SCHUNK SVP-4 User instructions

Translation of the original manual
Polygonal Clamping System
Clamping Device SVP-4
Assembly and Operating manual
Superior Clamping and Gripping

Imprint
2 05.00|Clamping Device SVP-4|en
Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights re-
served. Any reproduction, processing, distribution (making available to third parties), transla-
tion or other usage - even excerpts - of the manual is especially prohibited and requires our
written approval.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 0289017
Version: 05.00 |30/01/2018|en
© SCHUNK GmbH & Co. KG
All rights reserved.
Dear Customer,
thank you for trusting our products and our family-owned company, the leading technology
supplier of robots and production machines.
Our team is always available to answer any questions on this product and other solutions. Ask
us questions and challenge us. We will find a solution!
Best regards,
Your SCHUNK team
SCHUNK GmbH & Co. KG
Spann- und Greiftechnik
Bahnhofstr. 106 – 134
D-74348 Lauffen/Neckar
Tel. [phone]
Fax [phone]
[email protected]k.com
schunk.com

Table of contents
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3
Table of contents
1
General .............................................................................................................................. 5
1.1
About this manual ............................................................................................................. 5
1.1.1
Presentation of Warning Labels ........................................................................... 5
1.1.2
Applicable documents........................................................................................... 6
1.2
Warranty ............................................................................................................................ 6
1.3
Scope of delivery................................................................................................................ 6
1.4
Accessories ......................................................................................................................... 6
1.4.1
Power adapter ....................................................................................................... 7
2
Basic safety notes ............................................................................................................. 8
2.1
Intended use ...................................................................................................................... 8
2.2
Not intended use ............................................................................................................... 8
2.3
Constructional changes ..................................................................................................... 8
2.4
Spare parts ......................................................................................................................... 8
2.5
Environmental and operating conditions ........................................................................ 9
2.6
Personnel qualification...................................................................................................... 9
2.7
Transport .......................................................................................................................... 10
2.8
Disposal ............................................................................................................................ 10
2.9
Fundamental dangers...................................................................................................... 11
2.9.1
Protection during handling and assembly......................................................... 11
2.10
Notes on particular risks ................................................................................................. 12
3
Technical data.................................................................................................................. 14
3.1
Technical characteristics and functions ......................................................................... 15
3.2
Technical Data of the optional handhold scanner ........................................................ 16
3.3
Position of the safety notes and type plates ................................................................. 17
3.3.1
Type plates and safety notes.............................................................................. 17
4
Assembly and installation................................................................................................ 18
4.1
Fastening the clamping device onto a work bench....................................................... 18
4.2
Software installation instructions................................................................................... 18
4.2.1
System requirements.......................................................................................... 18
4.2.2
Program installation ............................................................................................ 18
4.3
Assembly of the length adjustment for TRIBOS SVP-4 ................................................. 24
5
Operation ........................................................................................................................ 25
5.1
Reduction insert and Toolholder.................................................................................... 25
5.2
Operating the module for stationary use and the pressure regulator ........................ 27
5.2.1
Tab "Initial Page" ................................................................................................. 29
5.2.2
Tab "Information 1" ............................................................................................ 30

Table of contents
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5.2.3
Tab "Information 2" ............................................................................................ 30
5.2.4
Tab "Progress of work cycle".............................................................................. 31
5.2.5
Handhold scanner for DataMatrix-Code ........................................................... 31
5.3
Behavior in the event of malfunctions........................................................................... 33
5.4
Error codes ....................................................................................................................... 33
5.5
Notes on clamping and unclamping............................................................................... 35
5.6
TRIBOS pressure table..................................................................................................... 37
6
Troubleshooting .............................................................................................................. 38
6.1
Tool shank cannot be inserted if pressure is built up ................................................... 38
6.2
Tool shank can only be partially inserted into the toolholder ..................................... 40
6.3
Tool cannot be removed from the toolholder .............................................................. 41
6.4
Tool shank can be inserted outside the pressure range if slight pressure is applied . 42
6.5
Tool shank can yet not be inserted at maximum pressure .......................................... 42
6.6
Torque / clamping force / holding force too low .......................................................... 43
6.7
Concentricity errors on the clamped tool...................................................................... 44
7
Maintenance.................................................................................................................... 45
8
Short manual ................................................................................................................... 46
9
Declaration of conformity................................................................................................ 47

