SCHUNK OPS 80 User instructions
Translation of the original manual
Collision and Overload Protection
OPS 80 - 300
Assembly and Operating manual
Superior Clamping and Gripping
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Imprint
2 01.00|OPS 80 - 300|en
Imprint
Copyright:
This manual remains the copyrighted property of SCHUNK GmbH & Co. KG. It is solely
supplied to our customers and operators of our products and forms part of the product.
This documentation may not be duplicated or made accessible to third parties, in particu-
lar competitive companies,
without our prior permission.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 0389668
Edition: 01.00 |29/08/2014|en
© SCHUNK GmbH & Co. KG
All rights reserved.
Dear customer,
congratulations on choosing a SCHUNK product. By choosing SCHUNK, you have opted for
the highest precision, top quality and best service.
You are going to increase the process reliability of your production and achieve best
machining results – to the customer's complete satisfaction.
SCHUNK products are inspiring.
Our detailed assembly and operation manual will support you.
Do you have further questions? You may contact us at any time – even after purchase.
Kindest Regards
Yours SCHUNK GmbH & Co. KG
Spann- und Greiftechnik
Bahnhofstr. 106 – 134
D-74348 Lauffen/Neckar
Tel. +49-7133-103-0
Fax +49-7133-103-2399
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Table of contents
01.00|OPS 80 - 300|en
3
Table of contents
1
About this manual .................................................................................................... 4
1.1
Warnings................................................................................................................... 4
1.2
Applicable documents .............................................................................................. 4
2
Basic safety notes .................................................................................................... 5
2.1
Intended use............................................................................................................. 5
2.2
Not intended use...................................................................................................... 5
2.3
Ambient conditions and operating conditions......................................................... 5
2.4
Product safety........................................................................................................... 6
2.4.1
Protective equipment ................................................................................... 6
2.4.2
Constructional changes, attachments, or modifications.............................. 6
2.5
Personnel qualification............................................................................................. 6
2.6
Using personal protective equipment...................................................................... 6
2.7
Notes on particular risks........................................................................................... 7
3
Warranty.................................................................................................................. 8
4
Scope of delivery ...................................................................................................... 8
5
Technical Data.......................................................................................................... 8
6
Assembly.................................................................................................................. 9
6.1
Mechanical connection ............................................................................................ 9
6.2
Electrical connection .............................................................................................. 12
6.2.1
Sensor PNP-Version (standard)................................................................... 13
6.2.2
Sensor NPN-Version (special) ..................................................................... 14
6.3
Air connections....................................................................................................... 15
6.3.1
Module OPS 80-100 .................................................................................... 15
6.3.2
Module OPS 160-300 .................................................................................. 15
6.3.3
Maximum operating pressure .................................................................... 15
6.4
How to dertermine the operating pressure........................................................... 16
6.4.1
Calculation of the input air pressure (P)..................................................... 16
7
Troubleshooting ...................................................................................................... 20
7.1
OPS does not react? ............................................................................................... 20
7.2
OPS does not lock? ................................................................................................. 20
7.3
No electrical signal?................................................................................................ 20
8
Maintenance and Care ............................................................................................ 21
8.1
Notes....................................................................................................................... 21
8.2
Disassembly of the module .................................................................................... 22
8.3
Renew seals and O-Ring ........................................................................................ 23
8.4
Assembly of the module......................................................................................... 24
9
Seal kit .................................................................................................................... 25
10
Enclosed pack.......................................................................................................... 26
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About this manual
4 01.00|OPS 80 - 300|en
About this manual
This instruction is an integral part of the product and contains impor-
tant information for a safe and proper assembly, commissioning, op-
eration, maintenance and help for easier trouble shooting.
Before using the product, read and note the instructions, especial-
ly the chapter "Basic safety notes".
Warnings
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Danger for persons.
Non-compliance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons.
Ignoring a safety note like this can lead to irreversible injury and
even death.
CAUTION
Dangers for persons.
Non-observance can cause minor injuries.
