SCHUNK ROTA THWvario User instructions

Translation of Original Operating Manual
Jaw quick-change with arbor or
collet chuck adapter
ROTA THW vario
Assembly and Operating Manual
Superior Clamping and Gripping

Imprint
2 01.00|ROTA THW vario |en-US
Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights
reserved.
Technical changes:
We reserve the right to make technical improvements.
Document number: 889033
Version: 01.00 |12/10/2020|en-US
Dear Customer
Dear Customer,
Thank you for putting your trust in our products and our family-owned company, the
leading technology supplier of robots and production machines.
Our team is always available to answer any questions on this product and other solutions.
We look forward to your challenging questions. We will find a solution!
Best regards,
Your SCHUNK team
H.-D. SCHUNK GmbH & Co.
Spanntechnik KG
Lothringer Str. 23
D-88512 Mengen
Tel. [phone]
Fax [phone]
[email protected]
schunk.com
Customer Management
Tel. [phone]
Fax [phone]
custo[email protected]
Please read the operating manual in full and keep it close to the product.

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3
1
General information ................................................................................................. 6
1.1
Safety notes .............................................................................................................. 6
1.2
Applicable documents.............................................................................................. 7
2
Basic safety notes..................................................................................................... 8
2.1
Appropriate use........................................................................................................ 8
2.2
Inappropriate use ..................................................................................................... 9
2.3
Notes on particular risks........................................................................................... 9
2.4
Notes on safe operation......................................................................................... 12
2.4.1
Substantial modifications............................................................................ 15
2.5
Personnel qualification........................................................................................... 15
2.6
Organizational measures........................................................................................ 16
2.7
The use of personal protective equipment............................................................ 16
3
Warranty................................................................................................................. 17
4
Scope of delivery ..................................................................................................... 17
4.1
ROTA THW vario 215-62......................................................................................... 17
4.2
ROTA THW vario D.................................................................................................. 17
4.3
ROTA THW vario F .................................................................................................. 17
5
Screw torques ......................................................................................................... 18
6
Technical data ......................................................................................................... 19
6.1
Chuck data .............................................................................................................. 19
6.2
Clamping force RPM diagrams ............................................................................... 20
6.3
Calculating the clamping force and RPM ............................................................... 21
6.3.1
Calculation of the required clamping force at a specified speed of rotation
..................................................................................................................... 21
6.3.2
Calculation example: required initial clamping force for a given RPM ...... 23
6.3.3
Calculation of the permissible RPM in case of a given initial clamping force
..................................................................................................................... 25
6.4
Accuracy classes ..................................................................................................... 26
6.5
Permitted imbalance .............................................................................................. 26
7
Product description ................................................................................................. 27
7.1
Segmented mandrel ROTA THW vario D................................................................ 27
7.2
Collet chuck ROTA THW vario F.............................................................................. 28
8
Assembly................................................................................................................. 30
8.1
Mounting the lathe chuck onto the machine spindle............................................ 30
8.2
Segmented mandrel ROTA THW vario D................................................................ 33
8.2.1
Mounting the segmented mandrel on the power chuck ........................... 33

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8.2.2
Changing the segmented clamping sleeve ................................................. 36
8.2.3
Changing the stops...................................................................................... 36
8.2.4
Disassembling and assembling the segmented mandrel ........................... 37
8.3
Collet chuck ROTA THW vario F.............................................................................. 38
8.3.1
Mounting the segmented mandrel on the power chuck ........................... 38
8.3.2
Replacing vario F clamping head ................................................................ 41
8.3.3
Back stops.................................................................................................... 42
8.3.4
Disassembling and assembling the collet chuck......................................... 43
9
Function .................................................................................................................. 44
9.1
Function and handling............................................................................................ 44
9.2
Base jaw position.................................................................................................... 45
9.3
Replacement or enlargement of jaws .................................................................... 45
9.4
Center sleeve range................................................................................................ 45
9.5
Disassembling and assembling the chuck .............................................................. 47
10
Troubleshooting ...................................................................................................... 49
10.1
Segmented mandrel ROTA THW vario D................................................................ 49
10.2
Collet chuck ROTA THW vario F.............................................................................. 50
11
Maintenance ........................................................................................................... 51
11.1
General information ............................................................................................... 51
11.2
Cleaning .................................................................................................................. 52
11.3
Lubrication.............................................................................................................. 52
11.4
Maintenance plan................................................................................................... 53
11.5
Technical condition ................................................................................................ 55
11.6
Changing the stepped jaws .................................................................................... 55
12
Spare parts .............................................................................................................. 56
12.1
ROTA THW vario 215-62......................................................................................... 56
12.1.1
Versions and spare parts, segmented mandrel ROTA THW vario D........... 58
12.1.2
Design and spare parts, collet chucks ROTA THW vario F .......................... 59
13
Assembly drawing ................................................................................................... 60
13.1
ROTA THW vario 215-62......................................................................................... 60
13.1.1
Segmented mandrel ROTA THW vario D .................................................... 62
13.1.2
Collet chuck ROTA THW vario F .................................................................. 63
14
Accessories.............................................................................................................. 64
14.1
Segmented clamping sleeve ROTA THW vario D ................................................... 64
14.1.1
SAD segmented clamping sleeve ................................................................ 64
14.1.2
Back stops.................................................................................................... 67
14.1.3
Mandrex ...................................................................................................... 68

