SCHUNK SMPL User instructions

Translation of the original manual
Assembly- and Operating Manual
SMPL with ISST, SFM and ISBL

Imprint
2 01 | SMPL with ISST, SFM and ISBL | Assembly- and Operating Manual | en-US |
1512656
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 alterations for the purpose of
technical improvement.
Document number:
1512656
Version:
01 | 28.04.2022 | en
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
Customer Management
Tel. [phone]
Fax [phone]
[email protected]
Please read the operating instructions in full and keep them
close to the product.

Table of contents
Table of contents
1 General.................................................................................................................... 5
1.1 About these instructions ...................................................................................... 5
1.2 Depiction of Warnings.......................................................................................... 5
1.3 Associated Documentation .................................................................................. 5
1.4 Warranty .............................................................................................................. 6
2 Fundamental Safety Instructions.............................................................................. 7
2.1 Intended Use ........................................................................................................ 7
2.2 Non-Intended Use ................................................................................................ 7
2.3 Danger Zone ......................................................................................................... 7
2.4 Environmental and Operating Conditions ............................................................ 8
2.5 Personnel Qualifications....................................................................................... 8
2.6 Personal Protective Equipment............................................................................ 9
2.7 Technical Condition .............................................................................................. 9
2.8 Responsibility of the Operating Company..........................................................10
2.9 Country-Specific Regulations for the Operating Company................................. 10
3 Product Description ................................................................................................11
3.1 Description of the Steel-Plate Clamping System with Suction Cups and FlexMat...
11
3.2 Variants and Type Keys / Technical Data............................................................ 14
3.3 Properties of the Clamping System .................................................................... 17
3.4 Calculating the Clamping Force .......................................................................... 19
4 Transport and Storage ............................................................................................20
4.1 Checking the Delivery......................................................................................... 20
4.2 Storage ............................................................................................................... 20
5 Installation .............................................................................................................21
5.1 Installation Instructions...................................................................................... 21
6 Start of Operations .................................................................................................22
6.1 Personnel Qualification ...................................................................................... 22
6.2 Before Initial Start of Operations ....................................................................... 22
7 Operation ...............................................................................................................24
7.1 Preparations ....................................................................................................... 24
7.2 Processing........................................................................................................... 25
8 Troubleshooting .....................................................................................................27
8.1 Safety.................................................................................................................. 27
8.2 Faults, Causes, Solutions when Working with Steel-Plate and Suction Cups .....27
8.3 Faults, Causes, Solutions when Working with Steel-Plate and FlexMat............. 33
301 | SMPL with ISST, SFM and ISBL | Assembly- and Operating Manual | en-US |
1512656

Table of contents
9 Maintenance ..........................................................................................................39
9.1 Safety.................................................................................................................. 39
9.2 Maintenance and Cleaning of the Steel-Plate ISST-SMPL .................................. 39
9.3 Maintenance and Cleaning of the Suction Cups ISBL .........................................39
9.4 Maintenance and Cleaning of the FlexMat SFM................................................. 39
9.5 Accessories, Spare Parts and Wearing Parts ...................................................... 40
10 Disposing of the Product.........................................................................................41
4 01 | SMPL with ISST, SFM and ISBL | Assembly- and Operating Manual | en-US |
1512656

General
1 General
1.1 About these instructions
These instructions contain important information for safe and
proper use of the product.
These instructions are an integral component of the product and
must be stored in such a way that personnel can access them at
any time. Before beginning any work, personnel must read these
instructions and understand them. The prerequisite for safe work
is complying with all of the safety information in these
instructions. Illustrations in these instructions serve purposes of
basic understanding and may vary from the actual version.
In addition to these instructions, the documents listed under
chapter 1.3, “Associated Documentation”, apply.
1.2 Depiction of Warnings
To elucidate hazards, the warnings use the following signal words
and symbols.
DANGER
Hazards for people!
Non-compliance will certainly lead to irreversible injuries, up to
and including death.
WARNING
Hazards for people!
Non-compliance can lead to irreversible injuries, up to and
including death.
CAUTION
Hazards for people!
Non-compliance can lead to minor injuries.
NOTICE
Damage to property!
Information about avoiding damage to property.
1.3 Associated Documentation
• General Terms and Conditions *
• Catalog data sheet of the product purchased *
• Assembly and operating instructions for accessories *
• Assembly instructions for the Matrix-Plate *
501 | SMPL with ISST, SFM and ISBL | Assembly- and Operating Manual | en-US |
1512656

