SCHUNK ROTA THW plus Series User instructions

Translation of original operating manual
Power chuck
ROTA THWplus
Assembly and operating manual
Superior Clamping and Gripping

Imprint
2 01.00|ROTA THWplus |en
Imprint
Copyright:
This manual remains the copyrighted property ofSCHUNK GmbH & Co. KG. It issolely
supplied toour customers andoperators of our products andforms part ofthe product.
This documentation may not beduplicated ormade accessible to third parties, in particu-
lar competitive companies,
without our prior permission.
Technical changes:
We reserve the right tomake alterations for the purpose of technical improvement.
Document number: 0889020
Edition: 02.00 |24/04/2017|en
© SCHUNK GmbH & Co. KG
All rights reserved.
Dear customer,
congratulations on choosing a SCHUNK product. By choosing SCHUNK, you have opted for
the highest precision, top quality and best service.
You are going to increase the process reliability of your production and achieve best
machining results – to the customer's complete satisfaction.
SCHUNK products are inspiring.
Our detailed assembly and operation manual will support you.
Do you have further questions? You may contact us at any time – even after purchase.
Kindest Regards
Your H.-D. SCHUNK GmbH & Co.
Spanntechnik KG
Lothringer Str. 23
D-88512 Mengen
Tel. [phone]
Fax [phone]
[email protected]
www.schunk.com

Table of contents
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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......................................................................................... 11
2.4.1
Substantial 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 ..................................................................................................... 18
6
Technical data ......................................................................................................... 19
6.1
Chuck data .............................................................................................................. 19
6.2
Clamping force / speed diagrams........................................................................... 19
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............................................................................................ 27
7
Attachment and disassembly of the chuck............................................................... 28
7.1
Pre-assembly measures.......................................................................................... 28
7.2
Mounting of the Chuck to the Machine Spindle .................................................... 28
7.3
Disassembling and assembling the chuck .............................................................. 31
8
Function and handling ............................................................................................. 33
8.1
Function of the chuck ............................................................................................. 33
8.2
Handling the chuck and the base jaws................................................................... 33
8.3
Base jaw position.................................................................................................... 34
8.4
Change or supplement of jaws............................................................................... 34

Table of contents
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9
Maintenance ........................................................................................................... 36
9.1
Lubrication.............................................................................................................. 36
9.2
Maintenance intervals............................................................................................ 37
9.3
Technical condition ................................................................................................ 37
10
Disposal .................................................................................................................. 38
11
Chuck mounts and Spare parts ................................................................................ 39
11.1
Chuck mounts......................................................................................................... 39
11.2
Spare parts.............................................................................................................. 39
12
Drawings ................................................................................................................. 41
13
Translation of the original declaration of incorporation........................................... 43
14
Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B ..... 44

General
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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, espe-
cially 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
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WARNING
Warning about hand injuries
WARNING
Warning about hot surfaces
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 www.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 chuck is used to clamp workpieces on machine tools and other
suitable technical facilities, paying particular attention to the tech-
nical data specified by the manufacturer. The technical data speci-
fied 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, Page 19)
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 de-
vice or as lifting equipment.
• the product is used for unintended machines or workpieces.
• the technical data is exceeded when using the product. (6,
Page 19)
• if workpieces are not clamped properly, paying particular at-
tention 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 01.00|ROTA THWplus |en
Notes on particular risks
This product may pose a danger to persons and property if, for ex-
ample:
• 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 Di-
rective are not observed.
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 au-
tomated 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 main-
tain 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 re-
quirements of the EC Machinery Directive; specifically, they
must have effective technical measures to protect against po-
tential mechanical hazards.
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 Di-
rective; specifically, they must have effective technical
measures to protect against possible mechanical hazards.
2.3

Basic safety instructions
01.00|ROTA THWplus |en
9
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 re-
quirements of the EC Machinery Directive; specifically, they
must have effective technical measures to protect against po-
tential 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, instal-
lation or removal.
• Take special care in the danger zone when transporting, in-
stalling 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.

Basic safety instructions
10 01.00|ROTA THWplus |en
CAUTION
Danger of limbs being crushed by opening and closing of the
chuck jaws during manual loading and unloading or when re-
placing 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 machin-
ing 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
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.

