SCHUNK SWS-L User instructions

Original manual
Assembly and operating manual
SWS-L
Heavy Load Change System

Imprint
2
02.00 | SWS-L | Assembly and operating manual | en | 0389037
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),
translation or other usage - even excerpts - of the manual is especially prohibited and re-
quires our written approval.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 0389037
Version: 02.00|12/11/2018|en
© SCHUNK GmbH & Co. KG
All rights reserved.
Dear Customer,
thank you for trusting our products and our family-owned company, the leading techno-
logy 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
1.2 Warranty .............................................................................................................. 6
1.3 Accessories ........................................................................................................... 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 Personnel qualification......................................................................................... 8
2.5 Personal protective equipment............................................................................ 8
2.6 Notes on particular risks....................................................................................... 9
3 Technical Data ........................................................................................................11
4 Product description.................................................................................................13
4.1 Quick-change head (SWK-L) ............................................................................... 13
4.2 Quick Change Adapter (SWA-L) .......................................................................... 16
4.3 Optional Modules............................................................................................... 18
5 Installation .............................................................................................................19
5.1 SWK-L ................................................................................................................. 21
5.2 SWA-L ................................................................................................................. 22
5.3 Tool Stand Design ............................................................................................... 23
6 Operation ...............................................................................................................25
6.1 Coupling Sequence ............................................................................................. 25
6.2 Fail-Safe Operation............................................................................................. 27
6.3 Uncoupling ......................................................................................................... 27
6.4 Integrated Sensors (SWS-L-1210) ....................................................................... 29
7 Troubleshooting .....................................................................................................31
8 Maintenance and Care............................................................................................35
8.1 Preventive Maintenance .................................................................................... 35
8.2 Cleaning, Lubrication, Adjustment and Replacement ........................................37
8.2.1 Cleaning and Lubrication of the Locking Mechanism ............................37
8.2.2 Lock and Unlock Sensor Assembly Replacement....................................39
8.2.3 Lock/Unlock Sensor Adjustment and Replacement (Units using individual
sensors) ..................................................................................................44
8.2.4 RTL Sensor Replacement ........................................................................46
8.2.5 Alignment Pin Replacement ...................................................................49
8.3 Recommended Spare Parts ................................................................................ 51

Table of contents
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8.3.1 SWS-L-210...............................................................................................51
8.3.2 SWS-L-310...............................................................................................51
8.3.3 SWS-L-510...............................................................................................51
8.3.4 SWS-L-1210.............................................................................................51
8.4 Assembly drawings ............................................................................................. 52
8.4.1 SWS-L-210...............................................................................................52
8.4.2 SWS-L-310...............................................................................................54
8.4.3 SWS-L-510...............................................................................................56
8.4.4 SWS-L-1210.............................................................................................58
9 Translation of original declaration of incorporation ................................................60
9.1 Annex to Declaration of Incorporation............................................................... 61

General
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1 General
1.1 About this manual
This manual contains important information for a safe and appro-
priate 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 under-
stood 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 Ap-
plicable 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
1.2 Warranty
If the product is used as intended, the warranty is valid for 24
months from the ex-works delivery date under the following con-
ditions:
• Observe the specified maintenance and lubrication intervals
• Observe the ambient conditions and operating conditions
Parts touching the workpiece and wear parts are not included in
the warranty.
1.3 Accessories
A wide range of accessories are available for this product
For information regarding which accessory articles can be used
with the corresponding product variants, see catalog data sheet.

Basic safety notes
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2 Basic safety notes
2.1 Intended use
The product (quick-change system SWS-L, consisting of quick-
change head SWK-L and quick-change-adapter SWA-L) was de-
signed for quickly 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 ob-
served and complied with.
• When implementing and operating components in safety-re-
lated 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 ap-
plication parameters.
• The product is intended for industrial use.
2.2 Not intended use
It is not intended use if the product is used, for example, as a
pressing tool, stamping tool, lifting gear, guide for tools, cutting
tool, clamping device or a drilling tool.
• Any utilization that exceeds or differs from the appropriate use
is regarded as misuse.
2.3 Ambient conditions and operating conditions
Required ambient conditions and operating conditions
Incorrect ambient and operating conditions can make the product
unsafe, leading to the risk of serious injuries, considerable material
damage and/or a significant reduction to the product's life span.
• Make sure that the product is used only in the context of its
defined application parameters, Technical Data [}11].
• Make sure that the product is 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.