General
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5
General
About this manual
This manual contains important information for a safe and appropri-
ate 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 understood
this operating manual. Prerequisite for safe working is the ob-
servance 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
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Applicable documents
• General terms of business*
• Catalog data sheet of the purchased product *
• Assembly and Operating manual "TRIBOS Polygonal Clamping de-
vice" (Toolholder) *
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
Warranty
The warranty is valid for 24months from the delivery date to the pro-
duction facility or 50 000 clamping operations under following condi-
tions:
• Intended use in 1-shift operation
• Recommended operating and maintenance regulations
Basically tool and machine contacting components, and wear parts
(actuation screw and seal) are not part of the warranty.
Scope of delivery
The scope of delivery includes:
• TRIBOS clamping device SVP-4 in the ordered model (230V or
110V).
• Operating manual SVP-4
• USB-A cable
Accessories
• Cylindrical brush (see catalog Tool holder systems "Accessories")
• Insert SRE (see catalog Tool holder systems "Accessories")
• Protective cover for TRIBOS clamping device SVP-4 (Id. Nr.:
9957700)
• Length adjustment LMG-M (Id No: 0201961)
• Stacker (Id No.0211768)
• Protective cover for stacker (Id No.: 0211768)
• Handheld scanner,
• Power adapter, (1.4.1, Page 7)
1.1.2
1.2
1.3
1.4

General
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7
Power adapter
• China / Australia - ID No.: 9958139
• Italy - ID no.: 9958140
• England - ID no.: 9958141
• USA / Canada - ID no.: 9958142
• Switzerland - ID no.: 9958143
• South Africa - ID no.: 9961009
• France - ID no.: 9900076
Note: Product pictures see catalog Tool holder systems "Accessories"
1.4.1

Basic safety notes
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Basic safety notes
Intended use
The clamping device has been designed to equip and replace tools in
TRIBOS toolholders.
TRIBOS toolholders are suitable to clamp rotationally symmetric tools
or work pieces. With shank tools, all shanks can be clamped accord-
ing to DIN 1835 Form A, B, E or DIN 6535 Form HA, HB, HE (shank tol-
erance h6).
The polygon clamping system (clamping device, reduction inserts and
TRIBOS toolholders) may only be used within the framework of its
defined application parameters (3, Page 14).
• The product is intended for industrial and industry-oriented use.
• Appropriate use of the product includes compliance with all in-
structions in this manual.
Not intended use
It is an not intended use of the clamping device if toolholders were
used that are not SCHUNK TRIBOS toolholders.
Constructional changes
Implementation of structural changes
By conversions, changes, and reworking, e.g. additional threads,
holes, or safety devices can impair the functioning or safety of the
product or damage it.
• Structural changes should only be made with the written approval
of SCHUNK.
Spare parts
Use of unauthorized spare parts
Using unauthorized spare parts can endanger personnel and damage
the product or cause it to malfunction.
• Use only original spare parts or spares authorized by SCHUNK.
2
2.1
2.2
2.3
2.4

Basic safety notes
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Environmental and operating conditions
The TRIBOS clamping device may be stored and operated only in
clean, dust-free and dry rooms at a temperature of +15°C till + 40°C.
The relative humidity can be between 20 - 80%.
NOTE
• Please observe the operating time of the pump in continuous
mode.
• If the on-time is not observed, the power supply unit my be over-
loaded. The clamping device switches off until the power supply
unit has cooled off again.
The on-time and the associated rest periods must be adhered to as
follows:
At ambient temperature 20°C: 100% on-time S3 / 60 Min.
At ambient temperature 40°C: 40% on-time S3 / 60 Min.
(Operating period 24 minutes, rest period 36 minutes)
Personnel qualification
The initial commissioning, maintenance, and repair of the clamping
device may only be performed by trained specialist personnel. Every
person called upon by the operator to work on the clamping device
must have read and understood the complete assembly and operat-
ing manual, especially the chapter "Basic safety notes" (2, Page 8).
This applies particularly to personnel only used occasionally at the
TRIBOS clamping device.
2.5
2.6