General
6 01 | SMPL with ISST, SFM and ISBL | Assembly- and Operating Manual | en-US |
1512656
The documents marked with an asterisk (*) can be downloaded on
schunk.com.
1.4 Warranty
The warranty is 12 months as of the ex-works delivery date in the
event of proper use under the following conditions:
• Compliance with the environmental and operating conditions (>
see chapter 2.4).
• Compliance with the prescribed maintenance intervals (> see
chapter 10).
Parts that come into contact with workpieces and wearing parts
are not covered by the warranty.

Fundamental Safety Instructions
2 Fundamental Safety Instructions
2.1 Intended Use
The Matrix-Plate (SMPL) forms a system with its accessories Steel-
Plate (ISST), FlexMat (SFM) and suction cups (ISBL) and is intended
exclusively for clamping workpieces on a CNC machining center. A
workpiece is secured to the clamping system by applying a vacuum
and can then be machined from five sides.
The clamping system must be used with an operating vacuum of
-750mbar (guide value) Pneumatic Connection.
The product is intended for industrial use.
Intended use includes observing the technical data and the
installation and operating instructions in this manual.
2.2 Non-Intended Use
SCHUNK accepts no liability for damages caused by the use of the
clamping system for purposes other than those described under
“Intended Use”.
Non-intended use includes the following:
• In potentially explosive atmospheres
• Unauthorized refits
2.3 Danger Zone
Hazards arise when the clamping system is clamped to a machine
table and a workpiece is being processed.
Due to the function of the clamping system in connection with the
machine table and the tool in use, constant vibrations occur. As a
result, mechanical and fluid connections may loosen or even
become disconnected.
Measures for avoiding accidents:
• Ensure that no persons are present in the danger zone.
• Ensure that no persons enter the danger zone during operation.
CAUTION
Vacuum close to the eye
Severe eye injury!
•Wear eye protection.
•Do not look into vacuum openings such as suction lines and
hoses.
701 | SMPL with ISST, SFM and ISBL | Assembly- and Operating Manual | en-US |
1512656

Fundamental Safety Instructions
8 01 | SMPL with ISST, SFM and ISBL | Assembly- and Operating Manual | en-US |
1512656
CAUTION
Noise pollution caused by exhaust air or leakage during
operation
Hearing damage
•In the event of leakage, check connections and lines and
remedy leakages
•Wear ear protectors.
2.4 Environmental and Operating Conditions
The clamping system must not be operated under the following
conditions:
• In potentially explosive atmospheres
• Use in an environment with highly acidic or alkaline media
The clamping system is installed with a separate vacuum supply on
a machine tool or machining center.
NOTE
To ensure that the workpiece is securely held on the clamping
plate, you must check the vacuum level directly on the clamping
device.
DANGER
Flying workpiece due to insufficient clamping force during
machining, resulting from insufficient vacuum or excessive
machining forces.
Risk of injury or death due to flying workpiece
•Monitor the vacuum value as close to the clamping location as
possible.
•Wear personal protective clothing.
• If in doubt, consult SCHUNK before the start of operations.
2.5 Personnel Qualifications
Unqualified personnel cannot recognize dangers and are therefore
exposed to higher risks!
The operating company must ensure the following points:
• The personnel must be commissioned for the activities
described in these operating instructions.
• The staff must be at least 18 years of age and physically and
mentally capable.
• The product must be operated only by persons who have
undergone appropriate training.