Basic safety notes
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2.4 Personnel qualification
Inadequate qualifications of the personnel
If the personnel working with the product is not sufficiently quali-
fied, the result may be serious injuries and significant property
damage.
• All work may only be performed by qualified personnel.
• Before working with the product, the personnel must have read
and understood the complete assembly and operating manual.
• Observe the national safety regulations and rules and general
safety instructions.
The following personal qualifications are necessary for the various
activities related to the product:
Trained electrician Due to their technical training, knowledge and experience, trained
electricians are able to work on electrical systems, recognize and
avoid possible dangers and know the relevant standards and regu-
lations.
Qualified personnel Due to its technical training, knowledge and experience, qualified
personnel is able to perform the delegated tasks, recognize and
avoid possible dangers and knows the relevant standards and reg-
ulations.
Instructed person Instructed persons were instructed by the operator about the del-
egated tasks and possible dangers due to improper behaviour.
Service personnel of
the manufacturer
Due to its technical training, knowledge and experience, service
personnel of the manufacturer is able to perform the delegated
tasks and to recognize and avoid possible dangers.
2.5 Personal protective equipment
Use of personal protective equipment
Personal protective equipment serves to protect staff against
danger which may interfere with their health or safety at work.
• When working on and with the product, observe the occupa-
tional health and safety regulations and wear the required per-
sonal protective equipment.
• Observe the valid safety and accident prevention regulations.
• Wear protective gloves to guard against sharp edges and
corners or rough surfaces.
• Wear heat-resistant protective gloves when handling hot sur-
faces.
• Wear protective gloves and safety goggles when handling haz-
ardous substances.
• Wear close-fitting protective clothing and also wear long hair in
a hairnet when dealing with moving components.

Basic safety notes
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2.6 Notes on particular risks
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/sys-
tem!
•Switch off the energy supply.
WARNING
Remove all temporary protective materials (caps, plugs, tape,
etc.) on locking face of Tool Changer and modules prior to oper-
ation. Failure to do so will result in damage to Tool Changers,
modules, and end-of-arm tooling and could cause injury to per-
sonnel.
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.

Basic safety notes
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WARNING
During operation, the area between the Quick-Chance-Head
SWK and Quick Change Adapter 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 person-
nel.
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 SWK locking mechanism must not be actuated without be-
ing mounted to the robot interface plate.
Damage to the Cover Plate and O-ring may result.
•Always attach the SWK to the Robot interface plate prior to at-
tempting any operations.

Technical Data
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3 Technical Data
Designation Description SWS-L
210 310 510 1210
Suggested Payload
[kg]
The mass attached to the
Tool Changer.
300 510 700 1350
Working temperature
[°C]
5 – 60 5 – 60 5 – 60 5 – 60
Operating pressure
[bar]
Locking mechanism sup-
ply pressure operating
range. Supply to be clean,
dry, and filtered to 50 mi-
cron or better.
5 – 6.9 5 – 6.9 5 – 6.9 5 – 6.9
Coupling Force @ 5,5
bar [N]
Axial holding force. 31,000 38,000 62,000 93,000
Max. Moment
Load [Nm]
(X, Y) Maximum recommended
working load for optimum
performance of the Tool
Changer.
8,100 9,900 14,700 16,200
(Z) Torsion 6,900 9,600 10,500 16,200
Positional Repeatab-
ility [mm]
Repeatability tested at rated
load at one million cycles.
0.015
Weight [kg]
(coupled, no modules)
Total 8.2 20.4 28 28
SWK-L 5.4 12.7 19.3 18
SWK-A 2.7 7.7 8.7 10
Max. Recommen-
ded distance
between SWK-L and
SWA-L [mm]
No-Touch™ locking techno-
logy allows the SWK-L and
SWA-L to lock with separa-
tion when coupling.
2.5 2.5 2.5 1
Designation Description SWS-L
210 310 510 1210
Mounting/
Customer
Interface
SWK-L Meets
ISO 9409-1-A125
Meets
ISO 9409-1-A200
Also Supports
ABB ISO Pattern
Meets ISO 9409-
1-200-6-M12
(Position 11)
Assembly
drawings
[}52]
SWA-L Meets ISO
9409-1-A125
Also supports (8)
Fasteners on 160
mm BC Pattern
Meets ISO 9409-
1-A200
Also Supports
(6) Fasteners on
ABB ISO Pattern
ISO 9409-
1-200-12-M16
(Position 12)
Assembly
drawings
[}52]

