SCHUNK SWS-001 User manual

Original Manual
Quick-Change System
SWS-001
Installation and Operating Manual
Superior Clamping and Gripping

Imprint
2 01.00|SWS-001 |en
Imprint
Copyright:
This manual remains the copyrighted property of SCHUNK GmbH & Co. KG. It is solely
supplied to our customers and operators of our products and forms part of the product.
This documentation may not be duplicated or made accessible to third parties, in particu-
lar competitive companies,
without our prior permission.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 0389698
Edition: 01.00 |07/07/2015|en
© SCHUNK GmbH & Co. KG
All rights reserved.
Dear customer,
congratulations on choosing a SCHUNK product. By choosing SCHUNK, you have opted for
the highest precision, top quality and best service.
You are going to increase the process reliability of your production and achieve best
machining results – to the customer's complete satisfaction.
SCHUNK products are inspiring.
Our detailed assembly and operation manual will support you.
Do you have further questions? You may contact us at any time – even after purchase.
Kindest Regards
Yours SCHUNK GmbH & Co. KG
Spann- und Greiftechnik
Bahnhofstr. 106 – 134
D-74348 Lauffen/Neckar
Tel. [phone]
Fax [phone]
[email protected]
www.schunk.com

Table of contents
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3
Table of contents
1 About this manual .................................................................................................... 5
1.1 Warnings................................................................................................................... 5
1.2 Applicable documents .............................................................................................. 5
2 Basic safety notes..................................................................................................... 6
2.1 Intended use............................................................................................................. 6
2.2 Not intended use ...................................................................................................... 6
2.3 Ambient conditions and operating conditions......................................................... 6
2.4 Product safety........................................................................................................... 7
2.4.1 Protective equipment ................................................................................... 7
2.4.2 Constructional changes, attachments, or modifications.............................. 7
2.5 Personnel qualification............................................................................................. 7
2.6 Using personal protective equipment...................................................................... 7
2.7 Notes on particular risks........................................................................................... 8
3 Warranty................................................................................................................. 10
4 Technical Data......................................................................................................... 11
5 Product Overview.................................................................................................... 12
5.1 SWK Quick-Change Head........................................................................................ 13
5.2 Quick-Change Adapter SWA................................................................................... 14
6 Assembly................................................................................................................. 15
6.1 SWK Quick-Change Head Assembly ....................................................................... 15
6.2 SWA Quick-Change Adapter Assembly .................................................................. 16
6.3 Lock/Unlock Pneumatic Connections and Valving................................................. 17
6.3.1 Air Requirements ........................................................................................ 17
6.3.2 Valve Requirements and Connections........................................................ 18
6.3.3 Manual Uncouple SWK and SWA................................................................ 19
6.4 Wiring and Electrical Connections for Optional Modules...................................... 20
7 Operational Considerations ..................................................................................... 22
7.1 Coupling Sequence ................................................................................................. 22
7.2 Uncoupling Sequence............................................................................................. 23
7.3 Tool Stand Design ................................................................................................... 24
7.3.1 Tool Locating Features ................................................................................ 26
7.3.2 Tool Stands Sensors .................................................................................... 26
8 Maintenance .......................................................................................................... 27
8.1 Preventive Maintenance ........................................................................................ 27
8.2 Cleaning and Lubrication of the Locking Mechanism ............................................ 29

Table of contents
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8.3 Rubber O-ring Inspection and Replacement.......................................................... 30
8.4 Spring Pin Replacement ......................................................................................... 31
9 Troubleshooting ..................................................................................................... 33
10 Recommended Spare Parts...................................................................................... 34
11 Drawings ................................................................................................................. 35
11.1 Tool Changer........................................................................................................... 35
11.2 E04 Electrical Module............................................................................................. 38
12 Translation of original declaration of incorporation................................................. 39

About this manual
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5
About this manual
This instruction is an integral part of the product and contains im-
portant information for a safe and proper assembly, commission-
ing, operation, maintenance and help for easier trouble shooting.
Before using the product, read and note the instructions, especial-
ly the chapter "Basic safety notes".
Warnings
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Danger for persons.
Non-compliance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons.
Ignoring a safety note like this 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.
Applicable documents
•General terms of business
•Catalog data sheet of the purchased product
•Assembly and Operating manuals of the accessories
The documents listed here, can be downloaded on our homepage
www.schunk.com
1
1.1
1.2

