SCHUNK ROTA-S plus 2.0 User instructions

Translation of the original manual
Manual chuck
ROTA-S plus 2.0
Assembly and Operating Manual
Superior Clamping and Gripping

Imprint
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05.00|0889002_ROTA-S plus 2.0 |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: 0889002
Version: 05|28/03/2019|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
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3
Table of Contents
1
About this manual.................................................................................................... 5
1.1
Presentation of Warning Labels ............................................................................... 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............................................................................... 14
2.5
Personnel qualification........................................................................................... 14
2.6
Organizational measures........................................................................................ 14
2.7
Personal protective equipment.............................................................................. 15
3
Warranty................................................................................................................. 16
4
Torque per screw .................................................................................................... 16
5
Scope of delivery ..................................................................................................... 16
6
Technical data ......................................................................................................... 17
6.1
Chuck data .............................................................................................................. 17
6.2
Clamping force / speed diagrams........................................................................... 18
6.3
Calculations for clamping force and speed ............................................................ 22
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 Fsp0 for a given rpm n
..................................................................................................................... 24
6.3.3
Calculation of the permissible rpm nzul in case of a given initial clamping
force Fsp0.................................................................................................... 26
6.4
Grades of Accuracy................................................................................................. 26
6.5
Permissible imbalance............................................................................................ 26
7
Attachment of the manual chuck............................................................................. 27
7.1
Handling prior to attachment................................................................................. 27
7.2
Preparing the chuck attachment............................................................................ 27
7.3
Mounting of the Manual Chuck ............................................................................. 28
8
Function .................................................................................................................. 29
8.1
Handling and jaw change ....................................................................................... 29
8.2
Important notes...................................................................................................... 31
8.3
Control of the chuck ............................................................................................... 32
8.4
Control of true-running .......................................................................................... 32

Table of Contents
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9
Maintenance ........................................................................................................... 34
9.1
Disassembling and assembling the chuck .............................................................. 34
9.2
Jaw change ............................................................................................................. 36
9.3
At least once a month ............................................................................................ 36
9.4
In the case of decreasing clamping force or after approx. 200 operating hours .. 37
9.5
Maintenance intervals............................................................................................ 37
10
Disposal .................................................................................................................. 38
11
Spare parts.............................................................................................................. 39
12
Assembly drawing ................................................................................................... 40

About this manual
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5
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
(1.2, 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

About this manual
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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 *
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
1.2

Basic safety instructions
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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 product is suitable for clamping workpieces on milling or lathe
machines and other suitable tooling machines.
•The product may only be used within the scope of its technical
data, (6, 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 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, Page 17)
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, Page 17)
•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
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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
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9
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.
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.
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.

Basic safety instructions
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CAUTION
Danger of damage due to incorrectly selected clamping position
of the clamping jaws to the workpiece.
An incorrectly selected clamping position of the clamping jaws to
the workpiece can result in damage to the base and top jaws.
•Make sure that the workpiece clamping is concentric.
•In the case of a chuck with a quick-change jaw system the top
jaws must not protrude radially beyond the base jaws used.
Exception: The supporting jaw variant 3 protrudes beyond the
chuck base jaw due to the construction of the jaw. In this case,
the T-nuts must always be inserted completely into the groove
of the chuck base jaw.
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
•Do not start the machine spindle until the workpiece is
clamped and the spanner wrench has been removed from the
chuck.
•Only operate the lathe chuck when all protective equipment
has been fitted and is in full working order.
•Check the lathe chuck at least once per shift for externally
visible damage and faults.
Functional test
After installation of the lathe chuck, its function must be checked
prior to start-up:
•Clamping force! At max. torque, the clamping force specified
for the chuck must be reached.
2.4

Basic safety instructions
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11
•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 manual chuck's reliability and safety can only be guaranteed if
the operator complies with the manufacturer's maintenance
instructions.
•For lubrication, we recommend our tried and tested special
grease, LINOMAX plus. Unsuitable lubricants can have a
negative impact on the functioning of the chuck (clamping
force, coefficient of friction, wear characteristics).
(For product information about LINOMAX plus, see the
"Accessories" chapter of the SCHUNK lathe chuck catalog or
contact SCHUNK.)
•Use a suitable high-pressure grease gun to ensure that you
reach all the greasing areas.
•To ensure correct distribution of the grease, move the lathe
chuck to its end positions several times, lubricate again, and
then check the clamping force.

Basic safety instructions
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•We recommend checking the clamping force using a clamping
force tester before starting a new production run and between
maintenance intervals. *Optimum safety can only be
guaranteed through regular checks*.
•The clamping force should always be measured with the chuck
in the same condition as it is used in for the current clamping
application. 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 should be measured
dynamically.
•Move the lathe chuck through to its end position several times
after 500 clamping strokes, at the latest. (This moves the
lubricant back to the force transmission surfaces so that the
clamping force is retained for longer).
Safety notes for servicing
Follow all the applicable legal standards 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.
Immediately report any changes including operational behavior to
the competent units/persons; if necessary, immediately shut down
and secure the machine on which the lathe chuck is mounted. Do
not start up the machine that the chuck is mounted on again until
the malfunction has been eliminated.