Fundamental Safety Instructions
• Personnel must receive regular safety briefings (frequency as
per country-specific regulations).
• Installation, maintenance, and repairs must be carried out only
by specialists from SCHUNK GmbH & Co. KG or by persons who
can prove that they have undergone appropriate training at
SCHUNK.
The following target groups are addressed in these operating
instructions:
• Persons trained in operating and cleaning the product.
• Specialists in mechanics who are responsible for
troubleshooting and maintaining the product.
The operator of the system must comply with country-specific
regulations regarding the age, ability and training of the personnel.
Valid for Germany:
A qualified employee is defined as an employee who has received
technical training and has the knowledge and experience –
including knowledge of applicable regulations – necessary to
enable him or her to recognize possible dangers and implement
the appropriate safety measures while performing tasks. Qualified
personnel must observe the pertinent industry-specific rules and
regulations.
2.6 Personal Protective Equipment
To avoid injury, always use appropriate protective equipment that
is suitable for the situation.
Observe the notes on protective equipment in the corresponding
chapters and any country-specific regulations.
2.7 Technical Condition
If the product is operated while in a defective state, safety and
function will be impaired.
• The product must only be operated when in perfect technical
working order – i.e., in its original condition.
• Follow the maintenance plan Maintenance.
• Use only original spare parts from SCHUNK.
• If the operating behavior should change, check the product for
faults. Rectify faults immediately.
• Unauthorized conversion or modification of the product is
prohibited.
• Safety features must not be disabled under any circumstances.
SCHUNK assumes no liability for consequences of modifications
over which it has no control.
901 | SMPL with ISST, SFM and ISBL | Assembly- and Operating Manual | en-US |
1512656

Fundamental Safety Instructions
10 01 | SMPL with ISST, SFM and ISBL | Assembly- and Operating Manual | en-US |
1512656
2.8 Responsibility of the Operating Company
The operating company is obligated to perform a risk assessment
for the environmental conditions at the installation location.
The operating company is responsible for mounting the clamping
system on the machine table. It is therefore responsible for
ensuring that the clamping system is correctly mechanically
attached, that the pneumatic connections are in good condition
and that the pneumatic monitoring (gauge) is working.
The operating company is also responsible for third parties in the
working area of the machining center and the clamping system.
The operating company must ensure that they have the
appropriate qualifications and skills.
• Ensure that the clamping system cannot be started up by
unauthorized persons.
• Ensure that the machining center cannot be operated during
maintenance or repair work on the clamping system.
• Clearly define the responsibilities for the various activities
performed with the gripper.
• Ensure that these responsibilities are observed.
2.9 Country-Specific Regulations for the Operating Company
1. Observe the country-specific regulations regarding accident
prevention, safety testing and environmental protection.
2. The product is used in combination with a machine tool/
machining center.
Ensure that the appropriate country-specific regulations and
safety regulations are adhered to.

Product Description
3 Product Description
3.1 Description of the Steel-Plate Clamping System with Suction
Cups and FlexMat
The products Steel-Plate ISST, FlexMat SFM and suction cups ISBL
are designed as accessories for the Schunk Matrix-Plate SMPL and
expand its range of applications.
Matrix-Plate
Workpiece clamped onto Matrix-Plate via Steel-Plate
and suction cups
Workpiece clamped directly
onto Matrix-Plate
Workpiece clamped onto Matrix-Plate via Steel-Plate and
FlexMat
Workpiece Clamped Directly onto Matrix-Plate
This option is described in the Assembly instructions for the
Matrix-Plate.
Steel-Plate ISST
The Steel-Plate ISST is a flat, 3mm magnetic steel plate featuring
vacuum holes with a diameter of 7mm distributed evenly across
the plate as well as countersunk mounting holes. It serves as a
base plate for the use of suction cups ISBL or the FlexMat SFM and
is primarily screwed onto a Matrix-Plate of the corresponding size.
The Steel-Plate is not suitable for direct clamping of workpieces,
which requires either suction cups ISBL or a FlexMat SFM.
Workpiece Clamped onto Matrix-Plate via Steel-Plate and
Suction Cups
The vacuum is supplied to the system via the grid system of the
Matrix-Plate (1) Other Applicable Documents. The attached
clamping equipment is supplied with a vacuum through the
vacuum holes on the Steel-Plate. The tightness of the system is
ensured by the sealing gasket, which is inserted into the grid of the
1101 | SMPL with ISST, SFM and ISBL | Assembly- and Operating Manual | en-US |
1512656

