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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02.00|1416054_ROTA-M2 + 2 |en-US
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

Table of Contents
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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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7
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

Basic safety notes
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11
Ambient conditions 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 only used within its defined
application parameters, (3, Page 19).
•Make sure that the product is a sufficient size for the
workpiece.
•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 46). Only perform the clamping force test with a
calibrated clamping force tester.
2.6

Basic safety notes
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If the clamping force has dropped too much or if the base jaws no
longer move properly, the chuck must be disassembled, cleaned,
and relubricated (7, Page 46).
Personnel qualification
The following personnel qualifications are required for the various
types of work on the product:
Specialist personnel have the specialized training, knowledge, and
experience to perform the tasks entrusted to them, to recognize
and avoid potential dangers, and know the relevant standards and
regulations.
The user has been instructed by the operator regarding the tasks
entrusted to them and the potential dangers of inappropriate
behavior. The user may only carry out tasks that go beyond the
use in normal operation if this is indicated in this manual and the
operator has expressly instructed them to do so.
•Order all work to be performed only by appropriately qualified
personnel.
•Personnel must have read and understood the complete
manual before beginning any work on the product.
•Observe national accident prevention regulations and the
general safety notes.
Inadequate qualification of personnel
Any work on the product by inadequately qualified personnel can
lead to serious injuries and considerable material damage.
2.7
Specialist personnel
User

Basic safety notes
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13
Personal protective equipment
Use of personal protective equipment
Personal protective equipment serves to protect staff in the event
of a danger that 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.
Notes on safe operation
An incorrect manner of working can make the product unsafe and
risks 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.
•Rectify malfunctions as soon as they occur.
•Observe the care and maintenance instructions.
•Observe the current safety, accident prevention, and
environmental protection regulations for the application field
of the product.
2.8
2.9

Basic safety notes
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Transport
Handling during transport
Incorrect handling during transport can make the product unsafe
and risk serious injuries and considerable material damage.
•When handling heavy weights, use lifting equipment to lift the
product and transport it by appropriate means.
•During transport and handling, secure the product to prevent it
from falling.
•Do not walk under 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
Incorrect handling during disposal can make the product unsafe
and risks serious injuries and considerable material and
environmental harm.
•Follow local regulations on dispatching product components for
recycling or orderly disposal.
Fundamental dangers
General
•Observe safety distances.
•Never deactivate safety installations.
•Before commissioning the product, take appropriate protective
measures to secure the danger zone.
2.10
2.11
2.12
2.13

Basic safety notes
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15
•Disconnect power sources before installation, modification,
maintenance, or calibration. Ensure that no residual energy
remains in the system.
•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 can make the product unsafe and
pose a risk of serious injuries and considerable material damage.
•Order all work to be performed only by appropriately qualified
personnel.
•For all work, secure the product against accidental operation.
•Observe the relevant accident prevention regulations.
•Use suitable assembly and transport equipment and take
precautions to prevent jamming and crushing.
Incorrect lifting of loads
Falling loads can cause serious injuries and even death.
•Stand clear of suspended loads and do not step within 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.
2.13.1
2.13.2

Basic safety notes
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Protection against dangerous movements
Unexpected movements
If the system still retains residual energy, serious injuries can be
caused while working on 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.
Limit/prevent accidental access for people in this area through
technical safety measures. The protection 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 commissioning 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.
Notes on particular risks
DANGER
Risk of fatal injury from suspended loads!
Falling loads can cause serious injuries and even death.
•Stand clear of suspended loads and do not step within their
swiveling range.
•Never move loads without supervision.
•Do not leave suspended loads unattended.
•Wear suitable protective equipment.
2.13.3
2.13.4

Basic safety notes
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17
DANGER
Possible risk of fatal injury to operating personnel if a jaw
breaks or if the chuck fails because the technical data have been
exceeded and a workpiece is released or parts fly off!
•The technical data specified by the manufacturer for using the
lathe chuck must never be exceeded.
•The lathe chuck may only be used on machines and facilities
that fulfill the minimum requirements of the EC Machinery
Directive; specifically, they must have effective technical
measures to protect against possible mechanical hazards.
DANGER
Risk of fatal injury to operating personnel from clothing or hair
being caught on the lathe chuck and being dragged into the
machine!
Loose clothing or long hair may become caught on projecting
parts of the lathe chuck and be drawn into the machine.
•The machines and equipment must fulfill the minimum
requirements 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 lathe chuck.
DANGER
Possible risk of fatal injury to operating personnel from
workpiece loss or parts flying off due to incorrectly selected
clamping position of the chuck jaws to the workpiece.
•The chuck jaws must not touch in the clamping position → no
collision as otherwise no clamping force is transmitted to the
workpiece.
•When fastening the chuck jaws, ensure sufficient clamping
reserves (lathe chuck residual jaw stroke) as otherwise no
clamping force is transmitted to the workpiece.

Basic safety notes
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CAUTION
Risk of limbs being crushed when opening and closing the chuck
jaws during manual loading or unloading or when exchanging
moving parts.
•Do not reach between the chuck jaws.
•Wear protective gloves.
•Follow the safety and accident prevention regulations when
operating the chuck, especially when working with machine
tools and other technical equipment.
CAUTION
Risk of damage due to incorrect choice of clamping position for
chuck jaws on workpiece.
If an incorrect clamping position is chosen for the chuck jaws on
the workpiece, the base and top jaws may become damaged.
•The T-nuts for connecting the top jaws to the base jaws must
not protrude beyond the base jaws in the radial direction.
•The diameter of the workpiece may not be bigger than the
chuck diameter.

Screw tightening torques
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19
Technical data
Lathe chuck data
ROTA-M flex 2+2
260
315
400
500
630
800
1000
1200
Max. actuation moment
[Nm]
120
120
200
250
250
250
250
250
Max. clamping force [kN]
100
100
150
180
180
180
180
180
Max. speed [rpm]
2700
2200
1500
1100
950
800
700
600
Overall stroke per jaw
[mm]
9.5
9.5
14.5
17.8
17.8
17.8
17.8
17.8
Compensation per jaw
[mm]
5.1
5.1
7.9
10
10
10
10
10
Weight with base jaws [kg]
41.7
62.9
124.8
227.2
307.4
395
520
620
Weight of base jaws [kg]
0.93
1.2
2.07
0.577
4.91
6.688
8.603
10.518
Mass moment of inertia
[kgm2]
0.36
0.81
2.54
7.27
14.14
23.06
45.34
75.08
Centrifugal torque of base
jaw [kgm] McGB
0.08
0.11
0.262
0.577
0.925
1.538
1.979
2.419
Spindle holder ISO 702-4
No. 8
(220
H6)
No. 11
(300
H6)
No. 15
(380
H6)
No. 15
(380
H6)
No. 15
(380
H6)
Base plate
Operating temperature
+ 15°C to + 60°C
Ensure minimal weight for all jaws.
For the respective machining task, the permissible speed of
rotation for a given initial clamping force or the required clamping
force for a given speed of rotation must be calculated according to
VDI 3106, whereby the maximum speed of rotation or the
maximum clamping force of the lathe chuck must not be
exceeded. The calculated values must be checked by dynamic
measurement. Functional monitoring must be performed
according to the guidelines of the insurance association.
3
3.1

Screw tightening torques
20
02.00|1416054_ROTA-M2 + 2 |en-US
Dimensions
3.2