Basic safety instructions
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13
DANGER
Possible risk of fatal injury to operating personnel due to
toolholder failure if the maintenance and servicing instructions
for the toolholder 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 chuck jaws
When using special chuck jaws, please observe the following rules:
•The chuck jaws should be designed to be 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 special chuck jaws 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 bolts into the bore holes furthest
apart.
•The maximum recommended speed may only be operated in
conjunction with the maximum clamping force and only with
the lathe chuck in optimum, fully functioning condition.
•If the chuck is involved in a collision, it must be subjected to a
crack test before using it again. Damaged parts must be
replaced 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.

Basic safety instructions
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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.
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
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15
Spare parts
Only ever use original SCHUNK spare parts.
Environmental regulations
Comply with the applicable legal norms when disposing of waste.
Personal protective equipment
Use of personal protective equipment
Personal protective equipment serves to protect staff against
danger which 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.
2.7

Scope of delivery
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Warranty
The warranty period is 60 months after delivery date from factory
or 50 000 cycles*, if it is used as intended, under the following
conditions:
•Observe the applicable documents, (1.2, Page 6)
•Observe the ambient conditions and operating conditions.
•Observe the specified maintenance and lubrication intervals,
(9, Page 34)
Parts touching the workpiece and wear parts are not included in
the warranty.
* A cycle consists of a complete clamping process ("Open" and
"Close").
Torque per screw
Maximum admissible torque for fastening screws to mount the
lathe chuck (screw grade 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
Maximum admissible torque per screw for mounting top jaws
onto the lathe chuck (screw grade 12.9)
Screw size
M8
M10
M12
M16
M20
M24
Tightening torque (Nm)
25
60
80
100
180
230
Scope of delivery
1
Manual chucks (complete)
either with cylindrical recess and mounting screws
or with the respective flange and accessories for spindle in
accordance with
–DIN ISO 702-1 short-taper mount with the screws to the front
–DIN ISO 702-2 short-taper mount with Camlock mounting
–DIN ISO 702-3 short-taper mount with bayonet mounting
1
Spanner wrench
1
Operating manual
3
4
5

Technical data
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17
Technical data
Chuck data
ROTA-S plus 2.0
3-jaw chuck
2-jaw chuck
160-42
200-52
250-62
315-92
160-42
200-52
250-62
315-92
Max. torque [Nm]
80
120
210
220
55
80
140
150
Stroke per jaw [mm]
6.5
7.0
7.7
9.9
6.5
7
7.7
9.9
Recommended speed
[RPM]
5400
4800
4200
3400
5400
4800
4200
3400
Max. jaw clamping force:
[kN]
65
100
160
180
40
65
105
120
Mass moment of inertia [kg
m2]
0.029
0.091
0.249
0.758
0.033
0.1
0.276
0.8196
Chuck bore [mm]
42
52
62
92
42
52
62
92
Weight without jaws [kg]
7.94
16.1
28.8
54.2
8.5
18.2
30.4
60.5
Centrifugal force of the
base jaw
with fine serration
McGB [kgm]
For the ROTA-S plus 2.0 chuck, it is necessary to specifically
determine this data.
Examples of calculation can be found in the "Special chuck
jaws/technology" chapter in our current chuck jaw catalog.
Max. jaw eccentricity of
center of gravity in axial
direction amax [mm]
The maximum RPM stated is only valid with the maximum
clamping force and when using the hard standard stepped jaws
that go with the chuck.
For soft top jaws or special chuck jaws the speed permitted for the
cutting task must be calculated in accordance with VDI 3106
whereby the max. recommended speed of rotation may 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.
The recommended speed is valid for ROTA-S plus 2.0 with
SCHUNK stepped block jaws, hard, type STF.
For this, the base jaws are inserted flush with outer diameter of
the chuck.
3-jaw chuck
2-jaw chuck
Jaw type
STF 160
STF 200
STF 250
STF 315
STF 160
STF 200
STF 250
STF 315
Weight/set
1.1 kg
1.9 kg
3.3 kg
5.3 kg
0.73 kg
1.27 kg
2.2 kg
3.5 kg
6
6.1

Technical data
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The speed of rotation must be reduced for jaws with a higher
weight!
Max. oscillating circle –With type SFG base jaws
ROTA-S plus 2.0
160-42
200-52
250-62
315-92
Oscillating circle Ø
208.5
264
323
401.5
At the rated speed the chucks are balanced to Q 6.3
Warranty and maximum clamping cycles
Length of warranty
60 months
Maximum clamping cycle number
50,000 cycles
Clamping force / speed diagrams
Clamping force/RPM curves have been determined by using hard
jaws. In the determination process, the maximum actuating force
was applied and the jaws were set flush with the outer diameter of
the chuck.
The chuck is in perfect condition and lubricated with SCHUNK
LINOMAX plus special grease.
If one or more of these prerequisites is modified, the graphs will
no longer be valid.
Chuck setup for clamping force/RPM graph
FspB
Jaw clamping force
S
Center of gravity
Fs
Center of gravity radius
amax
Max. jaw eccentricity of
center of gravity in axial
direction
Fmax
Max. actuating force
6.2

Technical data
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19
Clamping force RPM diagram ROTA-S plus 2.0 160-42 - 3 jaws
Clamping force RPM diagram, ROTA-S plus 2.0 200-62 - 3 jaws
Clamping force RPM diagram ROTA-S plus 2.0 250-52 - 3 jaws

Technical data
20
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Clamping force RPM diagram, ROTA-S plus 2.0 315-92 - 3 jaws
Clamping force RPM diagram ROTA-S plus 2.0 160-42 - 2 jaws
Clamping force RPM diagram, ROTA-S plus 2.0 200-62 - 2 jaws