SCHUNK ROTA-S flex 550 User instructions

Translation of original operating manual
Manual chuck
ROTA-S flex
Assembly and Operating Manual
Superior Clamping and Gripping

Imprint
2
04|ROTA-S flex |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: 0889139
Version: 04 |01/04/2019|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
04|ROTA-S flex |en
3
Table of contents
1
General .................................................................................................................... 5
1.1
Warnings................................................................................................................... 5
1.2
Applicable documents .............................................................................................. 6
2
Basic safety instructions ........................................................................................... 7
2.1
Intended use............................................................................................................. 7
2.2
Not intended use ...................................................................................................... 7
2.3
Notes on particular risks........................................................................................... 8
2.4
Notes on safe operation......................................................................................... 10
2.4.1
Constructional changes, attachments or modifications............................. 14
2.5
Personnel qualification........................................................................................... 14
2.6
Organizational measures........................................................................................ 14
2.7
Using personal protective equipment.................................................................... 15
3
Warranty................................................................................................................. 16
4
Torques per screw ................................................................................................... 17
5
Scope of delivery ..................................................................................................... 17
6
Technical data ......................................................................................................... 18
6.1
Chuck data .............................................................................................................. 18
6.2
Clamping force / speed diagrams........................................................................... 19
6.3
Calculations for clamping force and speed ............................................................ 21
6.3.1
Calculation of the required clamping force in case of a given rpm............ 22
6.3.2
Calculation example: required initial clamping force for a given speed .... 24
6.3.3
Calculation of the permissible speed in case of a given initial clamping
force ............................................................................................................ 25
6.4
Grades of Accuracy................................................................................................. 26
6.5
Permissible imbalance............................................................................................ 26
7
Attachment of the entire manual chuck................................................................... 27
7.1
Handling prior to attachment................................................................................. 27
7.2
Preparing the chuck attachment............................................................................ 27
7.3
Assembly of the entire manual chuck .................................................................... 27
8
Function .................................................................................................................. 28
8.1
Handling and jaw change ....................................................................................... 28
8.2
Important notes on the ROTA-S plus or ROTA-S plus 2.0 manual chuck............... 29
8.3
Checking the ROTA-S plus or ROTA-S plus 2.0 manual chuck................................ 29
9
Maintenance ........................................................................................................... 30
9.1
Disassembling and assembling the chuck .............................................................. 30

Table of contents
4
04|ROTA-S flex |en
9.2
Jaw change ............................................................................................................. 30
9.3
At least once a month ............................................................................................ 31
9.4
In the case of decreasing clamping force or after approx. 200 operating hours .. 31
10
Spare parts.............................................................................................................. 32
11
Assembly drawing ................................................................................................... 33
12
................................................................................................................................ 34
13
................................................................................................................................ 35
14
................................................................................................................................ 36
15
................................................................................................................................ 37

General
04|ROTA-S flex |en
5
General
This operating manual is an integral component of the product and
contains important information on safe and proper assembly,
commissioning, operation, care, maintenance and disposal. This
manual must be stored in the immediate vicinity of the product
where it is accessible to all users at all times.
Before using the product, read and comply with this manual,
especially the chapter “Basic safety notes”.(2, Page 7)
If the product is passed on to a third party, these instructions must
also be passed on.
Illustrations in this manual are provided for basic understanding of
the product and may differ from the actual product design.
We accept no liability for damage resulting from the failure to
observe and comply with this operating manual.
Warnings
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

General
6
04|ROTA-S flex |en
WARNING
Warning about hand injuries
WARNING
Warning about hot surfaces
Applicable documents
General terms of business
Katalogdatenblatt des gekauften Produkts
Calculation of the jaw centrifugal forces
("Technology" chapter in the lathe chuck catalog)
The above mentioned documents can be downloaded at
www.de.schunk.com.
1.2

Basic safety instructions
04|ROTA-S flex |en
7
Basic safety instructions
Improper handling, assembly and maintenance of this product may
result in risk to persons and equipment if this operating manual is
not observed.
Report any failures and damage immediately and repair without
delay to keep the extent of the damage to a minimum and prevent
compromising the safety of the product.
Only original SCHUNK spare parts may be used.
Intended use
The chuck is used to clamp workpieces on machine tools and other
suitable technical facilities, paying particular attention to the
technical data specified by the manufacturer. The technical data
specified by the manufacturer must never be exceeded.
The product is intended for industrial use.
Intended use also means that the user has read and understood
this operating manual in its entirety, especially the chapter “Basic
safety notes”.
The maximum RPM of the chuck and the required clamping force
must be determined by the user for the respective clamping task
based on the applicable standards and technical specifications of
the manufacturer.
(See also “Calculations for clamping force and RPM” in the chapter
“Technical data”). (6.1, Page 18)
Not intended use
A not intended use of the product is for example:
•It is used as a press, a punch, a toolholder, a load-handling
device or as lifting equipment.
•the product is used for unintended machines or workpieces.
•the technical data is exceeded when using the product.
(6.1, Page 18)
•if workpieces are not clamped properly, paying particular
attention to the clamping forces specified by the manufacturer.
•if it is used in working environments that are not permissible.
•if the product is operated without a protective cover.
2
2.1
2.2

