SCHUNK SWS-001 User manual

Original Manual
Installation and Operating Manual
SWS-001
Quick-Change

Imprint
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02.00 | SWS-001 | Installation and Operating Manual | en | 389698
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
requires our written approval.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 389698
Version: 02.00|07/06/2019|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]
schunk.com

Table of contents
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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 Ambient conditions and operating conditions .....................................................7
2.4 Product safety ...................................................................................................... 7
2.4.1 Protective equipment...............................................................................8
2.4.2 Constructional changes, attachments, or modifications ..........................8
2.5 Personnel qualification......................................................................................... 8
2.6 Using personal protective equipment .................................................................. 8
2.7 Notes on particular risks....................................................................................... 8
3 Technical Data ........................................................................................................11
4 Product Overview ...................................................................................................12
4.1 SWK Quick-Change Head.................................................................................... 12
4.2 Quick-Change Adapter SWA ............................................................................... 13
5 Assembly ................................................................................................................14
5.1 SWK Quick-Change Head Assembly.................................................................... 14
5.2 SWA Quick-Change Adapter Assembly............................................................... 15
5.3 Lock/Unlock Pneumatic Connections and Valving ............................................. 16
5.3.1 Air Requirements....................................................................................16
5.3.2 Valve Requirements and Connections....................................................17
5.3.3 Manual Uncouple SWK and SWA............................................................18
5.4 Wiring and Electrical Connections for Optional Modules ..................................19
6 Operational Considerations ....................................................................................20
6.1 Coupling Sequence ............................................................................................. 20
6.2 Uncoupling Sequence......................................................................................... 21
6.3 Fail-Safe Operation............................................................................................. 22
6.4 Tool Stand Design ............................................................................................... 23
6.4.1 Tool Locating Features............................................................................25
6.4.2 Tool Stands Sensors................................................................................25
7 Troubleshooting .....................................................................................................26

Table of contents
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8 Maintenance ..........................................................................................................27
8.1 Preventive Maintenance .................................................................................... 28
8.2 Cleaning and Lubrication of the Locking Mechanism ......................................... 30
8.3 Rubber O-ring Inspection and Replacement ......................................................32
8.4 Spring Pin Replacement...................................................................................... 33
9 Recommended Spare Parts .....................................................................................35
10 Drawings.................................................................................................................36
10.1 Tool Changer ...................................................................................................... 36
10.2 E04 Electrical Module......................................................................................... 39
11 Translation of original declaration of incorporation ................................................40

General
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1 General
1.1 About this manual
This manual contains important information for a safe and
appropriate use of the product.
This manual is an integral part of the product and must be kept
accessible 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 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
Applicable documents [}6] are applicable.
1.1.1 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.

General
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1.1.2 Applicable documents
• General terms of business*
• Catalog data sheet of the purchased product *
• Assembly and operating manuals of the accessories *
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
1.1.3 Sizes
This operating manual applies to the following sizes:
• SWS-001 001
1.2 Warranty
If the product is used as intended, the warranty is valid for 24
months from the ex-works delivery date under the following
conditions:
• Observe the maximum service life. Technical Data [}11]
• Observe the ambient conditions and operating conditions,
Ambient conditions and operating conditions [}7]
• Observe the specified maintenance and lubrication intervals,
Maintenance [}28]
Parts touching the workpiece and wear parts are not included in
the warranty.
1.3 Scope of delivery
The scope of delivery includes
• Quick-Change SWS-001 in the version ordered, containing the
following components:
– SWK quick-change head
– SWA quick-change adapter
• Accessory pack
Content of the accessory pack:
4x Screw DIN 7984 M3 x 14 mm

Basic safety notes
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2 Basic safety notes
2.1 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 or
for mounting to a robot. The applicable guidelines must be
observed and complied with.
• When implementing and operating components in safety-
related parts of the control systems, the basic safety principles
in accordance with DIN EN ISO 13849-2 apply. The proven safety
principles in accordance with DIN EN ISO 13849-2 also apply to
categories 1, 2, 3 and 4.
• Make sure that the product is only used within its defined
application parameters.
• The product is intended for industrial use.
2.2 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.
2.3 Ambient conditions and operating conditions
• Make sure that the product is a sufficient size for the
application.
• 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
environments.
2.4 Product safety
Dangers arise from the product, if:
• the product is not used in accordance with its intended
purpose.
• 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 is contained in the relevant chapters.

Basic safety notes
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2.4.1 Protective equipment
Provide protective equipment per EC Machinery Directive.
2.4.2 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.
2.5 Personnel qualification
The assembly, initial commissioning, maintenance, and repair of
the product may be performed only by trained specialist
personnel. 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" Basic safety notes [}7]. This applies particularly to
personnel only used occasionally, such as maintenance personnel.
2.6 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).
2.7 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
connected.
• Do not reach into the open mechanism or the movement area
of the module.
• Perform maintenance, modifications, and additions outside of
the danger zone.
• For all work, secure the unit against accidental operation.
• Take a precautionary approach by maintenance and
disassembly.
• Only specially trained staff should disassemble the module.