Basic safety notes
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Transport
Use the original SCHUNK packaging for transport. Transport the
clamping device only horizontally.
CAUTION
Risk of injury due to unsuitable means of transport!
The use of unsuitable means of transport can cause injuries.
• Use suitable means of transport.
Disposal
For proper disposal, return the clamping device to SCHUNK.
2.7
2.8

Basic safety notes
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Fundamental dangers
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 precau-
tions 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 swivel-
ing range.
• Never move loads without supervision.
• Do not leave suspended loads unattended.
2.9
2.9.1

Basic safety notes
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Notes on particular risks
DANGER
Risk of fatal injury due to electric current!
Touching live parts poses an immediate risk of fatal injury by elec-
trocution.
• Only allow a qualified electrician to perform work on electrical
components.
• Prior to commencing work on electric components, restore to a
de-energized state.
• In case of damage to the insulation, switch off the power supply
immediately and arrange for a repair.
• Keep humidity away from live parts.
WARNING
Risk of injury because of electrical energy!
Remove the energy supplies.
WARNING
Risk of injury due to lateral under high pressure escaping oil!
Lateral under high pressure escaping oil on seals or by opening the
vent screw can cause serious injuries.
• Wear protective gloves and safety goggles.
NOTICE
Material damage due to incorrect insertion of the toolholder / re-
duction insert!
The gripping force of the TRIBOS clamping device SVP-4 goes up to
800 000 N!
Incorrect insertion and positioning of the toolholder causes plas-
tically deformation and loss of function of the toolholder.
• Insert the toolholder till the stop into the reduction insert and
position correctly (via the flattened areas).
• Insert the reduction insert till the stop into the clamping device.
2.10

Basic safety notes
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13
NOTICE
Material damage due to incorrect positioning!
Incorrect Positioning of the TRIBOS toolholder in the reduction in-
sert causes plastical deformation when force is applied.
• Position toolholder over flattening in the reduction insert.
NOTICE
Material damage due to wear of the reduction insert.
Too high wear of the reduction insert causes loss of function of the
toolholder.
The wear of the reduction insert may be maximum of 0.04 mm.
• When exceeding the maximum wear replace reduction insert.
NOTICE
Material damage due to exceeding the permissible pressure!
Too high pressure causes deformation of the toolholder and loss of
function.
• Observe the pressure specifications of the toolholder.
NOTICE
Material damage due to false minimum clamping depth!
A too low minimum clamping depth causes loss of accuracy and
torque at the toolholder.
• Observe minimum clamping depth of the tool,
• See Assembly and Operating manual Toolholder.
NOTICE
Property damage due to incorrect connection!
Connecting a remote control during service and maintenance work
on the built-in pump type CPT-60/400 will damage the control
board.
• Do not connect a remote control during servicing and mainte-
nance work!

Technical data
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Technical data
Reference value
Value
Operating pressure [bar]
60 - 400
Voltage/frequency
230V AC, 50 - 60 HZ (Id-No.:
0219230)
110 V AC, 50 - 60 Hz (Id-No.:
0219231)
Power [W]
200
Drive motor
DC-Permanent Magnet Motor
Pressing time (depending on
clamping pressure and oil tem-
perature)
depending on clamping pressure
and oil temperature
(approx. 15 s at 400 bar)
Sound pressure
78 db(A) at a distance of 1m
Accelerations
< 2.5 m/s2
(weighted root mean square ac-
celeration value)
Hydraulic oil
AGIP EXIDIA HG - 68
Ambient temperature [°C]
+15 to +40
Dimensions (LxBxH) [mm]
610 x 320 x 460
Weight [kg]
40
IP protection class
2X
RS-232 interface
Pin1: +5VDC
Pin2: TXD
Pin3: RXD
PIN5: GND
3

