SCHUNK ROTA TP User instructions

Translation of the original manual
Pneumatic Chuck
ROTA TP / ROTA TP-LH
Assembly and operating manual
Superior Clamping and Gripping

Imprint
2 02.00|ROTA TP |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 re-
quires our written approval.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 0889118-en
Version: 02.00 |24/10/2017|en
© H.-D. SCHUNK GmbH & Co.
All rights reserved.
Dear Customer,
thank you for trusting our products and our family-owned company, the leading technol-
ogy 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
02.00|ROTA TP |en
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 ...................................................................................................... 6
2
Basic safety notes .................................................................................................... 7
2.1
Intended use............................................................................................................. 7
2.2
Not intended use...................................................................................................... 7
2.3
Constructional changes ............................................................................................ 7
2.4
Spare parts................................................................................................................ 8
2.5
Chuck jaws ................................................................................................................ 8
2.6
Environmental and operating conditions................................................................. 9
2.7
Personnel qualification............................................................................................. 9
2.8
Personal protective equipment.............................................................................. 10
2.9
Notes on safe operation......................................................................................... 10
2.10
Transport ................................................................................................................ 11
2.11
Malfunctions........................................................................................................... 11
2.12
Disposal................................................................................................................... 11
2.13
Fundamental dangers............................................................................................. 12
2.13.1
Protection during handling and assembly .................................................. 12
2.13.2
Protection during commissioning and operation ....................................... 12
2.13.3
Protection against dangerous movements................................................. 13
2.13.4
Notes on particular risks ............................................................................. 13
3
Technical data ......................................................................................................... 17
3.1
Chuck data .............................................................................................................. 17
3.2
Clamping force / speed diagrams........................................................................... 18
3.3
Calculations for clamping force and speed ............................................................ 21
3.3.1
Calculation of the required clamping force in case of a given rpm............ 21
3.3.2
Calculation example: required initial clamping force for a given speed .... 24
3.3.3
Calculation of the permissible speed in case of a given initial clamping
force ............................................................................................................ 25
3.4
Grades of Accuracy................................................................................................. 26
3.5
Permissible imbalance............................................................................................ 26
3.6
Torques per screw .................................................................................................. 26

Table of contents
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4
Function .................................................................................................................. 27
4.1
Principle of Operation ............................................................................................ 27
4.2
Functional testing ................................................................................................... 27
4.3
Air transmission system ......................................................................................... 28
4.4
Pilot controlled check valve.................................................................................... 29
4.5
Clamping or jaw actuation ..................................................................................... 30
4.6
Power Chuck with extended and standard jaw stroke (LH)................................... 31
5
Transport ................................................................................................................ 32
6
Mounting ................................................................................................................ 33
6.1
Installing and connecting ....................................................................................... 33
6.2
Inclusion.................................................................................................................. 34
6.3
Distributor ring ....................................................................................................... 35
6.3.1
Distributor ring: normal fastening .............................................................. 35
6.3.2
Stationary mounting of the distributor ring ............................................... 37
6.3.3
Mounting with bracket ............................................................................... 39
6.3.4
Mounting with 2-part clamping ring (D.R.M.B.) ......................................... 40
7
Commissioning and maintenance ............................................................................ 43
7.1
Initial operation ...................................................................................................... 43
7.2
Maintenance........................................................................................................... 44
7.3
Maintenance intervals............................................................................................ 47
7.4
Hardened Reversible Jaws and Soft Top Jaws........................................................ 47
7.5
Disassembly ............................................................................................................ 48
7.6
Assembly................................................................................................................. 49
8
Spare parts.............................................................................................................. 51
9
Assembly drawings.................................................................................................. 52
10
Translation of the original declaration of incorporation........................................... 54
11
Appendix on Declaration of Incorporation, as per 2006/42/EC, Annex II, No. 1 B ..... 55

General
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5
General
About this manual
This manual contains important information for a safe and appro-
priate use of the product.
This manual is an integral part of the product and must be kept ac-
cessible for the personnel at all times.
Before starting work, the personnel must have read and under-
stood 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.
NOTICE
Material damage!
Information about avoiding material damage.
1
1.1
1.1.1