Technical Data
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Designation Description 210 - 510 1210
Sensor Information,
signal name
L/U (Lock/Unlock) Internal proximity
sensors (2) with cable
and connector for direct
wiring to the control/
signal module to indic-
ate locking mechanism
position.
Internal proximity
sensors (6) with cable
and connector to indic-
ate locking mechanism
position.
RTL
(Ready-To-Lock)
Flat Pack proximity
sensor with cable and
connector for direct wir-
ing to control/signal
module to indicate SWK-
L and SWA-L mating sur-
faces within close prox-
imity of each other.
Proximity sensors (3)
with cable and con-
nector for direct wiring
to control/signal module
to indicate SWK-L and
SWA-L mating surfaces
within close proximity of
each other.

Product description
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4 Product description
4.1 Quick-change head (SWK-L)
The Quick-change head (SWK-L) includes an anodized aluminum
body, a hardened stainless-steel locking mechanism, and hardened
steel alignment pins (see Figure).
The SWK-L plate has 4 (SWK-L-1210 Series: 6) flat sides for mount-
ing of optional modules. Flat ‘A’ is dedicated for mounting of the
control/signal module along with SWK-L supply air that is provided
through an air or valve adapter. Flats ‘B’, ‘C’, and ‘D’ (SWS-L-1210
Series and ‘F’) are fully interchangeable and optional modules can
be arranged to suit the application or robot dress as required.
The locking mechanism consists of a cylindrical housing with holes
that retain hardened chrome-steel balls. Tapered pins located on
the SWK-L mate with holes in the SWA-L to ensure repeatable
alignment during the coupling process. An extreme pressure
grease is applied to the cam, male coupling, ball bearings and
alignment pins to enhance performance and maximize life of the
components.
SWK-L-210: A dual-sensor assembly is mounted into the body of
the SWK-L to verify the lock/unlock position of the piston and cam.
The sensors provide the lock and unlock (L/U) signals through the
control/signal module.
SWK-L-310 and 510: Proximity sensors are designed into the body
of the SWK-L to verify the lock/unlock position of the piston and
cam. The sensors provide the lock and unlock (L/U) signals through
the control/signal module.
SWK-L-1210: The SWK-L is comprised of 3 locking mechanisms.
Each locking mechanism consists of a cam, male coupling, and
chrome-steel balls. Tapered pins located on the SWK-L mate with
holes in the SWA-L to ensure repeatable alignment during the
coupling process. Extreme pressure grease is applied to the cams,
male couplings, ball bearings, and pins to enhance performance
and maximize the life of the SWK-L.
Proximity sensors (6 total) are designed into the body of the SWK-L
to verify the locked/unlocked position of each locking mechanism.
Due to the multiple locking mechanism design, the proximity
sensors are grouped such that 3 sensors are for Lock and 3 are for
Unlock. The Lock/Unlock signal at each locking mechanism is
routed to the signal junction module. The junction module
provides the control/signal module with the Lock/Unlock state of
the SWK-L. See the cable routing illustrations in chapter "Installa-
tion" to understand the relationship between the sensors, junction
module and control module.)

Product description
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Prox Sensor
Location
(RTL Signal)
Ball Bearing (12x)
Cam
Male Coupling
Alignment Pin (2x)
Lock/UnlockAir Supplied Thru
Air/Valve Adapter Maunted to FlatA
Cable Retaining
Tabs
Common Ledge Feature
For Modul Mounting;
Flats B, C, and D
Internal Prox Sensors
(Lock/Unlock)
[Not Visible]
Prox Sensor
Location
(RTL Signal)
SWK-L 210
Prox Sensor
(RTL Signal)
Ball Bearing (9x)
Cam
Male Coupling
Alignment Pin (2x)
Lock/UnlockAir Supplied
Thru Air/Valve
Adapter Mounted to Flat A
Cable Retaining
Tabs
Common Ledge
Mounting Feature (3x)
Internal Prox Sensors
(Lock/Unlock)
[Not visible]
Prox Sensor
(RTL Signal)
SWK-L 310