Basic safety instructions
8
04|ROTA-S flex |en
Notes on particular risks
This product may pose a danger to persons and property if, for
example:
•It is not used as intended;
•It is not installed or maintained properly;
•The safety and installation instructions, local applicable safety
and accident prevention regulations or the EC Machinery
Directive are not observed.
DANGER
Possible risk of fatal injury to operating personnel if a jaw
breaks or if the lathe 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
Possible 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.
2.3

Basic safety instructions
04|ROTA-S flex |en
9
DANGER
Risk to life and limb of the operating personnel in case of not
completely clamped workpiece and not removed Allan key
Risk to life and limb of the operating personnel and significant
damage of the machine due to the possibility of parts flying off.
•The machine spindle should only be started when the
workpiece is clamped and the Allan key is removed from the
chuck.
•Unclamping may only be possible when the machine spindle
has come to a standstill.
WARNING
Risk of injury due to dropping the chuck during transport,
installation or removal.
•Take special care in the danger zone when transporting,
installing or removing the chuck.
•Note the relevant load securing regulations for working safely
with cranes, ground conveyors, lifting gear and load-handling
equipment.
WARNING
Risk of injury by catapulted brass cover caps (accessory) of the
clamping bolt in case of rotation of the chuck.
The brass cover caps (accessory) of the clamping bolt must only
be used for stationary use of the chuck.
CAUTION
Danger of slipping and falling in case of dirty environment
where the chuck is used (e.g. by cooling lubricants or oil).
•Ensure that the working environment is clean before starting
assembly and installation work.
•Wear suitable safety shoes.
•Follow the safety and accident-prevention regulations when
operating the chuck, especially when working with machine
tools and other technical equipment.

Basic safety instructions
10
04|ROTA-S flex |en
CAUTION
Danger of limbs being crushed by opening and closing of the
chuck jaws during manual loading and unloading or when
replacing moving parts.
•Do not reach between the jaws.
•Wear safety gloves.
•Observe the safety and accident prevention regulations during
operation of the chuck, especially in connection with
machining centers and other technical equipment.
CAUTION
Risk of burns due to workpieces with high temperatures.
•Wear protective gloves when removing the workpieces.
•Automatic loading is preferred.
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 the chuck's axial and concentric runout.
•Check options for remedying imbalances on special top jaws
and workpieces.
•Reduce the speed.
•Wear hearing protection.
Notes on safe operation
•The machine spindle should only be started when the
workpiece is clamped and the Allan key is removed from the
chuck.
•Only operate the chuck when all protective equipment has
been fitted and is in full working order.
•Check the manual chuck at least once per shift for externally
visible damage and faults.
2.4

Basic safety instructions
04|ROTA-S flex |en
11
Functional test
After installation of the chuck, its function must be checked prior
to start-up.
•Clamping force The max. clamping force specified for the
clamping device must be reached at max. torque.
•Indicator pin Never clamp or switch on the lathe when the
indicator pin is protruding. (Golden pin on the chuck's shell).
•Jaw lock! The spindle can only be turned when all the chuck
jaws have been fitted into the T-slot. This prevents the wedge
bars from being brought into the working position without
chuck jaws.
Speed
DANGER
Possible risk of fatal injury to operating personnel if the chuck's
top speed is exceeded and a workpiece is released or parts fly
off.
If the machine tool or technical equipment can reach a higher
speed than the chuck's top speed, a reliable speed limiter must
be installed and proof must be provided that the speed limiter is
effective.
WARNING
Vibrations caused by the processing can result a loss of clamping
force. Risk of injury due drop out of the workpiece.
Manually operated chucks can lose clamping force because of
vibration which is caused by the processing of the workpiece.
•Tighten the chuck regularly during processing to compensate
the loss of clamping force due to vibration.
Maintenance instructions
The power chuck's reliability and safety can only be guaranteed if
the operator complies with the manufacturer's maintenance
instructions.