Basic safety notes
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CAUTION
Possible risk of injury due to electrostatic energy!
Components or assembly groups may become electrostatically
charged. When touched, the electrostatic discharge can trigger a
startle response, which can result in injuries.
•The operator must ensure that all components and assembly
groups are included in the local equipotential bonding in line
with the applicable regulations.
NOTE
• The equipotential bonding must be installed by a specialist
electrician in line with the applicable regulations, paying
particular attention to the actual conditions in the working
environment.
• The effectiveness of the equipotential bonding must be verified
by a specialist electrician through regular safety measurements.
WARNING
Risk of injury from objects falling and being ejected!
Falling and ejected objects during operation can lead to serious
injury or death.
•Take appropriate protective measures to secure the danger
zone.
WARNING
Risk of injury due to unexpected movement of the machine/
system!
•Switch off the energy supply.
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.

Basic safety notes
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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
repair 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
personnel.
•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
tooling 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
interface plate prior to attempting any operations.

Technical Data
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3 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
website. 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 - 6.9 bar Locking mechanism supply pressure
operating range. Supply to be clean,
dry, and filtered.
Coupling Force @ 5 bar 170 N Axial holding force.
Static Moment Capacity: (x, y) 2.8 Nm Maximum recommended working
load for optimum performance of the
Tool Changer.
(z) 3.45 Nm Torsion
Positional Repeatability 0.01 mm Repeatability tested at rated load at
one million cycles.
Weight 0.03 kg
0.02 kg
SWK
SWA
Max. Recommended distance
between SWK and SWA
1.0 mm No-TouchTM locking technology
allows the SWK and SWA to lock with
separation when coupling.

Product Overview
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4 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
alignment during the coupling process. Extreme pressure grease is
applied to the posts on the SWA to enhance performance and
maximize 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
diameter tubing.
Both the SWK and the SWA have two mounting pockets that
support 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 connections to the Tool Changer.
4.1 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
elbow fittings for 4mm diameter tubing. The SWK has two
mounting pockets that support optional modules for electrical or
other pass-through connections.

Product Overview
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M3 Adjustable Elbow Fittings
for 4mm Dia. Tubing (2x)
Optional Modules
(2x)
Pneumatic M5
Pass-through
Ports (4x)
M5 Elbow Fittings
for 6 mm Dia.
Tubing
(4x)
Alignment Pins
(2x)
Coupling Orientation
Pocket
Visual Alignment
Indicators (4x)
M3
Lock Air Port O-ring Pneumatic
Seals (4x)
Locking Mechanism
Mounting holes (4x)
M3 x 14 Socket
Screws (4x)
Optional Modules
E04-A Electrical
Modules Shown
quick-change head SWK
4.2 Quick-Change Adapter SWA
The SWA quick-change adapter is made of an anodized aluminum
body. Harden stainless-steel alignment locking posts provide
reliable 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
diameter tubing. The SWA has two mounting pockets that support
optional 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.
3 mm H8 Through
Mounting Holes (2x)
M3 Through
Mounting Holes
Optional Modules
E04-M Electrical
Modules Shown
Coupling Orientation
Dowel Pin
Interface for
Optional Tool Stand
Alignment
Locking Posts (2x)
Pneumatic M5
Pass-through
Ports (4x)
M5 Elbow Fittings
for 6 mm Dia.
Tubing (4x)
Interface for
Optional Tool Stand
Visual Alignment
Indicators (4x)
Optional
Modules (2x)
quick-change adapter SWA

Assembly
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5 Assembly
5.1 SWK Quick-Change Head Assembly
M3 x 14 screws
(supplied by SCHUNK)
Mounting Fasteners
(supplied by user)
End-Effector
SWK-001
SWA-001
Adapter Plate if Required
(supplied by user)
SWA
Mating Surface
Mounting Fasteners
Must Not Protude
Above Mating Surface
Typical Installation
ØClean the debris from the robot wrist and SWK mounting
surface prior to installation.
ØApply Loctite 222® to the four M3 x 14 socket flat head cap
screws supplied.
ØAssemble 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.
ØPneumatic 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 Wiring and Electrical
Connections for Optional Modules [}19].
CAUTION
Failure of some critical electrical and/or pneumatic lines to
function properly may result in injury to personnel and
equipment.
•All pneumatic fittings and tubing must be capable of
withstanding the repetitive motions of the application without
failing.
•The routing of electrical and pneumatic lines must minimize
the possibility of stress pullout, kinking, rupture, etc.

