SCHUNK SWS Series User instructions

Original Operating Manual
Assembly and Operating Manual
SWS 005 – 300
Quick-Change-System

Imprint
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10.00 | SWS 005 – 300 | Assembly and Operating Manual | en | 389456
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: 389456
Version: 10.00|03/05/2019|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.................................................................................................................... 6
1.1 About this manual ................................................................................................ 6
1.1.1 Presentation of Warning Labels ...............................................................6
1.1.2 Applicable documents ..............................................................................7
1.1.3 Sizes ..........................................................................................................7
1.2 Warranty .............................................................................................................. 7
1.3 Scope of delivery .................................................................................................. 8
1.4 Accessories ........................................................................................................... 8
1.4.1 SWD Dust Cover for SWA quick-change adapter......................................8
1.4.2 Seal kit ....................................................................................................10
2 Basic safety notes ..................................................................................................11
2.1 Intended use....................................................................................................... 11
2.2 Not intended use................................................................................................ 11
2.3 Constructional changes ...................................................................................... 11
2.4 Spare parts ......................................................................................................... 11
2.5 Environmental and operating conditions ........................................................... 12
2.6 Personnel qualification....................................................................................... 12
2.7 Personal protective equipment.......................................................................... 13
2.8 Notes on safe operation ..................................................................................... 13
2.9 Transport ............................................................................................................ 13
2.10 Malfunctions....................................................................................................... 14
2.11 Disposal .............................................................................................................. 14
2.12 Fundamental dangers......................................................................................... 14
2.12.1 Protection during handling and assembly ..............................................14
2.12.2 Protection during commissioning and operation ...................................15
2.12.3 Protection against dangerous movements.............................................15
2.13 Notes on particular risks..................................................................................... 16
3 Technical Data ........................................................................................................18
4 Product Overview ...................................................................................................20
4.1 Quick-change head (SWK) .................................................................................. 20
4.2 Quick-change adapter (SWA) ............................................................................. 21
4.3 Optional modules ............................................................................................... 21

Table of contents
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5 Assembly ................................................................................................................22
5.1 Example of mounting ......................................................................................... 22
5.2 Interface Plate Design and Mounting................................................................. 23
5.3 Requirements of the storage magazine ............................................................. 24
5.4 Mechanical connection ...................................................................................... 27
5.4.1 Fastening of the quick-change head (SWK) ............................................27
5.4.2 Fastening the quick-change adapter (SWA) ...........................................28
5.4.3 Tightening torque ...................................................................................28
5.5 Pneumatic connection........................................................................................ 31
5.6 Valve Requirements and Connections................................................................ 32
5.7 Pneumatic plan................................................................................................... 32
5.8 Sensors - Piston Stroke Control .......................................................................... 33
5.8.1 Piston Stroke Control of the piston with SIP-plate .................................33
5.8.2 Piston Stroke Control integrated in the body.........................................34
5.8.3 Typ Lock and Unlock Sensors..................................................................35
5.9 Optional Module Installation.............................................................................. 36
5.9.1 Electrical Module Installation E10/E20 - SWS-005 and SWS-011 ..........36
5.9.2 Electrical Module Removal E10/E20 - SWS-005 and SWS-011 ...............36
5.9.3 SWK Electrical Module Installation A15/B15 - SWS-005 and SWS-011...... 37
5.9.4 SWA Electrical Module Removal E10/E20 - SWS-005 and SWS-011 ......37
5.9.5 Flat A Optional K Series Module Installation - SWS-020 and SWS-021 ...... 38
5.9.6 Flat A Optional K Series Module Removal - SWS-020 and SWS-021 ......39
5.9.7 Flat B Optional Module Installation - SWS-021 ......................................39
5.9.8 Flat B Optional Module Removal - SWS-021 ..........................................40
6 Operation ...............................................................................................................41
6.1 Conditions for Coupling ...................................................................................... 41
6.2 Fail-Safe Operation............................................................................................. 42
6.3 Conditions for Uncoupling.................................................................................. 43
7 Trouble shooting.....................................................................................................44
7.1 Quick-change head (balls) doesn’t move ........................................................... 44
7.2 Quick-change head doesn't clamp the quick-change adapter correctly ............44
7.3 Clamping force between quick-change head and quick-change adapter is
reducing.............................................................................................................. 44