General
6 02.00|ROTA TP |en
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 TP
125-26; 160-38; 200-52; 250-68; 315-90; 315-105; 315-115
• ROTA TP LH
350-115
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,
(2.6, Page 9)
• Observe the specified maintenance and lubrication intervals,
(7, Page 43)
Parts touching the workpiece and wear parts are not included in
the warranty.
* A cycle consists of a complete clamping process ("Open" and "Close").
Scope of delivery
1
Power lathe chucks
6
T-nuts
2
Elbow connectors
2
Straight connectors
1
Spacer ring
1
Headless screw for fastening the distributor ring
1
Angle for eye bolt
1
Eye bolt
Studs for assembling the chuck
1
Operating manual
1.1.2
1.1.3
1.2
1.3

Basic safety notes
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7
Basic safety notes
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 17).
• The product is intended for industrial and industry-oriented use.
• Appropriate use of the product includes compliance with all in-
structions in this manual.
• The maximum RPM of the chuck and the required clamping
force must be determined by the user for the respective clamp-
ing task based on the applicable standards and technical speci-
fications of the manufacturer.
(See also “Calculations for clamping force and RPM” in the
chapter “Technical data”). (3, 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.
(3, Page 17)
• 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.
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 ap-
proval of SCHUNK.
2
2.1
2.2
2.3

Basic safety notes
8 02.00|ROTA TP |en
Spare parts
Use of unauthorized spare parts
Using unauthorized spare parts can endanger personnel and dam-
age the product or cause it to malfunction.
• Use only original spare parts or spares authorized by SCHUNK.
Chuck jaws
Requirements of the chuck jaws
Stored energy can make the product unsafe and risk the danger of
serious injuries and considerable material damage.
• Only replace chuck jaws if no residual energy can be released.
• Do not use welded jaws.
• The jaws should be designed as light and as low as possible. The
clamping point must be as close as possible to the chuck face
(clamping points at a greater distance lead to greater surface
pressure in the jaw guidance and can significantly reduce the
clamping force).
• If for constructional reasons the special chuck jaws are heavier
than the top jaws assigned to the lathe chuck, greater centrifu-
gal forces must be accounted for when defining the required
clamping force and the recommended speed.
• The maximum recommended speed may only be operated in
conjunction with maximum actuating force and only with the
lathe chuck in optimal, fully functioning condition.
• After a collision, the lathe chuck and the chuck jaws must be
subjected to a crack test before being used again. Damaged
parts must be replaced with original SCHUNK spare parts.
• Screw the jaw mounting screws into the bore holes furthest
apart.
• The jaw fastening screws must be replaced if they show any
signs of wear or damage. Only use screws with a quality of 12.9.
2.4
2.5

Basic safety notes
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9
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 de-
fined application parameters, (3, Page 17).
• Make sure that the product is a sufficient size for the application.
• Only use high-quality cooling emulsions with anti-corrosive ad-
ditives during processing.
• Lubricating intervals must be adhered to (7.3, Page 47).
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 regu-
lations.
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
2.7
Trained electrician
Qualified personnel
Instructed person
Service personnel of
the manufacturer

Basic safety notes
10 02.00|ROTA TP |en
Personal protective equipment
Use of personal protective equipment
Personal protective equipment serves to protect staff against dan-
ger which may interfere with their health or safety at work.
• When working on and with the product, observe the occupa-
tional health and safety regulations and wear the required per-
sonal protective equipment.
• Observe the valid safety and accident prevention regulations.
• Wear protective gloves to guard against sharp edges and cor-
ners or rough surfaces.
• Wear heat-resistant protective gloves when handling hot sur-
faces.
• Wear protective gloves and safety goggles when handling haz-
ardous substances.
• Wear close-fitting protective clothing and also wear long hair in
a hairnet when dealing with moving components.
Notes on safe operation
Incorrect handling of the personnel
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Avoid any manner of working that may interfere with the func-
tion and operational safety of the product.
• Use the product as intended.
• Observe the safety notes and assembly instructions.
• Do not expose the product to any corrosive media. This does
not apply to products that are designed for special environ-
ments.
• Eliminate any malfunction immediately.
• Observe the care and maintenance instructions.
• Observe the current safety, accident prevention and environ-
mental protection regulations regarding the product's applica-
tion field.
2.8
2.9

Basic safety notes
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11
Transport
Handling during transport
Incorrect handling during transport may impair the product's safe-
ty 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.
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 malfunc-
tion.
• 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 en-
vironmental harm.
• Follow local regulations on dispatching product components for
recycling or proper disposal.
2.10
2.11
2.12

Basic safety notes
12 02.00|ROTA TP |en
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.
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 pre-
cautions 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.
2.13
2.13.1
2.13.2