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14.2
Collet chuck ROTA THW vario F.............................................................................. 70
14.2.1
HSW clamping heads for self-turning ......................................................... 70
14.2.2
Changing device .......................................................................................... 73
14.2.3
Jaw turning rings ......................................................................................... 75
15
Declaration of Incorporation ................................................................................... 77

General information
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General information
This operating manual is an integral part of the product and
contains important information on safe and proper assembly,
start-up, operation, care, maintenance and disposal. This manual
must be kept in the immediate vicinity of the product, accessible
to all users.
Pay particular attention to the chapter "Basic safety notes" prior to
using the product described in this manual. (2, Page 8)
If transferring the product to a third party, be sure to include this
operating manual.
The illustrations in this operating manual are intended to provide a
basic understanding of the product and may deviate from the
actual version.
We accept no liability for damage resulting from failure to
observe and comply with this operating manual.
Safety notes
To make risks clear,the following signal words and symbols are
used for safety notes.
DANGER
Danger to individuals!
Ignoring a safety note such as this will certainly lead to
irreversible injury and even death.
WARNING
Danger to individuals!
Ignoring a safety note such as this can lead to irreversible injury
and even death.
CAUTION
Danger to individuals!
Non-observance can cause minor injuries.
1
1.1

General information
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NOTICE
Material damage!
Information about avoiding material damage.
WARNING
Warning about hand injuries
WARNING
Warning about hot surfaces
Applicable documents
• General terms and conditions *
• Catalog data sheet for purchased product *
• Calculation of the jaw centrifugal forces, in the chapter
"Technology" of the lathe chuck catalog *
The documents indicated with an asterisk (*) can be downloaded
from schunk.com.
1.2

Basic safety notes
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Basic safety notes
The improper handling, assembly and maintenance of this product
may result in risk to persons and equipment if this manual is not
observed.
• Read through the manual carefully prior to assembly and
installation.
• Report any failures and damage to the manual lathe chuck
immediately following detection and repair it without delay to
keep the extent of the damage minimal and prevent
compromising the safety of the chuck. Only use original
SCHUNK spare parts when replacing damaged parts.
• Keep this manual accessible to all users at all times.
• If transferring the product to a third party, be sure to include
this manual.
Appropriate use
This product is intended for clamping workpieces on lathes and
other suitable machine tools.
• The product may only be used within the scope of its technical
data, (6, Page 19).
• 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 speed and the necessary clamping force must be
determined by the operator for each clamping task in
accordance with the valid standards or technical specifications
of the manufacturer.
(Also see "Calculation for clamping force and speed of rotation"
in chapter "Technical data".) (6, Page 19)
2
2.1

Basic safety notes
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Inappropriate use
The manual lathe chuck is not being used as intended if, for
example:
• workpieces are not properly clamped.
• safety regulations are disregarded and persons are working at
the manual lathe chuck (for example, to machine clamped
workpieces) without additional protective equipment.
• the technical data is exceeded when using the manual lathe
chuck.
• the manual lathe chuck is used with machines/systems or
workpieces that are not designed to be used with it.
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 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.
2.2
2.3

Basic safety notes
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DANGER
Risk of fatal injury to operating personnel from clothing or hair
being caught on the lathe chuck and being dragged into the
machine!
Loose clothing or long hair may become caught on projecting
parts of the lathe chuck and be drawn into the machine.
• The machines and equipment must fulfill the minimum
requirements of the EC Machinery Directive; specifically, they
must have effective technical measures to protect against
potential mechanical hazards.
• Always wear tight-fitting clothing and a hairnet when working
on the machine and the lathe chuck.
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 lathe chuck.
• Note the relevant load securing regulations for working safely
with cranes, ground conveyors, lifting gear and load-handling
equipment.
CAUTION
Risk of slipping or falling if the chuck's operational environment
is not clean (e.g. contaminated with cooling lubricants or oil).
• Ensure that the working environment is clean before starting
assembly and installation work.
• Wear suitable safety boots.
• Follow the safety and accident prevention regulations when
operating the chuck, especially when working with machine
tools and other technical equipment.