Technical data
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15
NOTE
A voltage can be measured between the positive pole and negative
pole of the power supply unit due to the electrical AC/DC conversions
in the power supply unit. This voltage is generated by the electronic
components during the c
onversion from 230/110 V to 18 V. Howev-
er, it cannot be compensated. This can be seen, for example, when-
ever the voltage is measured with a digital multimeter between the
TRIBOS pressure body or the intermediate sleeve. This AC voltage is
indicated on an e
lectronic measurement instrument (multimeter)
when measuring against ground. Digital measurement instruments
are designed with high impedance due to their measuring function.
This also applies to the power supply unit, which allows the existing
AC voltage to be indicated by the measurement instrument. In effect,
this is a measurement error of a digital measurement instrument.
The insulation resistance of the primary side on the secondary side of
the power supply unit is 999 M
Ω. Touch current measurements re-
sult in current values within the
μA range. The power supply unit is
designed for double insulated devices (double rectangle) and does
not allow the usage of a grounding conductor.
Technical characteristics and functions
• The pump body and all the functional components are made of
tested, high-strength materials.
• The light and compact pump housing is made of insulating, shock-
resistant, glass-fiber-reinforced polyamide.
• The system´s check valve is adjusted to 630 bar.
• Standardized hydraulic connection couplings on the pump.
• The pump´s displacement volume is approx. 0.15l/min.
• The device has a high return displacement volume for fast work
cycles.
• The pump motor is actuated via PWM (soft start in order to pre-
serve the gears, motor and the power supply).
• The pressure curve can optionally be shown on the display (pres-
sure and time).
• Input and output element can be operated via (I-Drive) rotary
knob.
• The device is controlled by a microcontroller.
• The pressure is monitored by an electronical pressure sensor.
• Electronically managed service management.
• The traceability of the pressure cycles is ensured by automatic re-
cording and saving on an internal memory.
3.
1

Technical data
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• The RS-232 interface allows reading in the clamping pressures via
a Data Matrix Code (DMC) into the control unit byusing a
handheld scanner.
• The USB interface can be used to export the stored data and up-
date the software.
• Remote diagnostics of the electrical elements is possible.
• Integrated, intelligent electronic module and large LCD display.
Technical Data of the optional handhold scanner
Dimensions (LxBxH) [mm]
151 x 93 x 35
IP class housing
IP64
Lightning
Diffuse bright field, dark field
Interface
seriel RS-232
Supply voltage [VDC]
+5
Power consumption [W]
2,2
Weight [g]
130
Operating/storage humidity
5% to 95% non-condensing
Ambient temperature [°C]
+15 to +40
Material
Polycarbonat housing
3.2
Handheld scanner
CR6000

Technical data
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17
Position of the safety notes and type plates
Type plates and safety notes
230 V-Version
110 V-Version
Safety note voltage
3.3
3.3.1

Assembly and installation
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Assembly and installation
Fastening the clamping device onto a work bench
WARNING
Risk of injury due to tilting, falling of the clamping device!
Due to tilting, falling of the clamping device hands and feet may be
squeezed and jammed.
• Fix clamping device.
In the base plate of the TRIBOS clamping device SVP-4 are four bore
holes.
The SVP-4 has to be fastened to a work bench through the mounting
holes using four screws M8 and shims (preferably made of plastic to
avoid optical damages to the housing)!
Software installation instructions
System requirements
System requirements for installing the analysis software
Operating system:
Windows 2000, Windows XP, Windows
Vista, Windows 7
CPU:
Pentium 4, minimum 1.7 GHz
Working memory:
512 MB or more (1 GB or more recom-
mended)
Hard drive:
200 MB (1 GB recommended)
Screen resolution:
1024 x 768 or higher, 65.535 or more
colors
Miscellaneous
CD-ROM drive, USB 2.0 interface
Program installation
Analysis software can be downloaded as a ZIP file in the download
area of the SCHUNK homepage (Service → down loads → 3. Tool-
holding and Workholding → Tribos SVP-4) for installation on a PC.
Connect the TRIBOS clamping device to the PC via the USB interface.
Once the software has been installed, the computer automatically
detects the compact pump and the SVP-4 programs or data can be
updated. The software displays the machine status, programs and
fault logs, among other things.
4
4.1
4.2
4.2.1
4.2.2

Assembly and installation
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19
"Machine status" menu item
The pump´s serial number and warranty period are stored here
(among other information), as well as the meter reading for the
clamping procedures carried out. The service meter, pressing time,
target pressure and maximum pressure are also stored here.
4.2.2.1

Assembly and installation
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"Programs" menu item
Individual pressure values can be stored here.
1 Select program number (1).
4.2.2.2