SCHUNK ROTA TB2 470-185 User instructions

Translation of the original operating manual
Pneumatic front-end chuck
ROTA TB2 / ROTA TB2 LH
Assembly and Operating Manual
Superior Clamping and Gripping

Imprint
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04.00|0889132_ROTA TB2 / ROTA TB2 LH |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: 0889132
Version: 04.00 |02/12/2020|en
© H.-D. SCHUNK GmbH & Co.
All rights reserved.
Dear Customer,
thank you for trusting our products and our family-owned company, the leading
technology supplier of robots and production machines.
Our team is always available to answer any questions on this product and other solutions.
Ask us questions and challenge us. We will find a solution!
Best regards,
Your SCHUNK team
H.-D. SCHUNK GmbH & Co.
Spanntechnik KG
Lothringer Str. 23
D-88512 Mengen
Tel. [phone]
Fax [phone]
[email protected]
schunk.com
Customer Management
Tel. [phone]
Fax [phone]
customercentermenge[email protected]k.com
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
Presentation of Warning Labels.................................................................... 5
1.1.2
Applicable documents................................................................................... 6
1.1.3
Sizes............................................................................................................... 6
1.2
Warranty................................................................................................................... 6
1.3
Scope of delivery ...................................................................................................... 7
2
Basic safety notes .................................................................................................... 8
2.1
Intended use............................................................................................................. 8
2.2
Not intended use ...................................................................................................... 9
2.3
Constructional changes ............................................................................................ 9
2.4
Spare parts................................................................................................................ 9
2.5
Environmental and operating conditions............................................................... 10
2.6
Notes on safe operation......................................................................................... 10
2.6.1
Substantial modifications............................................................................ 15
2.7
Personnel qualification........................................................................................... 15
2.8
Personal protective equipment.............................................................................. 16
2.9
Transport ................................................................................................................ 16
2.10
Malfunctions........................................................................................................... 17
2.11
Disposal................................................................................................................... 17
2.12
Fundamental dangers............................................................................................. 17
2.12.1
Protection during handling and assembly .................................................. 18
2.12.2
Protection during commissioning and operation ....................................... 18
2.12.3
Protection against dangerous movements................................................. 18
2.12.4
Notes on particular risks ............................................................................. 19
2.13
2-jaw chuck............................................................................................................. 22
3
Technical data ......................................................................................................... 23
3.1
Chuck data .............................................................................................................. 23
3.2
Clamping force / speed diagrams........................................................................... 25
3.3
Calculations for clamping force and speed ............................................................ 30
3.3.1
Calculation of the required clamping force in case of a given rpm............ 30
3.3.2
Calculation example: required initial clamping force for a given speed .... 32
3.3.3
Calculation of the permissible speed in case of a given initial clamping
force ............................................................................................................ 34
3.4
Grades of Accuracy................................................................................................. 35
3.5
Permissible imbalance............................................................................................ 35

Table of contents
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4
Torques per screw ................................................................................................... 35
5
Assembly................................................................................................................. 36
5.1
Pre-assembly measures.......................................................................................... 36
5.2
Distributor ring ....................................................................................................... 37
5.2.1
Mounting with bracket ............................................................................... 38
5.2.2
Mounting with 2-part clamping ring (D.R.M.B.) ......................................... 40
5.3
Attachment of the ROTA TB2 chuck....................................................................... 42
5.4
Optional mechanical pressure monitor with inductive proximity switch ............. 43
5.5
Mechanical stroke monitoring with inductive proximity switches on dual stroke
chucks ..................................................................................................................... 44
6
Function .................................................................................................................. 46
6.1
Principle of Operation ............................................................................................ 46
6.2
Air transmission system ......................................................................................... 47
6.3
Pilot controlled check valve.................................................................................... 48
6.4
Faults, causes and solutions ................................................................................... 49
7
Commissioning and maintenance ............................................................................ 51
7.1
Commissioning ....................................................................................................... 51
7.2
Maintenance........................................................................................................... 52
7.2.1
Maintenance intervals ................................................................................ 55
7.2.2
Hardened Reversible Jaws and Soft Top Jaws ............................................ 56
8
Disassembly and assembly ...................................................................................... 57
8.1
Disassembly and cleaning....................................................................................... 57
8.2
Assembly................................................................................................................. 59
8.2.1
Mounting of optional mechanical pressure monitoring system ................ 61
9
Control of types TB2, TB2 LH.................................................................................... 62
10
TB2S, TB2S LH stationary power chucks ................................................................... 62
11
Power Chuck with extended and standard jaw stroke (LH) ...................................... 63
12
Spare parts.............................................................................................................. 64
13
Assembly drawings.................................................................................................. 67
14
Translation of the original declaration of incorporation ........................................... 69

