SCHUNK SWS-I-011 User instructions

Assembly and Operating Manual
Quick-Change-System type SWS-I-011
1 Date printed 28.02.11
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. You can
reach us directly at the mentioned addresses in the last chapter of these instructions.
Kindest Regards,
Your SCHUNK GmbH & Co. KG
Precision Workholding Systems
Bahnhofstr. 106 - 134
D-74348 Lauffen/ Neckar
Tel. [phone]
Fax [phone]
[email protected]
www.schunk.com
Document last updated: 28.02.2011
SWS-I-011
QUICK-CHANGE-
SYSTEM
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Assembly and Operating Manual
Quick-Change-System type SWS-I-011
2 Date printed 28.02.11
Contents
1SAFETY.................................................................................................................................................3
1.1 SYMBOL KEY....................................................................................................................................3
1.2 APPROPRIATE USE ..........................................................................................................................3
1.3 ENVIRONMENTAL AND OPERATING CONDITIONS .................................................................................3
1.4 SAFETY NOTES................................................................................................................................4
2WARRANTY..........................................................................................................................................5
3SCOPE OF DELIVERY.........................................................................................................................5
4TECHNICAL DATA...............................................................................................................................5
5ASSEMBLY AND INSTALLATION.......................................................................................................6
5.1 ASSEMBLY.......................................................................................................................................6
5.2 EXAMPLE OF MOUNTING ...................................................................................................................7
5.3 INSTALLATION..................................................................................................................................8
5.3.1 Air connection........................................................................................................................8
5.3.2 Electrical connection..............................................................................................................9
5.3.3 Pinout of the electrical connection.......................................................................................10
6TROUBLESHOOTING........................................................................................................................11
7MAINTENANCE AND CARE...............................................................................................................13
7.1 MAINTENANCE AND CARE INTERVALS ..............................................................................................13
7.2 HINWEISE......................................................................................................................................13
8DISASSEMBLY OF THE QUICK-CHANGE-HEADS SWK-I-011.......................................................14
9PROGRAMMING AID .........................................................................................................................15
10 ASSEMBLY DRAWING ......................................................................................................................19
10.1 SWS-I-011 AXIAL OUTPUT .............................................................................................................19
10.2 SWS-I-011 RADIAL OUTPUT...........................................................................................................20
11 BILLS OF MATERIALS ......................................................................................................................21
11.1 SEAL KIT........................................................................................................................................21
11.2 BILLS OF SPARE PART ....................................................................................................................21
11.2.1 SWA-I-011 (Id.-No. 302 810)...............................................................................................21
11.2.2 SWK-I-011 radial output (Id.-No. 302 811)..........................................................................22
11.2.3 SWK-I-011 axial output (Id.-No. 302 812)............................................................................23
CONTACT ...................................................................................................................................................24
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Assembly and Operating Manual
Quick-Change-System type SWS-I-011
3 Date printed 28.02.11
1 Safety
1.1 Symbol key
You will find this symbol wherever hazards for persons or damage to the product
are possible.
This symbol indicates important information on the product or its handling.
1.2 Appropriate Use
The unit must only be used within the scope of its technical data.
Appropriate use also includes compliance with the conditions the manufacturer has specified
for commissioning, assembly, operation, environment and maintenance. Using the unit with
disregard to even a minor specification will be deemed inappropriate use. The manufacturer
assumes no liability for any injury or damage resulting from inappropriate use.
1.3 Environmental and operating conditions
- Use the unit only within the application parameters defined in the Technical Catalog.
The most recent version applies (according to the General Terms and Conditions).
Please make sure that your application has been checked based on the current
SCHUNK calculation program. If this is not the case, we can provide no warranty.
- Requirement for quality of the compressed air according to ISO 8573-1: 6 4 4
- Clean ambient conditions at room temperature are required. If these conditions are
not ensured, the maintenance interval will be shorter, depending on the actual
utilization.