Basic safety notes
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Basic safety notes
Intended use
The produkt (SWS Quick-Change systems consisting of SWK Quick-
Change Head and SWA Quick-Change Adapter) was designed for
quick changing parts and automation components at a robot in
context of the technical data.
The product is intended for installation in a machine/system. The
requirements of the applicable guidelines must be observed and
complied with.
The product may be used only in the context of its defined applica-
tion parameters (4, Page 11).
The product is designed for industrial use.
To use this unit as intended, it is also essential to observe the
technical data and installation and operation notes in this manual
and to comply with the maintenance intervals.
Not intended use
Use which is not specified as an intended use is for instance when
the product is for example used as a pressing tool, stamping tool,
lifting tool, guide for tools, cutting tool, tensioning mean, boring
tool.
Ambient conditions and operating conditions
•Make sure that the product has a sufficient size for the applica-
tion.
•Make sure that the environment is free from splash water and
vapors as well as from abrasion or processing dust. Exceptions
are products that are designed especially for contaminated en-
vironments.
2
2.1
2.2
2.3

Basic safety notes
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7
Product safety
Dangers arise from the product, if:
•the product is not used in accordance with its intended pur-
pose.
•the product is not installed or maintained properly.
•the safety and installation notes are not observed.
Avoid any manner of working that may interfere with the function
and operational safety of the product.
Wear protective equipment.
NOTE
More information are contained in the relevant chapters.
Protective equipment
Provide protective equipment per EC Machinery Directive.
Constructional changes, attachments, or modifications
Additional drill holes, threads, or attachments that are not offered
as accessories by SCHUNK may be attached only with permission
of SCHUNK.
Personnel qualification
The assembly, initial commissioning, maintenance, and repair of
the product may be performed only by trained specialist person-
nel. Every person called upon by the operator to work on the
product must have read and understood the complete assembly
and operating manual, especially the chapter "Basic safety notes"
(2, Page 6). This applies particularly to personnel only used oc-
casionally, such as maintenance personnel.
Using personal protective equipment
When using this product, you must comply with the relevant
health and safety at work rules and you must use the required
personal safety equipment (minimum: category 2).
2.4
2.4.1
2.4.2
2.5
2.6

Basic safety notes
8 01.00|SWS-001 |en
Notes on particular risks
Generally valid:
•Remove the energy supplies before installation, modification,
maintenance, or adjustment work.
•Make sure that no residual energy remains in the system.
•Do not move parts by hand when the energy supply is con-
nected.
•Do not reach into the open mechanism or the movement area
of the unit.
•Perform maintenance, modifications, and additions outside the
danger zone.
•Secure the product during all operations against uncontrolled
activation.
•Take a precautionary approach by maintenance and disassem-
bly.
•Only specially trained staff should disassemble the product.
WARNING
Risk of injury from objects falling and being ejected
•The danger zone must be surrounded by a safety fence during
operation.
WARNING
Risk of injury when the machine/system moves unexpectedly.
WARNING
Remove all temporary protective materials (caps, plugs, tape,
etc.) on the locking face of Tool Changer and modules prior to
operation.
Failure to do so will result in damage to Tool Changers, modules,
and end-of-arm tooling and could cause injury to personnel.
2.7

Basic safety notes
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9
WARNING
Injury or equipment damage can occur with power or air on.
•Do not perform maintenance or repair on Tool Changer or
modules with power or air on.
•Turn off power and air before performing maintenance or re-
pair on Tool Changer or modules.
WARNING
Failure to keep area clear will result in damage to Tool Changer,
modules, or end-of-arm tooling and could cause injury to per-
sonnel.
•During operation, the area between the quick-change master
SWK and quick-change tool SWA must be kept clear.
WARNING
Using the Tool Changer in applications other than intended will
result in damage to Tool Changer, modules, or end-of-arm tool-
ing and could cause injury to personnel.
•The Tool Changer is only to be used for intended applications
and applications approved by the manufacturer.
CAUTION
The quick-change master SWK locking mechanism must not be
actuated without being mounted to the robot interface plate.
Damage to the Cover Plate and O-ring may result.
•Always attach the quick-change master SWK to the robot in-
terface plate prior to attempting any operations.