Product Description
12 01 | SMPL with ISST, SFM and ISBL | Assembly- and Operating Manual | en-US |
1512656
Matrix-Plate before attaching the Steel-Plate. Since the vacuum
chamber limited by the sealing gasket can also enclose vacuum
holes in the Steel-Plate that are not required, they must be sealed
vacuum-tight with sealing magnets ISMST where necessary.
The suction cups ISBL (3) are equipped with a permanent magnet
on the underside as well as separate suction areas facing down to
the Steel-Plate and upward to the workpiece. Individual vacuum
blocks can be positioned over a vacuum hole of the Steel-Plate (2)
at any position and in any number. The vacuum hole must be
completely enclosed by the sealing lip of the suction cups. The
vacuum is supplied through these holes. The permanent magnet
pre-fastens the Suction Cups to the Steel-Plate. Once the
workpiece has been applied and the vacuum is activated, the
Suction Cups are fixed to the Steel-Plate and the workpiece to the
Suction Cups.
Any uncovered holes of the Steel-Plate must be sealed with the
supplied sealing magnets.
1
2
4
33
5
6
1 Matrix-Plate 2 Steel-Plate
3 Suction cup 4 Workpiece
5 Sealing magnets 6 Sealing gasket

Product Description
Workpiece Clamped onto Matrix-Plate via Steel-Plate and
FlexMat
Alternatively, the elastomer mat FlexMat SFM (3) can be used on
the Steel-Plate (2). It is placed on a free Steel-Plate without sealing
magnets. Nubs (3.1) are attached to the underside which engage
with the corresponding holes of the Steel-Plate (see dimensions L2
and B2 of the parameter drawing). The vacuum is routed upward
into the 32 separate suction cells via the grid that is also located
on the underside. This allows workpieces (4) with different
geometries to be secured. The FlexMat is designed as a wearing
part and can be cut to create recesses or outer contours.
Alternatively, it can also be reused multiple times, provided that it
remains undamaged.
Uncovered holes on the Steel-Plate must be sealed with sealing
magnets (5) Accessories.
1
2
3
4
6
5
3.1
1 Matrix-Plate 2 Steel-Plate
3 FlexMat 3.1 FlexMat,
positioning nubs
4 Workpiece 5 Sealing magnets
6 Sealing gasket
1301 | SMPL with ISST, SFM and ISBL | Assembly- and Operating Manual | en-US |
1512656

Product Description
14 01 | SMPL with ISST, SFM and ISBL | Assembly- and Operating Manual | en-US |
1512656
3.2 Variants and Type Keys / Technical Data
Steel-Plate ISST
The Steel-Plate ISST is available in six versions, three for use with
suction cups (ISST-SMPL) and three for use with the FlexMat (ISST-
SMPL SFM).
As well as the plate itself, the scope of delivery also includes
countersunk screws, the sealing gasket and sealing magnets (ISST-
SMPL only).
The version is indicated in the item designation. The item
designation is composed as follows:
Part
number
Brief
designation
L L1 L2 B B1 B2 Included
in the
sealing
magnets
1487787 ISST-SMPL
300x200x3
300 75 200 200 69.5 100 X
1487783 ISST-SMPL
400x300x3
400 69.5 100 300 75 200 X
1487784 ISST-SMPL
600x400x3
600 75 200 400 69.5 100 X
1487785 ISST-SMPL
300x200x3 SFM
300 75 200 200 69.5 100 ---
1487786 ISST-SMPL
400x300x3 SFM
400 69.5 100 300 75 200 ---
1487789 ISST-SMPL
600x400x3 SFM
600 75 200 400 69.5 100 ---
All specifications are in mm.