- The environment must be free of splashing water and vapors, and also of abrasive
dust and process dust. This does not apply to units designed especially for dirty envi-
ronments
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Assembly and Operating Manual
Quick-Change-System type SWS-I-011
4 Date printed 28.02.11
1.4 Safety Notes
Caution !
The pins of the electric module can be damaged during operation!
- Switch off the energy transmission during coupling and decoupling.
Caution !
When switching on the compressed air, the piston of the quick-change head can
puncture the piston cover plate.
- Always use a suitable adapter plate between the robot flange and the
quick-change head. This adapter plate must be bolted or clamped to the
quick-change head.
1.
The Quick-Change system has been built according to the level of technology
available at the time of delivery and is safe to operate. However, the gripper may
still be dangerous if, for example:
- the system is used, assembled or maintained inappropriately.
- the system is used for purposes other than those it is intended for.
- The EC Machine Directive, the accident prevention regulations, the VDE
guidelines, or the safety information and assembly notes are not adhered
to.
2.
Any persons who may be responsible for assembly, commissioning and mainte-
nance of the unit are obliged to have read and understood all of the operating in-
structions, in particular chapter 1 ‘‘Safety’’. We recommend that the customer
have this confirmed in writing.
3.
The installation, deinstallation, assembly of all motion detectors, connection and
commissioning may only be performed by authorized, appropriately trained per-
sonnel.
4.
Modes of operation and work methods that adversely affect the function and/or the
operational safety of the system are to be refrained.
5.
Do not touch any open mechanics or the area between the Quick Change Head
and the Quick Change Adaptor.
6.
Always disconnect the power supply lines during assembly, conversion, mainte-
nance and setting work.
7.
For maintenance, changes or attachments, we recommend to remove the system
from the machining table and to do these works outside the danger zone.
8.
Make sure, that the Gripper Change System won’t be actuated by accident by the
operator or any other person during mounting, connecting, adjusting, starting or
testing.
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Assembly and Operating Manual
Quick-Change-System type SWS-I-011
5 Date printed 28.02.11
9.
When using handling modules, protective covers must be used according to EC
Machine Directive, Point 1.4.
10.
There is a danger of injury and a risk of damages due to falling and catapulted
components. Precautions must be taken to prevent any potentially dangerous ob-
jects (processed workpieces, tools, chips, debris, waste etc.) from falling or being
catapulted out of the unit.
11.
Additional holes, threads or attachments which are not supplied as accessories by
SCHUNK may only be applied after obtaining the prior consent of SCHUNK.
12.
The maintenance and servicing intervals must always be complied with. The inter-
vals indicated refer to a standard working environment. Operating the unit in an
environment in which it is subjected to abrasive dusts or corrosive and/or aggres-
sive vapours and/or liquids requires the prior consent of SCHUNK.
13.
Above and beyond that, the safety and accident prevention regulations in force at
the location of use apply.
2 Warranty
The warranty period is 24 months after delivery date from the factory, assuming use in single-
shift operation and that the recommended maintenance and lubrication intervals are respected.
Components that come into contact with workpieces and wearing parts are never included in
the warranty. In this context, please also see our General Terms and Conditions.
3 Scope of Delivery
The scope of delivery comprises:
- SWA-I-011 (Quick-Change-Adaptor)
- SWK-I-011 (Quick-Change-Head)
- LITTLE PLASTIC BAG: 1 Cylinder pin, 4 cylinder head bolts
Accessories such as adapter plates can be ordered separately (see catalog).
4 Technical Data
The airborne sound emitted from the unit is <= 70dB(A)
Please consult our catalogue for further technical details. The last version is valid in each case
(in accordance with Chapter 2.3 General Terms and Conditions)
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Assembly and Operating Manual
Quick-Change-System type SWS-I-011
6 Date printed 28.02.11
5 Assembly and Installation
5.1 Assembly
CAUTION !
- Switch off the power supply during installation of the quick-change system.
- Comply with the safety instructions in Chapter 1.3, page 3.
- Always install the SWK-I-011 with an adapter plate!