Assembly
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5.2 SWA Quick-Change Adapter Assembly
ØClean the debris from the end-effector and SWA mounting
surfaces prior to installation.
ØThe 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 fasteners.
NOTICE
Fasteners that extend beyond the mating surface will create a
gap between the SWK and SWA and not allow the locking
mechanism to fully engage.
This could cause damage to the equipment.
•Make sure the mounting fasteners are flush or below the
mating surface of the SWA.
•Do not use mounting fastener that extend beyond the SWA
mating surface.
ØPneumatic lines and electrical cables are attached, bundled, and
must be strain-relieved in a manner that allows for freedom of
movement during operation. For electrical cabling instructions:
Wiring and Electrical Connections for Optional Modules [}19].

Assembly
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5.3 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
engage 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.
5.3.1 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
extended periods of time.
•Do not transport the Tool Changer in the fail-safe condition.

Assembly
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5.3.2 Valve Requirements and Connections
Lock Port
Unlock Port 4-way Valve
Supply Clean, Dry,
Non-Iubricated Air
4.5 - 5.5 bar
Exhaust
Open to Atmosphere
Pneumatic Connections
As with all pneumatic piston arrangements, smooth operation
requires proper porting of the supplied and vented air. It is
recommended 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.

Assembly
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5.3.3 Manual Uncouple SWK and SWA
It is possible to manually uncouple the SWK and SWA if air is
completely 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
restricted 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.
1.5mm Ball End
Allen Wrench
Remove M3 Elbow Fitting
Support Tool Plate and Tool if attached
Remove
Pneumatic
Tubing
Manual Uncouple Master and Tool Plates
ØRemove the Unlock air tubing.
ØUnscrew the M3 elbow fitting from the SWK.
ØUsing a 1.5mm Ball end Allen wrench, insert it through the
Unlock air port and push the locking piston to the unlocked
position.
ØSeparate the SWA from the SWK, supporting the SWA and tool
if attached.

Assembly
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5.4 Wiring and Electrical Connections for Optional Modules
SWK
Optional Module
E04-K Shown
M2 screw
1.5 mm Allen Wrench
Optional Module
E04-A Shown
SWA
Removable Optional Module
ØBoth the SWK and SWA have removable optional modules for
electrical pass-through connections. The electrical connections
have to be soldered to the connection pins.
ØRemove the M2 screw from the optional module using a 1.5mm
Allen wrench.
ØRemove the optional module from the SWK or SWA
Notch in pin
Heat Shrink
Strip wire the same
length as notch in pin
Solder wire to pin
Slide heat
shrink
over wire
Slide heat shrink
over solder
connection and
apply heat
Optional Module
E04-K Shown
Optional Module
E04-A Shown
Soldering the Electrical Connections
ØStrip the wire the same length as the notch in the pin.
ØSlide a piece of heat shrink tubing over the wire.
ØSolder the wire to the pin.
ØSlide the heat shrink tubing over the soldered connections and
apply heat using a heat gun until the heat shrink restricts tightly
over the connection.
ØRepeat this for all the connections.
ØReplace the optional module to the SWK or SWA and secure
with the M2 screw using a 1.5mm Allen Wrench. Torque to
approximately 0.24 Nm.

Operational Considerations
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6 Operational Considerations
The SWK locking mechanism is pneumatically driven to couple and
uncouple with the alignment Locking Posts on the SWA. The SWK
utilizes air ports to provide Lock and Unlock pressure to the locking
mechanism.
WARNING
During operation, the area between the SWK and SWA must be
kept clear.
Failure to keep area clear will result in damage to Tool Changer,
modules, or end-of-arm tooling and could cause injury to
personnel.
NOTICE
Safe, reliable operation of the Tool Changer is dependent on a
continuous supply of compressed air at a pressure of 4.5 - 5.5
bar.
Robot motion should be halted if the air supply pressure drops
below 4 bar for any reason.
6.1 Coupling Sequence
NOTICE
Before attempting to couple or uncouple, ensure that pass-
through air pressure and electrical signals are off.
Equipment could be damaged if air pressure and electrical signals
are not turned off.
ØPrior to coupling and with air supplied to the Unlock Port,
position the SWK above the SWA.
ØMove the SWK toward the SWA so that the two SWA alignment
locking posts enter the alignment holes on the SWK.
Note: Take care to program the robot so that the SWK and SWA
are aligned axially and are parallel to each other as closely as
possible. This will minimize tool movement and subsequent
wear during lock-up.
Note: Make sure the visual alignment indicators on the SWK
and the SWA are aligned properly before coupling to ensure
proper orientation.
ØWhen the two faces are within the specified No-Touch™
distance, release the pressure from the Unlock Port and supply
air to the Lock Port