Product description
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15
Prox Sensors (2x)
(RTL Signal)
Body
Male Coupling
Cam
Alignment Pins (2x)
Lock/Unlock air
supplied via Air/Valve
Adapter
mounted to Flat A
Ball Bearings (12x)
Common ledge
mounting feature (3x)
Internal Lock/Unlock
sensors
(Not visible)
SWK-L 510
Ball Bearings (36x)
Cam
Alignment Pin
Proximity Sensor
(RTL Signal)
Lock/Unlock Air Supplied through
Air/Valve Adapter Mounted to Flat A
Junction Modul
Proximity Sensor
(RTL Signal)
Male Coupling
Common Ledge Feature
For Module Mounting;
Flats A, B, C, D, E and F
Cable Retaining
Tabs
Proximity Sensor
(RTL Signal)
SWK-L 1210

Product description
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4.2 Quick Change Adapter (SWA-L)
The Quick Change Adapter (SWA-L) includes an anodized alu-
minum body and a hardened stainless-steel bearing race (SWS-
L-1210: 3 hardened stainless-steel bearing races). The SWA-L has 4
(SWS-L-1210: 6) flat sides for mounting of optional modules.
Alignment Pin
Bushing (2x)
Bearing Race
Prox Sensor
Target (RTL)
Prox Sensor
Target (RTL)
Common Ledge Feature
for Module Mounting:
Flats A, B, C, and D
SWA-L 210
Alignment Pin
Bushing (2x)
Bearing Race
Prox Sensor Target
(RTL)
SWA-L (Body)
Prox Sensor or Target
(RTL)
Common Ledge
Mountong Feature (4x)
SWA-L-310

Product description
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Bushings for Alignment
Pin Location (2x)
RTL Sensor
Target (2x)
SWA-L (Body)
Bearing Race
Common Ledge
Mounting Feature (4x)
SWAS-L-510
Proximity Sensor
Target (RTL)
Alignment Pin Bushing
Proximity Sensor
Target (RTL)
Bearing Race
Junction Module
Adapter
Common Ledge Feature
For Module Mounting;
Flats A, B, C, D, E and F
Proximity Sensor
Target (RTL)
SWA-L-1210

Product description
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4.3 Optional Modules
There are 4 (SWS-1210: 6) flats available for mounting of the op-
tional modules for support of various utility pass-through, such as
signal, fluid/air, and power.
For assistance in choosing the right modules for your particular ap-
plication, visit our website to see what is available or contact an
SCHUNK Sales Representative directly.
In general, flat ‘A’ is reserved for an air/valve adapter module and
a control/signal module.
Modules for flats ‘B’, ‘Modules for flats ‘B’, ‘C’, or ‘D’ (SWS-1210:
or ’F’) are interchangeable to suit the application or the dress-out
required.
The optional modules are mounted to the SWK-L or SWA-L using a
common ledge mounting feature. Only 2 M6 SHCS fasteners need
to be unscrewed in order to remove the module from the SWK-L/
SWA-L. A secondary mounting support, called a “cleat”, is factory-
installed to the SWK-L and SWA-L on each flat that is occupied
with a module. The cleats provide additional module support for
those situations when hoses or cables may inadvertently be
snagged or pulled and may otherwise result in damage to the
module.
If modules are added to a SWS-L in the field, then the SWK-L and
SKA-L may have to be uninstalled to facilitate the cleat installation.