Basic safety notes
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CAUTION
Risk of limbs being crushed when opening and closing the chuck
jaws during manual loading or unloading or when exchanging
moving parts.
• Do not reach between the chuck jaws.
• Wear protective gloves.
• Follow the safety and accident prevention regulations when
operating the chuck, especially when working with machine
tools and other technical equipment.
CAUTION
Risk of burns due to workpieces with high temperatures!
• Wear protective gloves when removing the workpieces.
• Automatic loading is preferred.
CAUTION
Risk of damage due to incorrect choice of clamping position for
chuck jaws on workpiece.
If an incorrect clamping position is chosen for the chuck jaws on
workpiece, the base and top jaws may break.
• Make sure that the workpiece is clamped concentrically.
• If the chuck has a quick-change jaw system, the top jaws must
not protrude beyond the base jaws in the radial direction.
Exception: The supporting jaw variant 3 protrudes beyond the
chuck base jaw due to its design. In this case, the T-nuts
always need to be completely inserted into the groove of the
chuck base jaw.

Basic safety notes
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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 RPM.
• Wear hearing protection.
NOTICE
If the lathe chuck is overlubricated, malfunctions (difficulty of
movement) may occur when changing the jaws or release
mechanism.
• Disassemble the chuck and remove excess grease.
• For lubrication, refer to the chapter "Maintenance".
Notes on safe operation
• Do not start the machine spindle until the workpiece is
clamped and the spanner wrench has been removed from the
clamping device.
Functional test
After installation of the clamping device, its function must be
checked prior to commissioning:
• 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.
2.4

Basic safety notes
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Maintenance instructions
The reliability of the clamping device can only be guaranteed if the
maintenance instructions in the operating manual are precisely
followed. Please observe the following in particular:
• For lubrication of the clamping device, we recommend using
our proven high-performance grease LINOMAX. Unsuitable
lubricants can have a negative impact on the functioning of the
clamping device (clamping force, coefficient of friction, wear
behavior).
• All surfaces to be lubricated must be reached during
lubrication. (The tight fittings of the components require a high
injecting pressure. Therefore use a high-pressure grease press.)
• 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 (e.g. GFT 270, ID 0890013) 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 chuck as used for the current clamping situation. If top jaws
with clamping steps are used, clamping must be done 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. In this case the
value of the operating clamping force should be measured
dynamically.
• It is useful to travel the clamping piston through to its end
position several times after 500 clamping strokes, at the latest.
(Removed lubricant will be pushed back to the pressure
surfaces again so that the clamping force is retained for longer).

Basic safety notes
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Safety during servicing
• Avoid any unsafe manner of working.
• Only operate the clamping device when all protective
equipment has been fitted and is in full working order.
• Check the clamping device at least once per shift for externally
visible damage and faults.
• Immediately report any changes including changed operational
behavior to the competent units/persons; if necessary,
immediately shut down and secure the machine on which the
clamping device is mounted.
• Do not start up the machine that the clamping device is
mounted on again until the malfunction has been eliminated.
Use of special chuck jaws
When using customized 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 front. (Clamping points at a greater distance cause higher
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 wider
and/or higher 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.
• Fasten the mounting screws so as to achieve the largest
possible effectiveness.
• If the clamping device 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.
• Renew 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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Substantial modifications
No substantial modifications may be made to the clamping device.
If the operator carries out a substantial modification to the
clamping device, the product no longer conforms to the EC
Machinery Directive 2006/42/EC!
Personnel qualification
Only specialist personnel may install or remove, commission or
maintain the clamping device. Specialist personnel are persons
who by their technical training, experience and knowledge are
capable of assessing the work to be performed and recognizing
potential dangers, and are thus able to take appropriate
countermeasures.
If need be, take advantage of the manufacturer's training courses.
Every person called upon by the operator to work on the clamping
device must have read and understood the complete assembly
and operating manual, especially Chapter 2 "Basic safety notes"
(2, Page 8).
The responsibility for operation, maintenance and repair must be
clearly specified.
Only allow personnel who are considered experts in the context of
the safety regulations to carry out maintenance and repair work in
the safety-relevant areas of the clamping device.
Specify the operator's responsibility, also with regard to safe
behavior, and authorize the operator to reject instructions from
third parties which breach safety regulations.
During training and instruction, personnel must only be permitted
to work with the clamping device if continuously supervised by a
specialist.
2.4.1
2.5