General
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General
About this manual
This manual contains important information for a safe and
appropriate use of the product.
This manual is an integral part of the product and must be kept
accessible for the personnel at all times.
Before starting work, the personnel must have read and
understood this operating manual. Prerequisite for safe working is
the observance of all safety instructions in this manual.
Illustrations in this manual are provided for basic understanding
and may differ from the actual product design.
In addition to these instructions, the documents listed under
(1.1.2, Page 6) are applicable.
Presentation of Warning Labels
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Danger for persons!
Non-observance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons!
Non-observance can lead to irreversible injury and even death.
CAUTION
Dangers for persons!
Non-observance can cause minor injuries.
1
1.1
1.1.1

General
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CAUTION
Material damage!
Information about avoiding material damage.
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
Sizes
This operating manual applies to the following sizes:
•ROTA TB2 470-185 / 470-185 LH
•ROTA TB2 520-191 LH
•ROTA TB2 600-275 / 600-275 LH
•ROTA TB2 630-175 LH
•ROTA TB2 685-325 / 685-325 LH
•ROTA TB2 850-375 / 850-375 LH
•ROTA TB2 1000-560 / 1000-560 LH
Warranty
The warranty period is 24 months after delivery date from factory
or 500 000 cycles*, if it is used as intended, under the following
conditions:
•Observe the applicable documents, (1.1.2, Page 6)
•Observe the ambient conditions and operating conditions.
•Observe the specified maintenance and lubrication intervals,
(7, Page 51)
Parts touching the workpiece and wear parts are not included in
the warranty.
* A cycle consists of a complete clamping process ("Open" and
"Close").
1.1.2
1.1.3
1.2

General
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Scope of delivery
1
Lathe chuck ROTA TB2 (LH)
6
T-nuts
2
Elbow connectors
2
Straight connectors
9 or 12
Fastening screws
1
Eye bolt
1
Operating manual
1.3

Basic safety notes
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Basic safety notes
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.
CONFIRMATION
We hereby confirm that the components comply with the
relevant basic and proven safety principles of Annex A and C of
ISO 13849-2, taking into account the requirements of the
documentation. The parameters, limitations, ambient conditions,
characteristic values, etc. for proper operation are defined in the
operating manual.
Intended use
This product is intended for clamping workpieces on machine tools
and other suitable technical devices.
•The product may only be used within the scope of its technical
data, (3, Page 23).
•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”). (3, Page 23)
2
2.1

Basic safety notes
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9
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.
(3, Page 23)
•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.
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.
Spare parts
Use of unauthorized spare parts
Using unauthorized spare parts can endanger personnel and
damage the product or cause it to malfunction.
•Use only original spare parts or spares authorized by SCHUNK.
2.2
2.3
2.4

Basic safety notes
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Environmental and operating conditions
Required ambient conditions and operating conditions
Incorrect ambient and operating conditions can make the product
unsafe, leading to the risk of serious injuries, considerable material
damage and/or a significant reduction to the product's life span.
•Make sure that the product is used only in the context of its
defined application parameters, (3, Page 23).
•Make sure that the product is a sufficient size for the
application.
•Only use high-quality cooling emulsions with anti-corrosive
additives during processing.
Clamping force measurement
Depending on the operating conditions, the function and clamping
force must be checked after a certain period of operation
(7.2.1, Page 55).
With the smallest possible actuating pressure (hydraulic cylinder),
the base jaws should move evenly. This method only provides a
limited indication and is not a substitute for measuring the
clamping force.
If the clamping force has dropped too much or if the base jaws and
piston no longer move properly, the chuck must be disassembled,
cleaned, and relubricated (7, Page 51).
Notes on safe operation
•The machine spindle may only be started up when clamping
pressure has built up in the cylinder and clamping has followed
in the permitted work area.
•Unclamping may only be possible when the machine spindle
has come to a standstill.
•If the clamping energy fails, the workpiece must remain firmly
clamped until the spindle is shut down and the workpiece is
secured.
•The technical safety requirements in the respective operating
instructions must be observed exactly.
2.5
2.6

Basic safety notes
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11
Functional test
After installation of the lathe chuck, its function must be checked
prior to commissioning.
Two important points are:
Clamping force! At max. actuating force/pressure, the clamping
force specified for the lathe chuck must be reached.
Stroke control! The pressure should be monitored by the lathe via
mechanical pressure sensing via sensors or wirelessly via a RSS-P1.
Stroke control lathe chuck ROTA TB2 with continuous stroke:
The base jaw edge should be within the marked range during
clamping.
Lathe chuck ROTA TB2 with rapid and clamping stroke (LH version):
Visual inspection: The gold-colored indicator pin (on each jaw)
should not protrude or the base jaw edge should be within the
area marked "Clamping Zone".

