incorporation........................................... 49
14
Appendix on Declaration of Incorporation, as per 2006/42/EC, Annex II, No. 1 B ..... 50

General
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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.
CAUTION
Material damage!
Information about avoiding material damage.
1
1.1
1.1.1

General
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Applicable documents
• General terms of business*
• VDI guideline 3106
Sizes
This operating manual applies to the following sizes:
• ROTA-M flex 2+2 260
• ROTA-M flex 2+2 315
• ROTA-M flex 2+2 400
• ROTA-M flex 2+2 500
• ROTA-M flex 2+2 630
Warranty
The warranty period is 24 months after delivery date from factory
or 500 000 cycles*, if it is used as intended, under the following
conditions:
• Observe the applicable documents, (1.1.2, Page 6)
• Observe the ambient conditions and operating conditions,
(2.6, Page 10)
• Observance of the specified care and maintenance instructions
(7, Page 38)
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
Manual lathe chuck in the ordered variant
4
Mounting screws
8
T-nuts with screws or 4 combi T-nuts (for variant with 60°
fine serration)
1
Assembly key
1
Actuation keys
1
Eye bolt
1
Assembly and Operating Manual
1.1.2
1.1.3
1.2
1.3

Basic safety notes
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Basic safety notes
Intended use
The product is used to clamp workpieces in machine tools or
assembly devices during machining.
• Rotation of the lathe chuck can be initiated by the machine
during machining or the lathe chuck can be at rest. The use of
coolants during machining is permitted.
• Use top jaws with a suitable interface and associated T-nuts.
• Workpiece specifications:
– Workpiece temperature between 0°C and 100°C.
– Interference circuit diameter of the workpiece must be
smaller or at most equal to the outer diameter of the lathe
chuck.
– Sufficient rigidity in the elastic range to absorb the clamping
force.
• The necessary speed of rotation and the clamping force of the
lathe chuck must be determined by the operator for the
respective clamping task, however the technical data engraved
on the lathe chuck should never be exceeded!
Any other use is not as intended.
Reasonably foreseeable misuse
Any use other than that defined under "Appropriate Use" or any
use that goes beyond that definition is considered improper use
and is prohibited.
Examples of foreseeable misuse:
• Operation by unauthorized personnel:
– incorrect mounting of the top jaws.
– incorrect actuation of the lathe chuck.
– incorrect feeding of the workpiece.
• Clamping in stroke end position of the lathe chuck:
– The clamping point is too close or directly on the stroke end
position of the lathe chuck, which means that the desired
clamping force will not act on the workpiece.
• Use of jaws that are too high or a clamping area that is too
high.
2
2.1
2.2

Basic safety notes
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• Due to the clamping force and height of the clamping area, a
moment load acts on the guideways of the lathe chuck. This
must not exceed the maximum value.
• Incorrect application parameters for the machining situation.
No determination of the clamping force or maximum speed of
rotation required for the clamping situation. These parameters
can be calculated from the desired machining situation.
• Exceeding the technical data of the lathe chuck. Actuation with
an actuation moment that is too high, rotation above the
maximum speed of rotation.
• Use on machines other than machine tools or assembly
devices.
• Use as a safety component.
• Carelessness, lack of concentration.
• Clamping of insufficiently rigid workpieces, clamping of
workpieces that do not meet the specifications:
– The rigidity of the workpiece is not sufficient to provide the
lathe chuck with the necessary resistance that will allow the
clamping force to build up.
• Use for stationary or rotating processes where there is no
workpiece or the workpiece is not clamped.
• Use of chuck jaws that have not been approved by SCHUNK
(self-built, third-party products).
• Removing the release mechanism from the actuation key.
• By removing the release mechanism, the actuation key can
remain on the lathe chuck.
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.
2.3

Basic safety notes
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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.
Chuck jaws
Requirements of the chuck jaws
Accumulated energy can make the product unsafe and risk the
danger of serious injuries and considerable material damage.
• Only change chuck jaws if no residual energy can be released.
• Do not use welded jaws.
• The chuck jaws must be designed to be as light and as low as
possible. The clamping point must be as close as possible to the
lathe chuck face (clamping points at a greater distance lead to
greater surface pressure in the jaw guidance and can
significantly reduce the clamping force).
• If, for constructional reasons, the special chuck jaws are heavier
than the top jaws assigned to the lathe chuck, greater
centrifugal forces must be taken into account when defining
the required clamping force and the recommended speed of
rotation.
• The maximum recommended speed of rotation may only be
operated in conjunction with maximum actuating force and
only with the lathe chuck in optimum, fully functioning
condition.
• After a collision, the lathe chuck and the chuck jaws must be
subjected to a crack test before being used again. Replace
damaged parts with original SCHUNK spare parts.
• Renew the chuck jaw mounting bolts if there are signs of wear
or damage. Only use bolts with a quality of 12.9.
2.4
2.5

Basic safety notes
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Environmental and operating conditions
Spatial limitations
The lathe chuck is operated in the
machining area of a machine tool or
an assembly device.
Interfaces
• Lathe chuck-machine/device:
mounting surface,
• Lathe chuck-workpiece: chuck
jaws.
• Lathe chuck-human: actuation
key, lubrication nipple.
Field of application
Industry
Environmental
limitations • Temperature range: 15°C to 60°C.
• Media: coolant.
Material limitations
• Auxiliary and operating materials:
grease LINOMAX plus, anti-rust oil
Branotect, Renolit HLT2.
• Materials used: steel alloys,
elastomers, aluminum alloys,
brass.
Safety data sheet for LINOMAX plus available at www.schunk.com
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 18).
• Make sure that the product is a sufficient size for the
application.
• Only use high-quality cooling emulsions with anti-corrosive
additives during processing.
Clamping force measurement
Depending on the operating conditions, the function and clamping
force must be checked after a certain period of operation (7.2,
Page 38). Only perform the clamping force test with a calibrated
clamping force tester.
2.6