NOTICE
Material damage
Information about avoiding material damage.
WARNING
Warning about dangerous electrical voltage
Applicable documents
•General terms of business
•Catalog data sheet of the purchased product
The documents listed here, can be downloaded on our homepage
www.schunk.com
1
1.1
1.2
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Basic safety notes
01.00|OPS 80 - 300|en
5
Basic safety notes
Intended use
The Kollision- and Overload Protection OPS was designed as a de-
vice to protect robots and handling unit from damage resulting
from collisions and overload conditions.
The product is intended for installation in a machine/system. The
requirements of the applicable guidelines must be observed and
complied with.
The product may be used only in the context of its defined applica-
tion parameters (5, Page 8).
The product is designed for industrial use.
To use this unit as intended, it is also essential to observe the
technical data and installation and operation notes in this manual
and to comply with the maintenance intervals.
Not intended use
Use which is not specified as an intended use is for instance when
the product is for example used as a pressing tool, stamping tool,
lifting tool, guide for tools, cutting tool, tensioning mean, boring
tool.
Ambient conditions and operating conditions
•Make sure that the product has a sufficient size for the 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 en-
vironments.
2
2.1
2.2
2.3
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Basic safety notes
6 01.00|OPS 80 - 300|en
Product safety
Dangers arise from the product, if:
•the product is not used in accordance with its intended pur-
pose.
•the product is not installed or maintained properly.
•the safety and installation notes are not observed.
Avoid any manner of working that may interfere with the function
and operational safety of the product.
Wear protective equipment.
NOTE
More information are contained in the relevant chapters.
Protective equipment
Provide protective equipment per EC Machinery Directive.
Constructional changes, attachments, or modifications
Additional drill holes, threads, or attachments that are not offered
as accessories by SCHUNK may be attached only with permission
of SCHUNK.
Personnel qualification
The assembly, initial commissioning, maintenance, and repair of
the product may be performed only by trained specialist person-
nel. Every person called upon by the operator to work on the
product must have read and understood the complete assembly
and operating manual, especially the chapter "Basic safety notes"
(2, Page 5). This applies particularly to personnel only used oc-
casionally, such as maintenance personnel.
Using personal protective equipment
When using this product, observe the relevant industrial safety
regulations and use the personal protective equipment (PPE) re-
quired!
•Use protective gloves, safety shoes and safety goggles.
•Observe safe distances.
•Minimal safety requirements for the use of equipment.
2.4
2.4.1
2.4.2
2.5
2.6
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Basic safety notes
01.00|OPS 80 - 300|en
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 con-
nected.
•Do not reach into the open mechanism or the movement area
of the unit.
•Perform maintenance, modifications, and additions outside the
danger zone.
•Secure the product during all operations against uncontrolled
activation.
•Take a precautionary approach by maintenance and disassem-
bly.
•Only specially trained staff should disassemble the product.
WARNING
Risk of injury when the machine/system moves unexpectedly.
WARNING
While disassembling uncontrollable moves of parts of the grip-
per possible!
WARNING
possibility of uncontrolled movements of individual parts of the
module during dissassembly!
2.7
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Technical Data
8 01.00|OPS 80 - 300|en
Warranty
If the product is used as intended, the warranty is valid for 24
months from the date of delivery from the production facility un-
der the following conditions:
•Observe the applicable documents (1.2, Page 4)
•Observance of the ambient conditions and operating conditions
(2.3, Page 5)
Parts touching the workpiece and wearing parts are not part of the
warranty.
Scope of delivery
The scope of delivery includes:
•Collision and Overload Protection OPS in the ordered model.
•Accessory pack
Technical Data
Size 80 100 160 200 300
Operating pressure [bar] 0.5 - 3 0.5 - 5 0.5 - 5 1 - 6 1 - 6
Axial deflection [mm] 12.0 14.0 8.0 9.5 3.5
Angular deflection [°] 12 12 5 4 ca. ± 1 *
Rotational deflection [°] 360 360 360 360 -
With rotational limitations - - - - 14
* The sizeOPS 300 (special) is equipped with flexible stop ele-
ments. Therefore higher payloads at larger angles of deflection are
involved.