Installation
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5 Installation
All fasteners used to mount the SWS-L to the robot and to user Tools
should be tightened to a torque value as indicated below. Further-
more, removable (blue) Loctite 242 must be used on these fasteners.
NOTE
Care should be taken to select fasteners for mounting that are not
too long, such that a gap is formed at the interface.
SWS-210
Mounting conditions Fastener Size and
Property Class
Recommen-
ded Torque
SWK-L to RIP (6061-T6 aluminum)
Minimum thread engagement of 15 mm (1.5 x fastener Ø)
M10–1.5
Class 12.9
75 Nm
SWK-L to Robot (steel; USS ≥ 90KSI)
Minimum thread engagement of 10 mm (1.0 x fastener Ø)
M10–1.5
Class 12.9
75 Nm
End-effector Interface Plate (aluminum) to SWA-L (7075-
T6 aluminum)
Minimum thread engagement of 15 mm (1.5 x fastener Ø)
M10–1.5
Class 12.9
52 Nm
End-effector Interface Plate (aluminum) to SWA-L (7075-
T6 aluminum)
Minimum thread engagement of 18 mm (1.5 x fastener Ø)
M12–1.75
Class 12.9
94 Nm
SWS-310
Mounting conditions Fastener Size and
Property Class
Recommen-
ded Torque
SWK-L to Robot Interface Plate (6061-T6 aluminum)
Minimum thread engagement of 24 mm (1.5 x fastener Ø)
M16-2.0
Class 12.9
225 Nm
SWK-L to Robot Interface Plate (6061-T6 aluminum)
Minimum thread engagement of 18 mm (1.5 x fastener Ø)
M12-1.75
Class 12.9
95 Nm
SWK-L to Robot (steel; USS ≥ 90KSI)
Minimum thread engagement of 16 mm (1.0 x fastener Ø)
M16-2.0
Class 12.9
225 Nm
SWK-L to Robot (steel; USS ≥ 90KSI)
Minimum thread engagement of 12 mm (1.0 x fastener Ø)
M12-1.75
Class 12.9
95 Nm
End-effector Interface Plate (aluminum) to SWA-L (7075-
T6 aluminum)
Thread engagement of 21 mm (1.3 x fastener Ø)
M16-2.0
Class 12.9
225 Nm
End-effector Interface Plate (aluminum) to SWA-L (7075-
T6 aluminum)
Minimum thread engagement of 18 mm (1.5 x fastener Ø)
M12-1.75
Class 12.9
94 Nm
End-effector Interface Plate (aluminum) to SWA-L (7075-
T6 aluminum)
Minimum thread engagement of 15 mm (1.5 x fastener Ø)
M10-1.5
Class 12.9
52 Nm
SWA-L to End-effector Interface Plate (6061-T6 aluminum)
Minimum thread engagement of 15 mm (1.5 x fastener Ø)
M10-1.5
Class 12.9
52 Nm

Installation
20
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SWS-510
Mounting conditions Fastener Size and
Property Class
Recommen-
ded Torque
SWK-L to Robot Interface Plate (6061-T6 aluminum)
Minimum thread engagement of 24 mm (1.5 x fastener Ø)
M16-2.0
Class 12.9
325 Nm
SWK-L to Robot Interface Plate (6061-T6 aluminum)
Minimum thread engagement of 18 mm (1.5 x fastener Ø)
M12-1.75
Class 12.9
135 Nm
SWK-L to Robot Interface Plate (steel; USS ≥ 40KSI)
Minimum thread engagement of 24 mm (1.5 x fastener Ø)
M16-2.0
Class 12.9
325 Nm
SWK-L to Robot Interface Plate (steel; USS ≥ 40KSI)
Minimum thread engagement of 18 mm (1.5 x fastener Ø)
M12-1.75
Class 12.9
135 Nm
SWK-L to Robot (steel; USS ≥ 90KSI)
Minimum thread engagement of 16 mm (1.0 x fastener Ø)
M16-2.0
Class 12.9
325 Nm
SWK-L to Robot (steel; USS ≥ 90KSI)
Minimum thread engagement of 12 mm (1.0 x fastener Ø)
M12-1.75
Class 12.9
135 Nm
End-effector Interface Plate (steel or aluminum) to SWA-L
(7075-T6 aluminum)
Minimum thread engagement of 24 mm (1.5 x fastener Ø)
M16-2.0
Class 12.9
225 Nm
End-effector Interface Plate (steel or aluminum) to SWA-L
(7075-T6 aluminum)
Minimum thread engagement of 18 mm (1.5 x fastener Ø)
M12-1.75
Class 12.9
94 Nm
SWS-1210
Mounting conditions Fastener Size and
Property Class
Recommen-
ded Torque
SWK-L to RIP (6061-T6 aluminum)
Minimum thread engagement of 15 mm (1.5 x fastener Ø)
M10–1.5
Class 12.9
75 Nm
SWK-L to RIP (Steel; USS ≥ 90KSI)
Minimum thread engagement of 15 mm (1.5 x fastener Ø)
M10–1.5
Class 12.9
75 Nm
SWA-L (aluminum) to End-Effector Interface Plate (6061-
T6 aluminum)
Minimum thread engagement of 15 mm (1.5 x fastener Ø)
M10–1.5
Class 12.9
52 Nm
SWA-L (aluminum) to End-Effector Interface Plate (7075-
T6 aluminum)
Minimum thread engagement of 15 mm (1.5 x fastener Ø)
M10–1.5
Class 12.9
52 Nm