Basic safety instructions
01.00|ROTA THWplus |en
11
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 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 se-
cured.
• The technical safety requirements in the respective operating
instructions must be observed exactly.
Functional test
After installation of the chuck, its function must be checked prior
to start-up.
Two important points are:
• Clamping Force! The clamping force of the chuck must be
achieved at max. operating force/pressure.
• Stroke control! The stroke of the clamping piston must allow a
safety zone at the front and rear end position. The machine
spindle may only be started when the clamping piston has
passed through the safety zone. Only limit switches that meet
the requirements for safety limit switches specified in DIN EN
60204-1 may be used.
When determining the necessary clamping force to machine a
workpiece, take the centrifugal force acting on the chuck jaws into
account (according to VDI 3106).
2.4

Basic safety instructions
12 01.00|ROTA THWplus |en
If the chuck jaws are changed, adjust the stroke control to the new
situation.
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.
Maintenance instructions
The chuck's reliability and safety can only be guaranteed if the op-
erator complies with the manufacturer's maintenance instructions.
• For lubrication, we recommend our tried and tested special
grease, LINOMAX. Unsuitable lubricants can have a negative
impact on the functioning of the chuck (clamping force, coeffi-
cient of friction, wear characteristics).
(For product information about LINOMAX, see the "Accesso-
ries" 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. "Only regular checks can guarantee op-
timal 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 ac-
counted for due to the centrifugal force acting on the chuck
jaws. The operating clamping force must in this case be deter-
mined by means of dynamic measurement.
• Move the clamping piston through to its end position several
times after 500 clamping strokes, at the latest. (This moves the

Basic safety instructions
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13
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 at-
tention to the operating system and hazard assessment.
DANGER
Possible risk of fatal injury to operating personnel due to chuck
failure if the servicing instructions for the chuck are disregard-
ed!
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 great-
er 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 instructions
14 01.00|ROTA THWplus |en
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
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 opera-
tor 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 ma-
chine 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
01.00|ROTA THWplus |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 01.00|ROTA THWplus |en
Warranty
If the product is used as intended, the warranty is valid for 24
months from the ex-works delivery date under the following con-
ditions:
• Observe the applicable documents (1.2, Page 6)
• Observe the ambient conditions and operating conditions
• Observe the maximum number of clamping cycles (6,
Page 19)
• Observe the specified maintenance and lubrication intervals
(9, Page 36)
Parts touching the workpiece and wear parts are not included in
the warranty.
3

Torques per screw
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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
4

Scope of delivery
18 01.00|ROTA THWplus |en
Scope of delivery
ROTA THW plus 165, 185, 215:
1
Power chuck
1
Set of base jaws
3
Mounting screws
1
Jaw change key
1
Operating manual
1
Short operating manual
ROTA THW plus 260, 315:
1
Power chuck
1
Set of base jaws
3
Mounting screws
1
Jaw change key
1
Operating manual
1
Short operating manual
1
Mounting wrench
5

Technical data
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19
Technical data
Chuck data
ROTA THW plus
165-43
185-52
215-66
260-81
315-104
Max. actuating force [kN]
30
36
46
65
90
Max. clamping force [kN]
45
64
82
115
160
Max. rotation speed [min-1]
6000
5700
5400
4000
3600
Stroke per jaw [mm]
5.9
6.7
7.4
8.2
8.6
Piston stroke [mm]
20
23
25
28
28
Through hole [mm]
43
52
66
81
104
Weight [kg]
14
18
26
45
70
Operating temperature
15 - 60 °C
Centrifugal torque of the base
jaw with
fine serration
McGB[kgm]
For the chuck THW plus 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 down-
load at www.de.schunk.com.
The maximum permissible speed for special machining has to be
defined by the user on the basis of the required clamping forces.
This speed must not exceed the maximum speed of the chuck.
Warranty and maximum clamping cycles
Length of warranty
24 Months
Maximum clamping cycle number
500 000 Cycles
Ensure minimal weight for all jaws.
For unhardened top jaws or chuck jaws in special design, the per-
missible RPM according to VDI 3106 must be calculated for the re-
spective machining job. Whereby the recommended maximum
speed must not be exceeded. The values calculated must be
checked by means of dynamic measurement using a clamping
force tester.
Clamping force / speed diagrams
The diagrams refer to 3-jaw-chuck.
Clamping force/rpm curves have been determined by using hard
jaws. In the determination process, the maximum actuating force
6
6.1
6.2

Technical data
20 01.00|ROTA THWplus |en
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 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
F/3
Clamping force per jaw
Fmax
Max. actuating force
rs
Center of gravity radius
S
Center of gravity
Clamping force / speed diagrams ROTA THW plus 165-43
Clamping force / speed diagrams ROTA THW plus 185-52