Basic safety notes
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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 clamping
device.
Monitoring 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 clamping device is
mounted are clearly legible and are observed.
Faults
If a fault occurs on the clamping device and this fault endangers
safety or if a problem is suspected due to production
characteristics, the machine where the manual lathe chuck is
mounted must be immediately stopped and remain shut down
until the fault has been located and remedied. Only allow
specialists to remedy malfunctions.
Spare parts
Only use original SCHUNK spare parts.
Environmental regulations
The applicable environmental regulations must be observed for all
maintenance and repair work.
The use of petroleum ether is prohibited. It is extremely
flammable, can build up an electrostatic charge and can form an
explosive gas air mixture. When selecting lubricants and
lubricating oils, pay attention to environmental compatibility,
health risks, disposal regulations and to local options for disposal
according to regulations.
The use of personal protective equipment
When using this product, you must conform with the relevant
heath & safety at work rules and you must use the required
personal protective equipment.
• Use safety gloves, safety shoes and safety glasses.
• Maintain safe distances.
2.6
2.7

Scope of delivery
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Warranty
If the product is used as intended, the warranty is valid for 24
months from the date of delivery from the production facility
under the following conditions:
• Refer to the applicable documents, (1.2, Page 7)
• Observance of the ambient conditions and operating conditions
• Observe the maximum number of clamping cycles - approx.
500,000 cycles
• Observance of the specified maintenance and lubrication
intervals (10, Page 49)
Parts touching the workpiece and wearing parts are not part of the
warranty.
Scope of delivery
ROTA THW vario 215-62
1
Flange
1
Bayonet adapter
1
Set of protective jaws
Screws
ROTA THW vario D
Segmented mandrel
Screws
ROTA THW vario F
Collet chuck (without clamping head)
Screws
3
4
4.1
4.2
4.3

Screw torques
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Screw torques
Tightening torques for mounting screws for clamping the chuck
(screw quality 10.9)
Screw size
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
Tightening torques
MA(Nm)
13
28
50
88
120
160
200
290
400
500
1050
1500
Tightening torques for mounting top jaws onto the lathe chuck
(screw quality 12.9)
Screw size
M8
M10
M12
M16
M20
M24
Maximum admissible torque
(Nm)
25
60
80
100
180
230
5

Technical data
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Technical data
Chuck data
ROTA THW vario
Max. actuating force [kN]
46
Max. clamping force [kN]
82
Max. speed of rotation [RPM]
5400
Stroke per jaw [mm]
7.4
Piston stroke [mm]
25
Chuck bore [mm]
62
Weight [kg]
25
Centrifugal torque of the base
jaw McGB [kgm]
For the THW vario chuck, it is necessary to
specifically determine this data. Examples of
calculation can be found in the "Special chuck jaw
design/technology" chapter in our current chuck jaw
catalog.
Max. jaw eccentricity of center
of gravity in axial direction
amax [mm]
The specified recommended speed of rotation only applies when
using the maximum clamping force and the SHF-type, hardened,
standard stepped jaws that go with the chuck.
If unhardened top jaws or special chuck jaws are used, ensure that
the weight is as low as possible.
For soft top jaws or special chuck jaws, the speed of rotation
permitted for the cutting task must be calculated in accordance
with VDI 3106 whereby the maximum recommended speed may
not be exceeded. The calculated values must be checked by
dynamic measurement. Function monitoring (piston movement
and actuating pressure) must be performed in accordance with the
guidelines of the Berufsgenossenschaft (employer's liability
insurance association).
WARNING
There is a risk of crushing when loading by hand!
If manual loading is used, set up the jaw position so that there is
no risk of injury when inserting the parts. The maximum opening
gap must be less than 8 mm when the workpiece is in contact
with one of the jaws.
6
6.1

Technical data
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Clamping force RPM diagrams
The diagrams relate to a 3-jaw chuck.
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 special grease.
If one or more of these prerequisites is modified, the graphs will
no longer be valid.
Chuck setup for clamping force/RPM diagram
FspB
Jaw clamping force
S
Center of gravity
rs
Center of gravity radius
a
max
Max. jaw eccentricity of center
of gravity in axial direction
Fmax
Max. actuating force
Clamping force RPM diagram for ROTA THW
6.2