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8 Maintenance and Care............................................................................................45
8.1 Preventive Maintenance .................................................................................... 45
8.2 Lubrication.......................................................................................................... 47
8.2.1 External...................................................................................................47
8.2.2 Internal ...................................................................................................47
8.3 Cleaning and Lubrication of the Locking Mechanism ........................................ 47
8.3.1 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins... 47
8.3.2 Cleaning the Bearing Race and Alignment Pin Bushings (SWA)..............49
8.4 Service of the sensors......................................................................................... 49
8.4.1 Proximity Sensor Adjustment, Test, or Replacement - SWS-011............49
8.4.2 Proximity Sensor Adjustment, Test, or Replacement - SWS
020/021/040/060/071/100/150.............................................................51
8.4.3 Magnetic Proximity Sensor Test or Replacement - SWS-007 .................53
8.4.4 Lock and Unlock Sensor Assembly Replacement (with Sensor
Assemblies for SWS 040Q, 046, 076, 110, 160) ................................... 54
8.5 Rubber Bushings................................................................................................. 55
8.5.1 Seal Inspection and Replacement for Electrical Modules.......................57
8.6 Alignment Pins.................................................................................................... 57
8.6.1 Replacemanent - SWS 005 / 011 /007....................................................57
8.6.2 Replacemanent - SWS 046 / 076 / 110 /160 ..........................................58
8.7 Disassembly of the SWK Quick-change head ..................................................... 60
8.7.1 Disassembly of SWK 005 - 011 ...............................................................60
8.7.2 Disassembly of SWK 020 - 300 ...............................................................61
9 Assembly drawings .................................................................................................62
9.1 Assembly SWS-005/011...................................................................................... 62
9.2 Assembly SWS-007 ............................................................................................. 63
9.3 Assembly SWS-020/021/041/060/071/150/300 ...............................................64
9.4 Assembly SWS-027 ............................................................................................. 65
9.5 Assembly SWS-046 ............................................................................................. 66
9.6 Assembly SWS-076/110/160 .............................................................................. 67
10 Translation of original declaration of incorporation ................................................68
11 Annex to Declaration of Incorporation....................................................................69

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 [}7] 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 005
• SWS 007
• SWS 011
• SWS 020
• SWS 021
• SWS 027
• SWS 040
• SWS 040Q
• SWS 041
• SWS 046
• SWS 060
• SWS 071
• SWS 076
• SWS 110
• SWS 150
• SWS 160
• SWS 300
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 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.

General
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1.3 Scope of delivery
The scope of delivery includes
• Quick-Change-System SWS in the version ordered, containing
the following components:
– SWK quick-change head
– SWA quick-change adapter
• Accessory pack
– Cylindrical pin
– Mounting screw (Size 005 – 071) Fastening of the quick-
change head (SWK) [}27]
1.4 Accessories
A wide range of accessories is available for this module.
For information about which accessories can be used with the
appropriate product version ☞ catalog.
1.4.1 SWD Dust Cover for SWA quick-change adapter
SWD dust cover
1 electrical option 3 SWD
2 SWK 4 SWA
The SWD dust cover is available in the following sizes
Size Designation ID number for electrical option (1)
020 SWD-020-K00-000 0302252 K19/K26 (connection side A)
021 SWD-021-K00-000 0302253 K19/K26 (connection side A)
040 SWD-040-R00-000 0302254 R19/R26 (connection side A)

General
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Size Designation ID number for electrical option (1)
041 SWD-041-R00-000 0302255 R19/R26 (connection side A)
060 SWD-060-K00-000 0302256 K19/K26 (connection side A)
071 SWD-071-R00-000 0302257 R19/R26 (connection side A)
076 SWD-076-000-R00 0302258 R19/R26 (connection side B)
110 SWD-110-R00-000 0302260 R19/R26 (connection side A)
150 SWD-150-R00-000 0302261 R19/R26 (connection side A)
In order to avoid contamination of the pneumatic feedthrough
openings, as well as of the contacts of the electric options at the
SWA quick- change tool, an SWD dust cover has to be used while it
is located in the storage rack.
The SWD is equipped with an integrated clamping device, which is
actuated by locking/ unlocking the SWK quick-change head.
Hereby the SWD dust cover can be removed from the SWA quick-
change adapter and can be located onto a further SWA quick-
change adapter.
The SWD dust cover (material PA2220) is protecting the SWA
quick-change adapter against the following contaminations:
• Dust
• Chips
• Various liquids (e.g. coolant)
NOTE
• The SWD dust cover is only suitable for covering the SWA quick-
change tool. It never should be used for transporting the SWA
quick-change tool together with the attached tools.
• If the SWD dust cover should be used in extremely dirty
conditions, an excessive filling of the interior of the SWK quick-
change master mounting with dirt particles has to be avoided.
Therefore, regular control and possible cleaning of the SWK will
be necessary.
• In case of excessive contamination there will be the risk that
the locking mechanism of the SWK will not completely move
into its final position, and the SWD will get damaged.