Warranty
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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 un-
der the following conditions:
•Intended use in 1-shift operation
•Observe the mandatory maintenance and lubrication intervals
•Observe the environmental and operating conditions
Parts touching the work piece and wear parts are not part of the
warranty.
3

Technical Data
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11
Technical Data
Specifications such the as payload, moment capacity, repeatability,
and weight for model can found in the product catalog and on our
website.
Drawings also can found in the product catalog and on our web-
site. 2-D and 3-D models are also available on our website.
Contact SCHUNK for specific information and drawings regarding
your installation. We encourage you to use our service department
to review your designs and answer your questions.
SWK Quick-Change Head and SWA Quick-Change Adapter
Suggested Payload Limit 1.4 kg The mass attached to the Tool Changer.
Operating Pressure Range 4.5 - 5.5 bar Locking mechanism supply pressure oper-
ating range. Supply to be clean, dry, and
filtered.
Coupling Force @ 5 bar 170 N Axial holding force.
Static Moment Capacity: (x, y) 0.98 Nm
Maximum recommended working load for
optimum performance of the Tool Chan-
ger.
(z) 1.15 Nm Torsion
Positional Repeatability 0.0102 mm Repeatability tested at rated load at one
million cycles.
Weight 0.056 kg
0.038 kg
SWK
SWA
Max. Recommended distance
between SWK and SWA
1.0 mm No-Touch
TM
locking technology allows the
SWK and SWA to lock with separation
when coupling.
4

Product Overview
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Product Overview
The Tool Changer consists of two primary parts: The quick-change
head SWK and the quick-change adapter SWA. The quick-change
head is attached to a robot while end-effectors such as grippers,
material handlers, etc. are attached to one or more quick-change
adapter SWA.
The locking mechanism consists of a cam, alignment posts, and
chrome-steel balls. Tapered pins located on the SWK mate with
alignment locking posts in the SWA to ensure repeatable align-
ment during the coupling process. Extreme pressure grease is ap-
plied to the posts on the SWA to enhance performance and max-
imize the life of the locking mechanism.
The Tool Changer has four M5 integrated pneumatic only pass-
through ports and is equipped with M5 elbow fittings for 6mm di-
ameter tubing.
Both the SWK and the SWA have two mounting pockets that sup-
port optional modules for support of various utility pass-through
connections. An electrical module E04 module provides four signal
connections, providing the capability of up to eight signal connec-
tions to the Tool Changer.
5

Product Overview
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13
SWK Quick-Change Head
The SWK quick-change head includes an anodized aluminum body,
hardened stainless-steel locking mechanism and hardened steel
alignment pins. The SWK is attached to the robot using four
mounting holes for M3 flathead screws. The four M3 x 14 socket
flathead cap screws are included with the Tool Changer.
The SWK is equipped with four M5 ports for pass-through air only
and two M3 threaded ports for Lock and Unlock air. The four O-
rings seal the pneumatic connection between the SWK and SWA.
The Lock and Unlock air ports are equipped with M3 adjustable el-
bow fittings for 4mm diameter tubing. The SWK has two mounting
pockets that support optional modules for electrical or other pass-
through connections.
quick-change head SWK
5.1

Product Overview
14 01.00|SWS-001 |en
Quick-Change Adapter SWA
The SWA quick-change adapter is made of an anodized aluminum
body. Harden stainless-steel alignment locking posts provide relia-
ble and repeatable coupling of the SWA. An end-effector can be
mounted with mounting holes on the bottom of the SWA.
The SWA is equipped with four M5 x 0.8 ports for pass through air
only and is equipped with four M5 elbow fittings for 6mm diame-
ter tubing. The SWA has two mounting pockets that support op-
tional modules for electrical or other pass-through connections.
Grooves are provided for interfacing with an optional tool stand.
A dowel pin on the SWA aligns with a pocket in the master plate to
ensure proper coupling orientation.
quick-change adapter SWA
5.2

Assembly
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15
Assembly
SWK Quick-Change Head Assembly
Typical Installation
1 Clean the debris from the robot wrist and SWK mounting sur-
face prior to installation.
2 Apply Loctite 222® to the four M3 x 14 socket flat head cap
screws supplied.
3 Assemble SWK to robot wrist, align the four mounting holes in
the SWK to the holes in the robot wrist and attach with the
four M3 x 14 socket flat head cap screws. Torque to 0.8 Nm.
4 Pneumatic lines and electrical cables can be installed after the
SWK is attached. The pneumatic lines and electrical cables
must be bundled, and strain-relieved in a manner that allows
for freedom of movement during operation (6.4, Page 20).
CAUTION
Failure of some critical electrical and/or pneumatic lines to func-
tion properly may result in injury to personnel and equipment.
•All pneumatic fittings and tubing must be capable of with-
standing the repetitive motions of the application without fail-
ing.
•The routing of electrical and pneumatic lines must minimize
the possibility of stress pullout, kinking, rupture, etc.
6
6.1