Basic safety instructions
12
04|ROTA-S flex |en
•For lubrication, we recommend our tried special grease,
LINOMAX. Unsuitable lubricants can have a negative impact on
the chuck (clamping force, coefficient of friction, wear
characteristics).
(For product information about LINOMAX, see the
"Accessories" section of the current SCHUNK lathe chuck
catalog or contact SCHUNK).
•Use a suitable high-pressure grease gun to ensure that you
reach all the greasing areas.
•For good distribution of the grease, move the chuck to its end
positions several times, lubricate again, and then check the
clamping force.
•We recommend checking the clamping force using a clamping
force tester before starting a new production run and between
maintenance intervals. “Only regular checks can guarantee
optimal safety”.
•The clamping force should always be measured in the state of
the chuck as used for the current clamping situation. If top jaws
with clamping steps are used, measuring must be performed in
the same step as for the respective clamping task. In the event
of high operating speeds, clamping force losses must be
accounted for due to the centrifugal force acting on the chuck
jaws. In this case, the value of the operating clamping force has
to be determined by a dynamic measurement.
•Move the clamping piston through to its end position several
times after 500 clamping strokes, at the latest. (This moves the
lubricant back to the surfaces of the force transmission. This
means that the clamping force is retained for longer).
Safety notes for servicing
Follow all the applicable legal norms for health and safety during
servicing. Use suitable personal protective equipment, especially
protective gloves, goggles and safety boots, paying particular
attention to the operating system and hazard assessment.
Report any alterations including alterations in operational
behaviour to the responsible place/persons immediately, if
necessary bring the machine to which the Power Chuck is
mounted to an immediate standstill and secure it. Only restart the
machine to which the Power Chuck is fitted when the cause of the
problem has been eliminated.

Basic safety instructions
04|ROTA-S flex |en
13
DANGER
Possible risk of fatal injury to operating personnel due to chuck
failure if the servicing instructions for the chuck are
disregarded!
The servicing instructions specified by the manufacturer must be
complied with to ensure safe operation of the chuck.
Work must be carried out by qualified specialist personnel with
the relevant safety training.
Use of special designed jaws
When using special designed jaws the following rules must be
observed:
•The jaws should be designed as light and as low as possible. The
clamping point must be as close as possible to the chuck face
(clamping points at a greater distance lead to greater surface
pressure in the jaw guidance and can significantly reduce the
clamping force).
•Do not use welded jaws.
•If for constructional reasons the chuck jaws in special design
are heavier than the top jaws assigned to the clamping device,
greater centrifugal forces must be accounted for when defining
the required clamping force and the recommended speed.
•Screw the jaw mounting screws into the bore holes furthest
apart.
•The maximum recommended speed may only be operated in
conjunction with maximum actuating force and only with the
chuck in optimal, fully functioning condition.
•If the clamping device is involved in a collision, it must be
subjected to a crack test before using it again. Damaged parts
must be replaced by original SCHUNK spare parts.
•The jaw fastening screws must be replaced if they show any
signs of wear or damage. Only use screws with a quality of 12.9.

Basic safety instructions
14
04|ROTA-S flex |en
Constructional changes, attachments or modifications
Modifications and rework (additional threads or bore holes) or
attaching fittings that are not offered as accessories by SCHUNK
may be performed only with permission of SCHUNK. This also
applies to the installation of safety devices.
Personnel qualification
Assembly and disassembly, commissioning, operation and repair of
the chuck may be performed only by qualified specialists who have
been instructed with respect to safety.
All persons who are assigned to operate, maintain and repair our
chuck must have access to the operating manual, especially the
chapter “Fundamental safety instructions”. We recommend that
the operator create in-house safety operating instructions.
Persons in training may be assigned to machines and technical
equipment in which a chuck is mounted only if they are under the
constant guidance and supervision of qualified specialists.
Organizational measures
Obeying the rules
Via suitable organizational measures and instructions, the
operator must ensure that the relevant safety rules are obeyed by
the persons asked to operate, maintain and repair the chuck.
Checking the behavior of personnel
The operator must at least occasionally check that the personnel
are behaving in a safety conscious manner and are aware of the
potential hazards.
Danger signs
The operator must ensure that the signs concerning safety and
hazards mounted on the machine where the chuck is mounted are
clearly legible and are observed.
Faults
If a fault occurs on the chuck and this fault endangers safety or if a
problem is suspected due to production characteristics, the
machine tool where the chuck is mounted must be immediately
stopped and remain shut down until the fault has been located
and remedied. Only allow specialists to remedy faults.
2.4.1
2.5
2.6

Basic safety instructions
04|ROTA-S flex |en
15
Spare parts
Only ever use original SCHUNK spare parts.
Environmental regulations
Comply with the applicable legal norms when disposing of waste.
Using personal protective equipment
When using this product, you must comply with the relevant
health and safety at work rules and you must use the required
personal safety equipment (minimum: category 2).
2.7