Further technical data can be found in the catalog data sheet.
The most recent version applies.
3
4
5
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Assembly
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9
Assembly
Mechanical connection
Fig. 1 OPS 80
Item Designation Item
Designation
1 Sensor connection 3 Air connection
2 Notch
ATool side
4 Cylinder head screw 4 x M6 5 Cylindrical pin 2x Ø 6mm
BRobot side
6 Cylinder head screw 3 x M4 7 Cylindrical pin 2x Ø 4mm
Fig. 2 OPS 100
Item Designation Item Designation
1 Sensor connection 3 Air connection
2 Notch
ATool side
4 Cylinder head screw 6 x M8 5 Cylindrical pin 2x Ø 8mm
BRobot side
6 Cylinder head screw 6 x M5 7 Cylindrical pin 2x Ø 5mm
6
6.1
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Assembly
10 01.00|OPS 80 - 300|en
Fig. 3 OPS 160
Item Designation Item Designation
1 Sensor connection 3 Air connection
2 Notch
ATool side
4 Cylinder head screw 6 x
M10
5 Cylindrical pin 2x Ø 10mm
BRobot side
6 Cylinder head screw 6 x M8 7 Cylindrical pin 2x Ø 8mm
Fig. 4 OPS 200
Item
Designation Item Designation
1 Air connection 3 Notch
2 Sensor connection
ATool side
4 Cylinder head screw 6 x
M10
5 Cylindrical pin 2x Ø
10mm
BRobot side
6 Cylinder head screw 6 x M8 7 Cylindrical pin 2x Ø 8mm
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Assembly
01.00|OPS 80 - 300|en
11
Fig. 5 OPS 300 (special)
Item
Designation Item Designation
1 Air connection 3 Notch
2 Sensor connection
ATool side
4 Cylinder head screw 6 x
M10
5 Cylindrical pin 2x Ø
10mm
BRobot side
6 Cylinder head screw 6 x M8 7 Cylindrical pin 2x Ø 8mm
NOTE
The basic position of the OPS is clearly defined, since it only snaps
in a certain position.
The OPS snaps, when the notch of the flange is aligned with the
notch on the housing.
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Assembly
12 01.00|OPS 80 - 300|en
Electrical connection
DANGER
Danger from electric voltage!
Touching live parts can result in death.
•Switch off the power supply before any assembly, adjustment
or maintenance work and secure against being switched back
on again.
•Only qualified electricians should perform electrical installations.
•Cover up live parts.
•Check if de-energized, ground it and hot wire.
WARNING
For connection of inductive loads switch a recovery diode paral-
lely to the load!
Please make sure that power supply will be correctly polarized.
The electronic has a reverse battery protection.
6.2
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Assembly
01.00|OPS 80 - 300|en
13
Sensor PNP-Version (standard)
When the OPS is in basic position (not released), the circuit is
closed. As soon as the collision sensor got deflected (no longer in
basic position), the circuit is open.
Fig. 6 Sensor connector
Fig. 7 Circuit diagram sensor PNP-Version
Item Designation Color
1 +24V Brown
2 Signal Black
3 GND Blue
4 Load
Designation Value
Power supply [VDC] 10 ... 30 (Remaining ripple max. 10%)
Power demand [mA] Max. 7.5 (wihtout load at 24 V)
Voltage drop [V] Max. 3,6
Output PNP switching
Max. power output [mA] 180 (resistive load); short circuit proof
Output signal OPS locked – transistor leading
OPS unlocked – transistor not leading
6.2.1
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Assembly
14 01.00|OPS 80 - 300|en
Sensor NPN-Version (special)
The basic sensor position is closed, the sensor is energized.