Fasting of the Quick-Change-Adaptor (SWA-I-011)
- Fasten the quick-change adapter SWA-I-011 with M3 screws.
Fasting of the Quick-Change-Head (SWK-I-011)
You can fasten the Quick-Change-Head SWK-I-011 with the screws which you will find in the
enclosed little plastic bag.
- For centering purposes, please use the cylinder pin out of the plastic bag.
Type SWK-I
011
/1/
Fastening screws DIN EN ISO 4762
M3 x 22
/2/
Cylinder pin for centering DIN 6325
3m6 x 12
Table 1: Overview of screws and cylinder pins for SWK-I-011
Figure 1: Mounting of SWK-I-011
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Assembly and Operating Manual
Quick-Change-System type SWS-I-011
7 Date printed 28.02.11
5.2 Example of mounting
An interface plate with a hole pattern for mounting holes is available optionally. The adapter
plate is bolted to the robot and the quick-change head (data for mounting and mounting bolts
can be found in our catalog).
The handling unit is mounted on the quick-change adapter using an interface plate, which was
designed and manufactured for the user (the required information can be found in our catalog
on the respective models).
The pneumatic connection and electric cables are fastened, bundled and mounted with strain
relief, to ensure maximum freedom of movement during use.
Figure 2: Example of mounting
Description
/3/
Robot arm
/4/
Interface plate (optional or supplied by user)
/5/
Piston cover plate
(not necessary if sealing is provided by interface plate)
/6/
Quick-Change-Head SWK-I-011
/7/
Quick-Change-Adaptor SWA-I-011
/8/
Interface plate for end-effector (supplied by user)
/9/
Tool (e.g. gripper)
Table 2: Description of components
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Assembly and Operating Manual
Quick-Change-System type SWS-I-011
8 Date printed 28.02.11
5.3 Installation
The connection dimensions can be found in the respective drawings in the current catalog or in
our CAD data service on the Internet (link under www.schunk.com).
5.3.1 Air connection
CAUTION!
- Switch off the power supply during installation of the quick-change system.
- Comply with the safety instructions in Chapter 1.3, page 3.
Requirements
Pressure medium
compressed air
Requirement for quality of the
compressed air
to DIN ISO 8573-1: 6 4 4
Hose connection
Connect the pressure hose to the mounted air connection.
Max. Betriebsdruck
6 bar
Type SWS-I
011
/10/
Thread diameter of air connection
M5
Table 3: Air connection threads
Figure 3: Air connection (radial or axial output)
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Assembly and Operating Manual
Quick-Change-System type SWS-I-011
9 Date printed 28.02.11
5.3.2 Electrical connection
CAUTION !
- Switch off the power supply during installation of the quick-change system.
- Comply with the safety instructions in Chapter 1.3, page 3.
For control of the integrated 3/2-way valves in the quick-change system a matching plug con-
nector is used (see Table 4). Two 3/2-way valves lock and unlock the quick-change system and
the remaining 3/2-way valves switch the internal air feed-throughs to supply the handling mod-
ules.
Type SWS-I
011
/11/
Connector
Plug SUB-D 15-pin
/12/
Connector
Circular plug-in connector 14-poles
Table 4: Plug size
Figure 4: Electrical connection (radial or axial output)
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Assembly and Operating Manual
Quick-Change-System type SWS-I-011
10 Date printed 28.02.11
5.3.3 Pinout of the electrical connection
The air feed-throughs L1, L3, L4 and L6 are switched via the valves 1, 3, 4 and 6. The valve 2
locks the quick-change system and the valve 5 unlocks the quick-change system. Signal volt-
age for valves is 24 VDC (current input 0.11A per valve).