Basic safety notes
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13
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, 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. Re-
strict unintentional access by persons to this range e.g. via a
protective cover, protective fence or photoelectric barrier. 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. Check the
function of the EMREGENCY STOP before starting up the machine
or system. If this protective equipment is not working properly,
prevent the operation of the machine.
Notes on particular risks
DANGER
Risk of fatal injury from suspended loads!
Falling loads can cause serious injuries and even death.
• Stand clear of suspended loads and do not step within their
swiveling range.
• Never move loads without supervision.
• Do not leave suspended loads unattended.
• Wear suitable protective equipment.
2.13.3
2.13.4

Basic safety notes
14 02.00|ROTA TP |en
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.

Basic safety notes
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15
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.
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 chuck jaws.
• Automatic loading is preferred.
• If manual loading is used, adjust the jaw position so that the
opening gap between the jaw and the workpiece is less than 4 mm.
• Wear protective gloves.
• Observe the safety and accident prevention regulations during
operation of the chuck, especially in connection with machin-
ing centers and other technical equipment.

Basic safety notes
16 02.00|ROTA TP |en
CAUTION
Risk of burns due to workpieces with high temperatures.
• Wear protective gloves when removing the workpieces.
• Automatic loading is preferred.
CAUTION
Risk of damages 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 the top jaws may be damaged.
• The T-nuts combine the top jaws with the base jaws and they
should never protude over the base jaws in radial direction.
• The outer diameter of the screwed top jaws must not exceed
the outer diameter of the chuck by more than 10%.
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.

Technical data
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17
Technical data
Chuck data
Size
125-26
160-38
200-52
250-68
315-90
315-105
315-115
LH 350-
115
Chuck through bore
[mm]
26
38
52
68
90
105
115
115
Max. clamping force [kN]
22
39
68
105
140
100
90
90
Max. rotation speed
[min-1]
4200
4200
3800
3500
2500
3000
2200
2200
Stroke per jaw [mm]
3.0
4.2
4.2
5.0
5.0
5.0
5.0
5.0
Serration of the jaws
[mm]
1/16"x90°
Chuck diameter [mm]
130
165
205
255
320
335
350
350
Distributor ring Ø [mm]
204
255
300
372
413
372
372
372
Centrifugal torque of
base jaw [kgm] McGB
0.012
0.033
0.061
0.118
0.186
0.200
0.209
0.275
Max. jaw eccentricity
of center of gravity in
axial direction [mm]
amax
16
24
30
40
32
32
32
32
The specified maximum speed of rotation stated only applies when
using the maximum clamping force and the SHB-type, soft, stand-
ard stepped jaws that go with the chuck.
WARNING
Risk of personal injury and property damage due to parts flying
off in the event of a screw breakage on unhardened top jaws!
• Soft standard top jaws must be hardened in the countersink region.
They should only be depth-hardened, not surface-hardened.
Ensure minimal weight for all jaws.
For unhardened top jaws or chuck jaws in special design, the permissi-
ble RPM according to VDI 3106 must be calculated for the respective
machining job. Whereby the recommended maximum speed must not
be exceeded. The values calculated must be checked by means of dy-
namic measurement using a clamping force tester.
3
3.1

Technical data
18 02.00|ROTA TP |en
Clamping force / speed diagrams
The diagrams refer to 3-jaw-chuck.
Clamping force/RPM curves have been calculated using hard jaws.
The chucks were operated with the max. permissable force and
the jaws were located exactly on line with the chuck O.D.
The chuck is in perfect condition and lubricated with SCHUNK
LINOMAX special grease.
Should one or several of the above mentioned parameters be
changed the diagrams are no longer valid.
Chuck set-up for clamping force / speed diagram
F/3
Clamping force per jaw
S
Center of gravity
rs
Center of gravity radius
a
max
Max. jaw eccentricity of cen-
ter of gravity in axial direc-
tion
F
max
Max. actuating force
Clamping force / speed diagram ROTA TP 125-26
3.2

Technical data
02.00|ROTA TP |en
19
Clamping force / speed diagram ROTA TP 160-38
Clamping force / speed diagram ROTA TP 200-52
Clamping force / speed diagram ROTA TP 250-68

Technical data
20 02.00|ROTA TP |en
Clamping force / speed diagram ROTA TP 315-90
Clamping force / speed diagram ROTA TP 315-105
Clamping force / speed diagram ROTA TP 350-115