General
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1.4.2 Seal kit
Seal kit for ID number
SWK 005 0370819
SWK 011 0370977
SWK 011 - High-temperature-version 39370977
SWK 020 0370821
SWA 020 0370822
SWK 021 0370978
SWK 027 30087124
SWK 040 0370823
SWK 040Q 0370949
SWK 041 0370979
SWK 060 0370824
SWK 071 0370980
SWK 076 0370948
SWK 110 0370806
SWK 150 0370826
SWK 150 - High-temperature-version 39370826
SWK 160 0370992
SWK 300 0370827
SWA 300 0370835
Contents of the sealing kit, Assembly drawings [}62].

Basic safety notes
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2 Basic safety notes
2.1 Intended use
The product (SWS quick-change systems, consisting of SWK quick-
change head and SWA quick-change adapter) was designed for a
quick changing of parts and automation components at a robot in
the context of its technical data.
• The product may only be used within the scope of its technical
data, Technical Data [}18].
• 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.
• The product is intended for installation in a machine. The
applicable guidelines must be observed and complied with.
• The product is intended for industrial and industry-oriented 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 Constructional changes
Implementation of structural changes
By conversions, changes, and reworking, e.g. additional threads,
holes, or safety devices can impair the functioning or safety of the
product or damage it.
• Structural changes should only be made with the written
approval of SCHUNK.
2.4 Spare parts
Use of unauthorized spare parts
Using unauthorized spare parts can endanger personnel and
damage the product or cause it to malfunction.
• Use only original spare parts or spares authorized by SCHUNK.

Basic safety notes
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2.5 Environmental 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.
See also Link Ungebungs- und Einsatzbedingungen.
2.6 Personnel qualification
Inadequate qualifications of the personnel
If the personnel working with the product is not sufficiently
qualified, 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
regulations.
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
regulations.
Instructed person Instructed persons were instructed by the operator about the
delegated 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.

Basic safety notes
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2.7 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
occupational health and safety regulations and wear the
required personal 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
surfaces.
• Wear protective gloves and safety goggles when handling
hazardous substances.
• Wear close-fitting protective clothing and also wear long hair in
a hairnet when dealing with moving components.
2.8 Notes on safe operation
Incorrect handling of the personnel
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Avoid any manner of working that may interfere with the
function and operational safety of the product.
• Use the product as intended.
• Observe the safety notes and assembly instructions.
• Do not expose the product to any corrosive media. This does
not apply to products that are designed for special
environments.
• Eliminate any malfunction immediately.
• Observe the care and maintenance instructions.
• Observe the current safety, accident prevention and
environmental protection regulations regarding the product's
application field.
2.9 Transport
Handling during transport
Incorrect handling during transport may impair the product's safety
and cause serious injuries and considerable material damage.
• When handling heavy weights, use lifting equipment to lift the
product and transport it by appropriate means.
• Secure the product against falling during transportation and
handling.
• Stand clear of suspended loads.

Basic safety notes
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2.10 Malfunctions
Behavior in case of malfunctions
• Immediately remove the product from operation and report the
malfunction to the responsible departments/persons.
• Order appropriately trained personnel to rectify the malfunction.
• Do not recommission the product until the malfunction has
been rectified.
• Test the product after a malfunction to establish whether it still
functions properly and no increased risks have arisen.
2.11 Disposal
Handling of disposal
The incorrect handling of disposal may impair the product's safety
and cause serious injuries as well as considerable material and
environmental harm.
• Follow local regulations on dispatching product components for
recycling or proper disposal.
2.12 Fundamental dangers
General
• Observe safety distances.
• Never deactivate safety devices.
• Before commissioning the product, take appropriate protective
measures to secure the danger zone.
• Disconnect power sources before installation, modification,
maintenance, or calibration. Ensure that no residual energy
remains in the system.
• If the energy supply is connected, do not move any parts by hand.
• Do not reach into the open mechanism or movement area of
the product during operation.
2.12.1 Protection during handling and assembly
Incorrect handling and assembly
Incorrect handling and assembly can make the product unsafe and
pose a risk of serious injuries and considerable material damage.
• Order all work to be performed only by appropriately qualified
personnel.
• For all work, secure the product against accidental operation.
• Observe the relevant accident prevention regulations.