Figure 5: Configuration of valves
Pin
Pin
Type SWS-I
011
Function of the valves
A
1
Signal valve 1
/16/
switches air feed-through L1
C
2
Signal valve 2
/17/
Locking
E
3
Signal valve 3
/18/
switches air feed-through L3
G
4
GND valve 1-3
/16/ /17/ /18/
-
J
5
Signal valve 4
/13/
switches air feed-through L4
L
6
Signal valve 5
/14/
Releasing
M
7
Signal valve 6
/15/
switches air feed-through L6
N
8
GND valve 4-6
/13/ /14/ /15/
-
O
9
El. feed-through 1
/19/
-
P
10
El. feed-through 2
/20/
-
R
11
El. feed-through 3
/21/
-
S
12
El. feed-through 4
/22/
-
T
13
El. feed-through 5
/23/
-
U
14
El. feed-through 6
/24/
-
Table 5: Pinout
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Assembly and Operating Manual
Quick-Change-System type SWS-I-011
11 Date printed 28.02.11
6 Troubleshooting
Malfunction
Possible cause
Corrective actions
Quick-change head
Head (balls) does not move
(1) Min. air pressure of
3.5 bar exceeded
(2) Valve 2 and 5 exchanged
(3) Valve 2 or 5 defective
(1) Check air supply and
adjust air pressure
(2) Check connections,
replace if necessary
(3) Contact your SCHUNK
representative
(see Chapter 0, page 24)
Quick-change head
Head does not correctly
clamp quick-change adapter
SWA
(1) Dirt between quick-change
head and adapter
(2) Dirt accumulation
(e.g. fine chips) in the air
feed-through cause
insufficient volumetric flow
and the clamping force of
the quick-change system
decreases.
(1) Clean the quick-change
system
(2) Please contact your
SCHUNK representative.
(see Chapter 0, page 24)
Clamping force between
quick-change head
SWK-I-011 and quick-change
adapter SWA-I-011
decreases
(1) Air pressure in system
decreases
(2) Min. air pressure of 3.5
bar exceeded
(3) Dirt accumulations or
maintenance interval due
(1) Check seals
(2) Check air supply and
adjust air pressure
(3) Clean quick-change
system and re-lubricate
Quick-change adapter
SWA-I-011 cannot be
released
(1) Valve 5 for unlocking
defective
(1) To unlock, loosen set
screw /24/ and blow in
compressed air
(max. 6 bar).
see Figure 6, page 12
or:
Please contact your
SCHUNK representative:
(see Chapter 0, page 24)
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Assembly and Operating Manual
Quick-Change-System type SWS-I-011
12 Date printed 28.02.11
Figure 6: Loosen set screw to unlock
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Assembly and Operating Manual
Quick-Change-System type SWS-I-011
13 Date printed 28.02.11
7 Maintenance and care
7.1 Maintenance and care intervals
Note
We recommend to replace the waering parts, marked in the Bill of materias (see Chap-
ter 11from page 21) at each service.
Type SWS-I
011
Maintenance intervals (million cycles)
2
Table 6: Maintenance intervals
7.2 Hinweise
CAUTION !
Comply with the safety instructions in Chapter 1.3, page 3.
In order to assure the proper function of the Quick-Change-System, please consider the
following instructions:
(1) Standard for quality of the compressed air according to DIN ISO 8573-1: 6 4 4.
(2) Service the quick-change system SWS-I according to Table 6: Maintenance intervals .
- At every maintenance work the sealing have to be exchanged.
(The complete seal kit can be ordered from SCHUNK. For Id.-No. of the seals, see
chapter 11.1 page 21).
- The piston bore as well as the sealing have to be lubrified with Renolit HLT 2 or any
equivalent lubricant. (basic greasing)
(3) If not advised differently, all screws and nuts have to be tightened with a starting torque as
per Table 7: Tightening torques and secured with Weicon No. 30243 or Loctite 242®and
270®.
Pos.
SWS-I-011
12
1,3 Nm
13
1,3 Nm
14
1,3 Nm
18
1,3 Nm
20
0,45 Nm
22
1,3 Nm
33
1,3 Nm
34
0,8 Nm
42
1,3 Nm
44
1,3 Nm
60
1,3 Nm
Table 7: Tightening torques
(For item no. see Assembly, Chapter 10 page 19)
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Assembly and Operating Manual
Quick-Change-System type SWS-I-011
14 Date printed 28.02.11
8 Disassembly of the Quick-Change-Heads SWK-I-011
CAUTION !