Product Description
FlexMat SFM
The FlexMat SFM is available in one version.
Part number Abbreviated
designation
L B
1378520 SFM 298.5 x 198.5 298.5 198.5
All specifications are in mm.
1501 | SMPL with ISST, SFM and ISBL | Assembly- and Operating Manual | en-US |
1512656

Product Description
16 01 | SMPL with ISST, SFM and ISBL | Assembly- and Operating Manual | en-US |
1512656
Suction Cups ISBL
The suction cups ISBL are available in six versions.
The version is indicated in the item designation. The item
designation is composed as follows:
Part number Abbreviated
designation
L L1 B B1 H H1
0425136 ISBL 80x80x38 80 80 80 80 38 ---
0425137 ISBL 80x40x38 80 80 40 80 38 13
0425138 ISBL 80x28x38 80 80 28 80 38 13
0425139 ISBL 80x80x97 80 80 80 80 97 ---
0425140 ISBL 80x40x97 80 80 40 80 97 47
0425141 ISBL 80x28x97 80 80 28 80 97 47
All specifications are in mm.

Product Description
3.3 Properties of the Clamping System
Basic Considerations, Processing Strategy
Note that not all processing can be carried out with vacuum
clamping systems.
However, vacuum clamping systems offer additional possibilities
for the user and expand the processing range of the respective
machines. The clamping systems are particularly suited for
processing flat and thin-walled workpieces with corresponding
clamping surfaces.
Other advantages include gentle and warp-free clamping,
suitability for non-ferromagnetic materials as well as the possibility
of five-side processing, formatting of the outer contour and
creation of recesses. However, the clamping forces with vacuum
are usually lower than, for example, the clamping forces of
mechanical clamping equipment Calculating the Clamping Force.
Therefore, selecting the correct clamping equipment is crucial for
ensuring efficient and reliable processing.
Direct Clamping on the Matrix-Plate
This variant offers the highest precision, robustness and stiffness.
In addition, the clamping surface can be optimally adapted to the
workpiece by inserting the sealing gasket, thereby increasing the
clamping force.
If recesses have to be created, the edges of the workpiece need to
be processed or spacing is required between the workpiece and
Matrix-Plate, the FlexMat SFM or the suction cups ISBL can be
used.
Clamping with the FlexMat
The FlexMat allows for the creation of recesses and edge
processing of the workpiece since it is possible to cut up to 1mm
into the FlexMat. The FlexMat is made from an elastomer material
and therefore generally offers higher shear force absorption than
when clamping directly onto the Matrix-Plate. The individual
suction cells also make it possible to clamp workpieces with
different contours without the need for any adjustments. If a
suction cell is completely covered by the workpiece, it is evacuated
and thus creates a clamping force matching the area of a suction
cell. As a result, the effective suction area tends to be lower than
with direct clamping onto the Matrix-Plate.
The following points must be taken into account:
• Suction cells are only evacuated when they are completely
covered.
• If the workpiece is drilled in the area of the suction cell or if its
sealing lip is damaged, the vacuum collapses suddenly, thereby
eliminating the clamping force of this cell.
1701 | SMPL with ISST, SFM and ISBL | Assembly- and Operating Manual | en-US |
1512656

Product Description
18 01 | SMPL with ISST, SFM and ISBL | Assembly- and Operating Manual | en-US |
1512656
• Even with a large workpiece area, it is possible that only a few
suction cells are completely covered, meaning that the actual
clamping force is significantly lower than expected.
• During processing, temperatures can develop on the workpiece
and on the tool, which can exceed the melting point of the
elastomer of the FlexMat.
Therefore, the FlexMat should only be used with an
appropriate coolant supply.
Clamping with the Suction Cup
The suction cups also allow lateral processing, e.g. with a swiveled
unit. As the workpiece is raised off the Matrix-Plate, this creates
space for the unit or tool. As a result, the friction pad of the
suction cups ISBL tends to produce higher frictional forces than
directly on the Matrix-Plate.
Note that a single suction cup ISBL has only a relatively small
clamping surface. This results in low clamping forces, which can be
compensated by a large number of suction cups.
The suction cups 80x80 have the same clamping surface for the
workpiece and the Steel-Plate. The additional holding force
produced by the permanent magnet facing the Steel-Plate is
negligible.
The machining force acts on the workpiece. The height of the
suction cups results in a lever effect that is strongest at the
connection point between the suction cup and the Steel-Plate. This
lever effect must be given particular consideration in the case of
high suction cups (97mm) and when suction cups are only used in
a line.
Processing on only one suction cup is not permitted. At least two
suction cups must always be used, but ideally as many suction
cups as possible.