Basic safety notes
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2.12.2 Protection during commissioning and operation
Falling or violently ejected components
Falling and violently ejected components can cause serious injuries
and even death.
• Take appropriate protective measures to secure the danger zone.
• Never step into the danger zone during operation.
2.12.3 Protection against dangerous movements
Unexpected movements
Residual energy in the system may cause serious injuries while
working with the product.
• Switch off the energy supply, ensure that no residual energy
remains and secure against inadvertent reactivation.
• Never rely solely on the response of the monitoring function to
avert danger. Until the installed monitors become effective, it
must be assumed that the drive movement is faulty, with its
action being dependent on the control unit and the current
operating condition of the drive. Perform maintenance work,
modifications, and attachments outside the danger zone
defined by the movement range.
• To avoid accidents and/or material damage, human access to
the movement range of the machine must be restricted. Limit/
prevent accidental access for people in this area due through
technical safety measures. The protective cover and protective
fence must be rigid enough to withstand the maximum possible
movement energy. EMERGENCY STOP switches must be easily
and quickly accessible. Before starting up the machine or
automated system, check that the EMERGENCY STOP system is
working. Prevent operation of the machine if this protective
equipment does not function correctly.

Basic safety notes
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2.13 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/
system!
•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
operation. Failure to do so will result in damage to Tool
Changers, modules, and end-of-arm tooling and could cause
injury to personnel.
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.

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
personnel.
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 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 SWK to the Robot interface plate prior to
attempting any operations.

Technical Data
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3 Technical Data
More technical data is included in the catalog data sheet.
Whichever is the latest version.
Designation SWS
005 007 011 020 021 022 027 040 040Q 041
Weight [kg] 0.36 0.24 0.22 0.99 0.8 0.8 1.39 1.85 1.85 2.1
Recommended handling
weight [kg]
8 16 25 38 50 50
Locking force
(at 5.5 bar) [N]
690 1100 2300 2300 3500 4500 5600 4500
Maximum distance on
locking [mm]
min.
max. 1.5
3.0
0
3.0
0
2.0
0
3.0
0
3.0
Repeatability
[at 2 Mio. cycles] 0.015 0.01 0.015 0.015
Noise emission [dB(A)] ≤ 70
Pressure medium Compressed air, compressed air quality according to
ISO 8573-1:7 4 4
Designation SWS
046 060 071 076 110 150 160 300
Weight [kg] 2.98 2.0 3.1 3.65 6.2 7.5 9.3 19.1
Recommended handling
weight [kg]
50 75 79 100 150 200 300 450
Locking force
(at 5.5 bar) [N]
5800 7400 8100 12000 16000 31000 350
00
Maximum distance on
locking [mm]
min.
max. 0
3.0
0
2.0
0
3.0
0
2.0
0
2.0
0
2.5
Repeatability
[at 2 Mio. cycles] 0.015
Pressure medium Compressed air, compressed air quality according to
ISO 8573-1:7 4 4

Technical Data
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Designation SWS
Ambient temperature [°C]
min.
max.
+5
+60
IP protection class (in lockled
state) *
40
Noise emission [dB(A)] ≤ 70
* For use in dirty ambient conditions (e.g. sprayed water, vapors,
abrasion or processing dust) SCHUNK offers corresponding
product options as standard. SCHUNK also offers customized
solutions for special applications in dirty ambient conditions.

Product Overview
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4 Product Overview
4.1 Quick-change head (SWK)
The Quick-change head (SWK) includes an anodized aluminum
body, a hardened stainless-steel locking mechanism, and hardened
steel alignment pins.
The SWK has sides for mounting of optional modules.
The locking mechanism consists of a cam, a male coupling, and
chrome-steel ball bearings.
Tapered pins located on the SWK are inserted in the bushings in
the SWA to ensure repeatable alignment during the coupling
process. An extreme pressure grease is applied to the cam, male
coupling, ball bearings, and pins to enhance performance and
maximize the life of the SWK
Two port connections are available to supply air pressure for coupling
and uncoupling the tool changer, Pneumatic connection [}31]
Port connections are available for pass through air for supplying air
to tools.
A mounting pattern is machined into the SWK for mounting to a
robot arm or a robot interface plate.
Cam Alignment pins (2x)
Male coupling
Ball bearing
Proximity sensor
assembly location
(RTL signal)
Proximity sensor
assembly location
(Lock/Unlock signal)
Ports for air feed through
Lock and unlock ports
SWK
For safe monitoring of the end position of the SWK’s locking
mechanism we are recommending the use of a piston stroke control.
Stroke control of the piston is available for Models SWS-007 and
larger.