SCHUNK ROTA-M flex 2+2 Series User instructions

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

Table of Contents
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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 technical improvements.
Document number: $Document-ID$
Version: 02.00 |11/16/2020|en
© H.-D. SCHUNK GmbH & Co.
All rights reserved
Dear Customer
Dear Customer,
Thank you for putting your trust in 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.
We look forward to your challenging questions. 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
Customer Management
Tel. [phone]
Fax [phone]
[e-mail]
Please read the operating manual in full and keep it close to the product.

Table of Contents
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3
Table of Contents
1
General .................................................................................................................... 5
1.1
About this Manual .................................................................................................... 5
1.1.1
Illustration of safety notes ............................................................................ 5
1.1.2
Applicable documents................................................................................... 6
1.1.3
Sizes............................................................................................................... 6
1.2
Warranty................................................................................................................... 6
1.3
Scope of delivery ...................................................................................................... 7
2
Basic safety notes..................................................................................................... 8
2.1
Appropriate use........................................................................................................ 8
2.2
Reasonably foreseeable misuse ............................................................................... 8
2.3
Structural changes.................................................................................................... 9
2.4
Spare parts.............................................................................................................. 10
2.5
Chuck Jaws.............................................................................................................. 10
2.6
Ambient conditions and operating conditions....................................................... 11
2.7
Personnel qualification........................................................................................... 12
2.8
Personal protective equipment.............................................................................. 13
2.9
Notes on safe operation......................................................................................... 13
2.10
Transport ................................................................................................................ 14
2.11
Malfunctions........................................................................................................... 14
2.12
Disposal................................................................................................................... 14
2.13
Fundamental dangers............................................................................................. 14
2.13.1
Protection during handling and assembly .................................................. 15
2.13.2
Protection during commissioning and operation ....................................... 15
2.13.3
Protection against dangerous movements................................................. 16
2.13.4
Notes on particular risks ............................................................................. 16
3
Technical data ......................................................................................................... 19
3.1
Lathe chuck data..................................................................................................... 19
3.2
Dimensions ............................................................................................................. 20
3.3
Clamping force RPM diagrams ............................................................................... 24
3.4
Calculating the clamping force and RPM ............................................................... 27
3.4.1
Calculation of the required clamping force at a specified speed of rotation
..................................................................................................................... 27
3.4.2
Calculation example: required initial clamping force for a given RPM ...... 30
3.4.3
Calculation of the permissible RPM in case of a given initial clamping force
..................................................................................................................... 31
3.5
Accuracy classes ..................................................................................................... 32

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3.6
Permissible imbalance DIN ISO 21940-11 .............................................................. 32
4
Screw tightening torques......................................................................................... 32
5
Assembly................................................................................................................. 33
5.1
Installing and connecting ....................................................................................... 33
5.2
Testing the spindle nose and/or machine table .................................................... 34
5.3
Assembly................................................................................................................. 35
5.3.1
Assembly of the lathe chuck (with cylindrical recess) ................................ 35
5.3.2
Assembly preparation for the lathe chuck with reduction or expansion
adapter plate............................................................................................... 37
5.3.3
Assembly preparation for the lathe chuck with direct mounting .............. 38
5.3.4
Assembly preparation for lathe chuck with base plate on machine table
(from size 800) ............................................................................................ 38
6
Function .................................................................................................................. 39
6.1
Function and handling............................................................................................ 39
6.2
Functional test before use...................................................................................... 39
6.3
Replacement or enlargement of jaws .................................................................... 40
6.4
Clamping the workpiece......................................................................................... 41
6.5
Compensation / workpiece dimensions................................................................. 42
6.6
Fixed workpiece stops and stop jaws..................................................................... 43
6.6.1
Assembly of the fixed workpiece stop ........................................................ 43
6.6.2
Assembly of the locking cover .................................................................... 44
6.6.3
Possibilities for clamping structure size 800 - 1200 ................................... 45
7
Maintenance ........................................................................................................... 46
7.1
Lubrication.............................................................................................................. 46
7.2
Maintenance intervals............................................................................................ 46
7.3
Disassembling and assembling the chuck .............................................................. 47
7.4
Assembling the lathe chuck.................................................................................... 49
8
Remedies for faults ................................................................................................. 52
9
Storage.................................................................................................................... 53
10
Disposal .................................................................................................................. 53
11
Spare parts.............................................................................................................. 54
12
Drawing................................................................................................................... 57
13
Declaration of Incorporation ................................................................................... 59
14
Appendix on Declaration of Incorporation, as per 2006/42/EC, Annex II, No. 1 B ..... 60

General
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5
General
About this Manual
This manual contains important information for the safe, correct
use of the product.
The manual is an integral part of the product and must be kept
accessible by personnel at all times.
Personnel must have read and understood this manual before
beginning any work. The observance of all safety notes in this
manual is the precondition for all safe working.
The illustrations in this manual are intended to provide a basic
understanding and may deviate from the actual version.
Besides this manual, other documents which apply are those listed
under (1.1.2, Page 6).
Illustration of safety notes
To make risks clear,the following signal words and symbols are
used for safety notes.
DANGER
Danger to individuals!
Ignoring a safety note such as this will certainly lead to
irreversible injury and even death.
WARNING
Danger to individuals!
Ignoring a safety note such as this can lead to irreversible injury
and even death.
CAUTION
Danger to individuals!
Non-observance can cause minor injuries.
NOTICE
Material damage!
Information about avoiding material damage.
1
1.1
1.1.1

General
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Applicable documents
•General terms and conditions*
•VDI guideline 3106
Sizes
This 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
•ROTA-M flex 2+2 800
•ROTA-M flex 2+2 1000
•ROTA-M flex 2+2 1200
Warranty
If the product is used as intended, the warranty is valid for 24
months from the date of delivery from the production facility or
500,000 cycles* under the following conditions:
•Refer to the applicable documents,
(1.1.2, Page 6)
•Observe the ambient conditions and operating conditions,
(2.6, Page 11)
•Observance of the specified care and maintenance instructions
(7, Page 46)
Parts touching the workpiece and wearing parts are not part of the
warranty.
* One cycle comprises one complete clamping procedure
("opening" and "closing").
1.1.2
1.1.3
1.2

General
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Scope of delivery
1
Manual lathe chuck in the ordered variant
4
Mounting screws (up to size 630)
8
T-nuts with screws or 4 combi T-nuts (for variant
with 60° fine serration)
1
Assembly key
1
Actuation key or wrench
(from size 800)
1 (2)
Eye bolt
(from size 800)
1
Assembly and Operating Manual
from size 800:
1
Locking cover
12 (16)
T-nuts with screw for table assembly
(size 1200)
1
Centering pin
12 (16)
Covers for mounting screws
(size 1200)
1.3

Basic safety notes
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Basic safety notes
Appropriate 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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9
•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.
Structural changes
Implementation of structural changes
Modifications, changes or reworking, e. g. additional threads,
holes, or safety devices, can damage the product or impair its
functionality or safety.
•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 and 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 design 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