Assembly
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SWA Quick-Change Adapter Assembly
1 Clean the debris from the end-effector and SWA mounting
surfaces prior to installation.
2 The end-effector is attached to the SWA using the four M3 x
0.5 mounting holes with mounting fasteners supplied by the
user. Removable thread locker (Loctite 222®) or fasteners with
pre-applied adhesive should be used for all mounting fasten-
ers.
NOTICE
Fasteners that extend beyond the mating surface will create a
gap between the SWK and SWA and not allow the locking me-
chanism to fully engage.
This could cause damage to the equipment.
•Make sure the mounting fasteners are flush or below the mat-
ing surface of the SWA.
•Do not use mounting fastener that extend beyond the SWA
mating surface.
3 Pneumatic lines and electrical cables are attached, bundled,
and must be strain-relieved in a manner that allows for free-
dom of movement during operation. For electrical cabling in-
structions: (6.4, Page 20).
6.2

Assembly
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17
Lock/Unlock Pneumatic Connections and Valving
CAUTION
Failure to use a 4-way valve and properly vent to atmosphere
may cause the locking mechanism to operate incorrectly and
may cause the Tool Changer to not lock or unlock as expected.
This could result in damage to the product, attached tooling, or
personnel.
Air must be supplied to the “Lock” air port on the SWK to move
the internal piston, which moves the cam, and forces the locking
balls outward. The locking balls move outward until they contact
the alignment locking post on the mating SWA. This will rigidly en-
gage the SWK and SWA providing high load capacity and positional
accuracy. In a fail-safe condition the cam profile prevents the SWA
from becoming disengaged in the event that there is a loss of air in
the locked state. To unlock the SWA from the SWK, lock air must
be vented and air supplied to the “Unlock” air port on the SWK.
Air Requirements
For proper operation of the Tool Changer, the SWK must be supplied
with clean, dry, non-lubricated air supplied between 4.5 – 5.5 bar.
NOTICE
Possible damage to the locking mechanism could occur.
•Do not use the Tool Changer in the fail-safe condition for ex-
tended periods of time.
•Do not transport the Tool Changer in the fail-safe condition.
6.3
6.3.1

Assembly
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Valve Requirements and Connections
Pneumatic Connections
As with all pneumatic piston arrangements, smooth operation re-
quires proper porting of the supplied and vented air. It is recom-
mended that a single 4-way valve be used to actuate the locking
mechanism in the SWK. The valve may be of either 4-port or 5-port
configuration. It is imperative that when air is supplied to the Lock
or Unlock Port on the SWK, that the opposite port be vented to
atmosphere (i.e., when air is supplied to the Lock Port, the Unlock
Port must be open to the atmosphere.) Failure to vent trapped air
or vacuum on the inactive port will negate the locking force of the
Tool Changer mechanism. The Lock and Unlock Ports are threaded
for M3 connections.
NOTICE
The Tool Changer locking mechanism will not function properly
when connected to a single 3-way valve as this type of valve is
incapable of venting trapped air pressure from within the Tool
Changer.
Connect the Lock and Unlock supply air to a single 4-way valve
with either 4 or 5 port configuration.
6.3.2

Assembly
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19
Manual Uncouple SWK and SWA
It is possible to manually uncouple the SWK and SWA if air is com-
pletely lost. This is not standard procedure and should only be use
when no other alternative is available.
NOTICE
If the tool is attached to the master it must be secured in the
tool stand or in a location where the tool weight is supported
before manually uncoupling. Use of manually uncoupling is re-
stricted to contingency situations.
Using the manual override will release the tool and may cause
damage to equipment.
•Do not manually uncouple the SWK and SWA if the tool is not
secured.
Manual Uncouple Master and Tool Plates
1 Remove the Unlock air tubing.
2 Unscrew the M3 elbow fitting from the SWK.
3 Using a 1.5mm Ball end Allen wrench, insert it through the Unlock
air port and push the locking piston to the unlocked position.
4 Separate the SWA from the SWK, supporting the SWA and tool
if attached.
6.3.3

Assembly
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Wiring and Electrical Connections for Optional Modules
Removable Optional Module
1 Both the SWK and SWA have removable optional modules for
electrical pass-through connections. The electrical connections
have to be soldered to the connection pins.
2 Remove the M2 screw from the optional module using a
1.5mm Allen wrench.
3 Remove the optional module from the SWK or SWA.
Soldering the Electrical Connections
4 Strip the wire the same length as the notch in the pin.
5 Slide a piece of heat shrink tubing over the wire.
6 Solder the wire to the pin.
6.4