Please observe chapter 7 page 13 as well as the safety information on page 3.
(Item.-No. see Assembly, chapter 10 page 19)
1. Remove the compressed air feeding and the plug connector.
2. Turn out the screws (item 18) and take off the Quick-Change-Head from your handling tool.
3. Separate the SWK-I-011 from the adaptor plate.
4. Take the O-ring (item 26) out of the countersunk of the housing. (item 1).
5. Carefully push the piston (item 5) from the housing (item 1).
Make sure that the balls (item 27) remain in their given position.
6. Remove the sealing (item 24) from the piston (item 5).
7. Take the sealing (item 23) out of the housing (item 1).
8. Loosen the screws (no. 33 ) from the housing (no. 1) and remove the ring (no. 16).
9. Remove the O-rings (no. 39, no. 45 and no. 46).
10. Thoroughly clean all components and check them for damage and wear.
11. Replace all sealings from the complete set of sealings.
Assembly is done out in reverse order.
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Assembly and Operating Manual
Quick-Change-System type SWS-I-011
15 Date printed 28.02.11
9 Programming aid
To simplify the teach process and programming, Schunk offers a programming aid (ID no.
302814) It consists oft he tool-side module SWA-I-011(ID no. 5517913) and the robot.side
module SWK-I-011 (ID no. 5517912). Both modules can be purchased separately.
A description of the teach process follows:
Step 1
- Place the programming aid /26/ in the tool changer.
- Program should be written using the programming aid /26/ located in the tool changer.
Step 2
- Place the programming aid /26/ on the tool-side change head /27/.
- The marking A must be on the side of the electric feed-through /28/.
Figure 7 Programming aid for tool-side change head
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Assembly and Operating Manual
Quick-Change-System type SWS-I-011
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Step 3
- Lock the programming aid /33/ with the robot-side change head /31/.
- The marking A must be on the side oft he electric feed-through /32/.
- Use the piston cover plate /3/ if necessary (not required if the interface is used for
sealing.
Figure 8 Programming aid for robot-side change head
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Assembly and Operating Manual
Quick-Change-System type SWS-I-011
17 Date printed 28.02.11
Step 4
- In the teach process, move the tool-side change head /27/ into position over the robot-
side change head /31/.
- Align the surfaces of the two programming aids /26/ and /33/ so that they are parallel.
- Make sure that the markings „A“ and „B“ line up.
Figure 9 Appropriate alignment of the programming aids
Step 5
Move the robot-side change head /31/ slowly and carefully downward until the distance be-
tween the two programming aids /33/ and /26/ is approx. 1 mm.
Figure 10 Joining the programming aids
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Assembly and Operating Manual
Quick-Change-System type SWS-I-011
18 Date printed 28.02.11
Step 6
- Make sure that the markings „A“ and „B“ line up with each other.
- Correct the position of the robot to compensate for any lateral misalignment.
- Use the triangular markings at „A“ and „B“ for the correct alignment.
Figure 11 Correct alignment
Step 7
- Note the coordinates from Step 6.
- Now the Z-coordinate has to be corrected. This depends on the Thickness oft eh pro-
gramming aids, and it is the only way to determine the correct coordinates.
- Use the following formula to calculate the Z-coordinate.
Z „Pick-up“ coordinate = (Z-coordinate from Step 6) –(40 mm)
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Assembly and Operating Manual
Quick-Change-System type SWS-I-011
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10 Assembly Drawing
10.1 SWS-I-011 axial output
Figure 12: Exploded drawing axial output
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Assembly and Operating Manual
Quick-Change-System type SWS-I-011
20 Date printed 28.02.11
10.2 SWS-I-011 radial output
Figure 13: exploded drawing radial output
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