Product Description
3.4 Calculating the Clamping Force
To establish the specific machining process, it is essential that:
• The workpiece is securely clamped at all times.
• The clamping forces exceed the arising machining forces
(including a safety buffer).
For this purpose, the theoretical machining forces must be
determined. The calculation of the clamping forces is explained in
detail in the Assembly Instructions for SMPL (see Other Applicable
Documents: Assembly Instructions for Matrix-Plate). Note also the
following regarding the suction cups ISBL and the FlexMat SFM.
Due to the elastomer contact surface, both the FlexMat and the
suction cups offer a higher theoretical friction coefficient on most
workpieces and therefore tend to have higher clamping forces.
However, the friction coefficient should be checked based on the
practical application.
The aforementioned clamping equipment offers the following
clamping surface:
• ISBL 80x80: 6400mm²
• ISBL 80x40: 3200mm²
• ISBL 80x28: 2240mm²
• FlexMat, whole suction cell: 1430mm²
• FlexMat, half suction cell on the outer edge: 530mm²
This can be used to calculate the theoretical clamping force
(according to the Assembly Instructions for SMPL).
When using vacuum clamping systems such as the Matrix-Plate,
suction cups and FlexMat, no generally applicable clamping forces
can be specified. Actual values can deviate from theoretical values,
and vary greatly from application to application.
As a rule, the process parameters must always be selected such
that the machining forces are kept as low as possible and safe
processing with a sufficient buffer is always possible. This should
always be carefully observed and monitored, particularly during
retraction, but also during processing.
1901 | SMPL with ISST, SFM and ISBL | Assembly- and Operating Manual | en-US |
1512656

Transport and Storage
20 01 | SMPL with ISST, SFM and ISBL | Assembly- and Operating Manual | en-US |
1512656
4 Transport and Storage
4.1 Checking the Delivery
The scope of delivery can be found in the order confirmation. The
weights and dimensions are listed in the delivery notes.
1. Compare the entire delivery with the supplied delivery notes
to make sure nothing is missing.
2. Damage caused by defective packaging or occurring in transit
must be reported immediately to the carrier and SCHUNK
GmbH & Co. KG.
The ISST-SMPL scope of delivery includes the following:
• Steel-Plate
• Sealing magnets (one per vacuum hole)
• Sealing gasket and screws
The ISST-SMPL SFM scope of delivery includes the following:
• Steel-Plate
• Sealing gasket and screws
4.2 Storage
If the products are not used immediately, we recommend storing
them horizontally in the transport packaging.
The following is generally recommended:
• Always store the Steel-Plate flat or horizontally, otherwise it
may deform.
• Store the FlexMat flat/horizontally. Do not bend or stress,
otherwise it may deform and become unusable.
The FlexMat, the seals and friction pads of the suction cups and
the sealing gaskets are made from elastomers.
Elastomer parts must be stored in a cool place (0°C to +15°C,
max. 25°C) that is dark, dry, low in dust and offers protection from
the weather, ozone and drafts. They must also be free of tension.
The effects of ozone, light (particularly UV), heat, oxygen and
humidity as well as mechanical influences can reduce the service
life of Suction Cups.
We therefore recommend storage in closed containers. Under
ideal storage conditions, the maximum storage period is 2 to 4
years (storage of elastomer parts in accordance with DIN7716).