Warranty
16
04|ROTA-S flex |en
Warranty
If the product is used as intended, the warranty is valid for 60
months from the ex-works delivery date under the following
conditions:
•Observe the applicable documents, (1.2, Page 6)
•Observe the ambient conditions and operating conditions
•Observe the maximum number of clamping cycles
(6.1, Page 18)
•Observe the specified maintenance and lubrication intervals,
(9, Page 30)
Parts touching the workpiece and wear parts are not included in
the warranty.
3

Scope of delivery
04|ROTA-S flex |en
17
Torques per screw
Tightening torques for mounting screws used to clamp the chuck
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
Tightening torques for mounting screws used to attach top jaws
onto the chuck (screw quality 12.9)
Screw size
M6
M8
M10
M12
M14
M16
M20
M24
Max. admissible torque MA(Nm)
16
30
50
70
130
150
220
450
Scope of delivery
Centering chuck (complete) ROTA-S plus 2.0 or ROTA-S plus
1
Console plate
3
Extensions of guideway
1
Set of long special base jaws
1
Set of short special base jaws
1
Cover plate
2
Centering bolts Ø 32g6 / Ø 50g6
Screws and T-nuts for mounting on the machine table
1
Allan key (up to size 1200 only)
1
Ratchet with adapter
1
Operating Manual ROTA-S flex
1
Operating Manual ROTA-S plus 2.0 or ROTA-S plus
4
5

Technical data
18
04|ROTA-S flex |en
Technical data
Chuck data
(with long base jaws)
ROTA-S flex
550
700
1000
1200
1400
Max. torque
Nm
120
220
280
320
350
Stroke per jaw
mm
7
9.7
12
12
15
Recommended max. speed
min-1
1000
800
500
500
400
Total gripping force max.
kN
100
180
230
270
270
Mass moment of inertia
kg m2
1.6
7.078
25.03
57.89
125.28
Chuck through hole
mm
52
92
102
162
252
Weight with jaws
kg
65
150
360
490
830
Centrifugal torque of the long
base jaws
McGB kgm
0.153
0.5448
1.8
2.66
5.59
Max. jaw center eccentricity in
axial direction (with long base
jaws)
amax mm
For the ROTA-S flex chucks it's necessary to
determine those data specific. Calculation
examples are in the chapter "Technology" in
the SCHUNK-lathe-chuck-catalog or in the
chapter "Special jaws/Technology" in the
SCHUNK-power-chuck-catalog. Those catalogs
are also available as download at
www.de.schunk.com.
The recommended max. speed is only valid for max. operating
force and the use of the suitable hard standard stepped jaws.
Warranty and maximum clamping cycles
Length of warranty
60 Months
Maximum clamping cycle number
50 000 Cycles
When using unhardened top jaws or jaws in special design, make
sure that their weight is as low as possible
For soft top jaws or jaws in special design the permissible speed of
the respective cutting task has to be calculated in accordance to
VDI 3106, whereby the maximum standard value may not be
exceeded. The calculated values have to be examined with a
dynamic measurement. Control of function (piston movement and
actuation pressure) has to be accomplished in accordance with the
guidelines of the professional association.
The recommended speed is valid for ROTA-S flex with long base
jaws and SCHUNK stepped block jaws, hard, type STF.
6
6.1

Technical data
04|ROTA-S flex |en
19
In this the base jaws are inserted flush with outer diameter of the
chuck.
Jaw type
SFA 200
SFA 315
SFA 400
SFA 500
SFA 630
Weight / Set [kg]
2.0
5.6
13.5
13.5
40.0
The speed of rotation must be reduced for jaws with a higher
weight!
Max. oscillating diameter –with base jaws type SFG
ROTA-S flex
550
700
1000
1200
1400
Oscillating diameter Ø [mm]
570
755
1000
1265
1400
The chuck is balanced at Q 6.3 at rated speed.
Clamping force / speed diagrams
The diagrams refer to 3-jaw-chuck.
Clamping force-/RPM curves were determined using long, hard
base jaws and hard SHF and SFA standard jaws. During this the
max. actuating force was applied.
The diagrams showing short, hard base jaws and hard SHF and SFA
standard jaws can be found in the ROTA-Splus or ROTA-Splus 2.0
operating manuals contained in the scope of delivery.
The chucks were in good condition and greased with special
SCHUNK grease LINO MAX.
After modification of one or several of these prerequisites the
diagram will no longer be valid.
Chuck set-up for clamping force / speed diagram
F / 3
Clamping force per jaw
S
Center of gravity
rs
Center of gravity radius
[mm]
amax
Max. jaw eccentricity of
center of gravity in axial
direction
Fmax
Actuating force
6.2

Technical data
20
04|ROTA-S flex |en
ROTA-S flex 550 (with long jaws)
ROTA-S flex 700 (with long jaws)
ROTA-S flex 1000 (with long jaws)