Basic safety notes
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Option for path control of the control cam with stationary
inductive proximity switch:
Neither of the two proximity switches should be wired.
When determining the clamping force required to machine a
workpiece, the centrifugal force acting on the chuck jaws must be
taken into account (according to VDI 3106).
If the chuck jaws are changed, adjust the stroke control to the new
situation.
Speed of rotation
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.
Maintenance instructions
The 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

Basic safety notes
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13
"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 clamping
piston 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. *Optimum safety can only be
guaranteed through regular checks*.
•The clamping force should always be measured in the state of
the lathe 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 should be measured dynamically.
•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. so that
the clamping force is retained for longer).
Caution
Following a longer shutdown period (more than approx. 6 hours),
always re-tension the clamped lathe chuck in order to compensate
for the setting properties of the clamping situation or possible
pressure losses and the resulting loss of clamping force.
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.

Basic safety notes
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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.
Observe the maintenance instructions in this manual.
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 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 chuck is involved in a collision, it must be subjected to a
crack test before using it again. Replace damaged parts with
original SCHUNK spare parts.
•Replace the chuck jaw mounting screws if there are signs of
wear or damage. Only use screws with a quality of 12.9.

Basic safety notes
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15
Caution
Following a longer shutdown period (more than approx. 6 hours),
always re-tension the clamped lathe chuck in order to compensate
for the setting properties of the clamping situation or possible
pressure losses and the resulting loss of clamping force.
Substantial modifications
No substantial modifications may be made to the chuck.
If the operator carries out a substantial modification to the
chuck, the product shall no longer conform to the EC Machinery
Directive 2006/42/EC.
Personnel qualification
Inadequate qualifications of the personnel
If the personnel working with the product is not sufficiently
qualified, the result may be serious injuries and significant
property damage.
•All work may only be performed by qualified personnel.
•Before working with the product, the personnel must have read
and understood the complete assembly and operating manual.
•Observe the national safety regulations and rules and general
safety instructions.
The following personal qualifications are necessary for the various
activities related to the product:
Due to their technical training, knowledge and experience, trained
electricians are able to work on electrical systems, recognize and
avoid possible dangers and know the relevant standards and
regulations.
Due to its technical training, knowledge and experience, qualified
personnel is able to perform the delegated tasks, recognize and
avoid possible dangers and knows the relevant standards and
regulations.
Instructed persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behaviour.
Due to its technical training, knowledge and experience, service
personnel of the manufacturer is able to perform the delegated
tasks and to recognize and avoid possible dangers.
2.6.1
2.7
Trained electrician
Qualified personnel
Instructed person
Service personnel of
the manufacturer

Basic safety notes
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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.
Transport
Handling during transport
Incorrect handling during transport may impair the product's
safety and cause serious injuries and considerable material
damage.
•When handling heavy weights, use lifting equipment to lift the
product and transport it by appropriate means.
•Secure the product against falling during transportation and
handling.
•Stand clear of suspended loads.
2.8
2.9

Basic safety notes
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17
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
The incorrect handling of disposal may impair the product's safety
and cause serious injuries as well as considerable material and
environmental harm.
•Follow local regulations on dispatching product components for
recycling or proper disposal.
Fundamental dangers
General
•Observe safety distances.
•Never deactivate safety devices.
•Before commissioning the product, take appropriate protective
measures to secure the danger zone.
•Disconnect power sources before installation, modification,
maintenance, or calibration. Ensure that no residual energy
remains in the system.
•If the energy supply is connected, do not move any parts by
hand.
•Do not reach into the open mechanism or movement area of
the product during operation.
2.10
2.11
2.12

Basic safety notes
18
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Protection during handling and assembly
Incorrect handling and assembly
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
•Have all work carried out by appropriately qualified personnel.
•For all work, secure the product against accidental operation.
•Observe the relevant accident prevention rules.
•Use suitable assembly and transport equipment and take
precautions to prevent jamming and crushing.
Incorrect lifting of loads
Falling loads may cause serious injuries and even death.
•Stand clear of suspended loads and do not step into 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.
Protection against dangerous movements
Unexpected movements
Residual energy in the system may cause serious injuries while
working with 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,
2.12.1
2.12.2
2.12.3

Basic safety notes
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19
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 due
through technical safety measures. The protective 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 starting
up 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 to operating personnel due to the workpiece
falling down or being flung out in the event of a power failure.
In the event of a power failure, the lathe chuck's clamping force
may fail immediately and the workpiece may be released in an
uncontrolled manner. This poses a risk of death or injury to the
operating personnel and can result in serious damage to the
system.
•The machine manufacturer and the operator of the machine
must carry out and document a hazard assessment and risk
analysis to ensure that suitable measures are taken to
maintain the lathe chuck's clamping force until the machine
comes to a standstill and the workpiece can be secured (e.g.
using a crane or suitable lifting equipment).
•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.
•Perform regular maintenance.
2.12.4

Basic safety notes
20
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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.
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.