Fig. 8 Sensor connector
Fig. 9: Circuit diagram sensor NPN-Version
Item Designation Color
1 +24V Brown
2 Signal Black
3 GND Blue
4 Load
Designation Value
Power supply [VDC] 10 ... 30 (Remaining ripple max. 10%)
Power demand [mA] Max. 2 (without load)
Voltage drop [V] Max. 3,5
Output NPN switching, Open Collector
Max. power output [mA] 40 (resistive load); short circuit proof
Output signal OPS locked – transistor not leading
OPS unlocked – transistor leading
6.2.2
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Assembly
01.00|OPS 80 - 300|en
15
Air connections
NOTICE
Observe the requirements for the air supply
(5, Page 8).
The compressed air must be filtered (10 μm), dry, oiled or unoiled.
Standard for quality of the compressed air according to ISO 8573-
1: 6 4 4.
Module OPS 80-100
Compressed air connection at the throttle check valve ensue with
a hose Ø4 x 1.
Module OPS 160-300
Compressed air connection at the throttle check valve ensue with
a hose Ø6 / Ø4.
Maximum operating pressure
•
OPS 80: 3 bar
•
OPS 100: 5 bar
•
OPS 160: 5 bar
•
OPS 200: 6 bar
•
OPS 300: 6 bar
6.3
6.3.1
6.3.2
6.3.3
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Assembly
16 01.00|OPS 80 - 300|en
How to dertermine the operating pressure
NOTICE
The OPS deflects during deaeration!
•During deflection air will exhaust permanently from the OPS. If
this should have to be avioded, the compressed air should be
switched off via an external valve during this time.
•If the facility should be switched off, please make sure that the
air supply of theOPS is assured. If this shouldn’t be possible,
the OPS has to be positioned in a way that no more deflection
may occur (possibly via devices or hanging position). During a
longer stillstand, for example over night or weekend put the
OPS always in a hanging position
NOTE
•Because of an attached throttle check valve the pressure in the
OPS can be short term maintain. This is especially important
during assembly work.
•Before adjusting the operating pressure open the throttle
check valve by turning the adjusting screw to the left.
Calculation of the input air pressure (P)
For the rough calculation of the input air pressure use the follow-
ing formulas and charts:
•Fy und Fz:
force (F) out of mass (m) and acceleration (a) calculated in N,
F=m·a
•My und Mz:
Moment (M) out of force (F) and lever arm (L) calculated in Nm,
M=F·L
•P:
input air pressure in bar
•S:
center of gravity
•D:
Distance of the mounting surfaceOPS to the center of gravity
(S) in mm
The determined input air pressure (P) must be within the operat-
6.4
6.4.1
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Assembly
18 01.00|OPS 80 - 300|en
Module OPS 160
Fig. 12 Calculation input air pressure OPS 160
Module OPS 200
Fig. 13 Calculation input air pressure OPS200
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Assembly
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19
Module OPS 300 (special)
Fig. 14 Calculation input air pressure OPS 300 (special)
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Troubleshooting
20 01.00|OPS 80 - 300|en
Troubleshooting
OPS does not react?
Possible cause Corrective action
Operating pressure is too high Check the operating pressure,
(
6.3.3,
Page 15)
OPS does not lock?
Possible cause Corrective action
Basic orientation is wrong Turn the module into basic orientation,
(
6.1, Page 9)
Dirt in the piston area Remove the cover, Clean the module and
relubricate it. (8, Page 21)
operating pressure is too low Check the operating pressure,
(
6.3.3,
Page 15)
Piston seal is dammaged Renew the sealings,
(
8, Page 21)
No electrical signal?
Possible cause Corrective action
Cable is not connected correctly Check if the circular connectors and the mi-
niature flat connectors are plugged in cor-
rectly..
The electrical outputs are misaligned Check, if strands are swapped. Observe Pin-
assignment..
The installed electrical signal transmitter are
dammaged
Send the module to SCHUNK with a repair
order..
Break of cable Replace the cable
7
7.1
7.2
7.3
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This manual suits for next models
4
Table of contents
