SCHUNK ROTA NCR Series User instructions

Translation of the original manual
Power Chuck
ROTA NCR
Assembly and operating manual
Superior Clamping and Gripping

Imprint
2 02.00|ROTA NCR |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: 0889064
Edition: 03.00 |18/12/2017|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
Your H.-D. SCHUNK GmbH & Co.
Spanntechnik KG
Lothringer Str. 23
D-88512 Mengen
Tel. [phone]
Fax [phone]
[email protected]
www.schunk.com

Table of Contents
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3
Table of Contents
1
General .................................................................................................................... 5
1.1
About this manual .................................................................................................... 5
1.1.1
Presentation of Warning Labels.................................................................... 5
1.1.2
Applicable documents................................................................................... 6
1.1.3
Sizes............................................................................................................... 6
1.2
Warranty................................................................................................................... 6
1.3
Scope of delivery ...................................................................................................... 6
2
Basic safety notes .................................................................................................... 7
2.1
Intended use............................................................................................................. 7
2.2
Not intended use ...................................................................................................... 7
2.3
Constructional changes ............................................................................................ 7
2.4
Spare parts................................................................................................................ 8
2.5
Chuck jaws ................................................................................................................ 8
2.6
Environmental and operating conditions................................................................. 9
2.7
Personnel qualification............................................................................................. 9
2.8
Personal protective equipment.............................................................................. 10
2.9
Notes on safe operation......................................................................................... 10
2.10
Transport ................................................................................................................ 11
2.11
Malfunctions........................................................................................................... 11
2.12
Disposal................................................................................................................... 11
2.13
Fundamental dangers............................................................................................. 12
2.13.1
Protection during handling and assembly .................................................. 12
2.13.2
Protection during commissioning and operation ....................................... 12
2.13.3
Protection against dangerous movements................................................. 13
2.13.4
Notes on particular risks ............................................................................. 13
3
Technical data ......................................................................................................... 17
3.1
Chuck data .............................................................................................................. 17
3.2
Clamping force / speed diagrams........................................................................... 18
3.3
Calculations for clamping force and speed ............................................................ 21
3.3.1
Calculation of the required clamping force in case of a given rpm............ 22
3.3.2
Calculation example: Required initial clamping force Fsp0
for a given rpm n ......................................................................................... 24
3.3.3
Calculation of the permissible rpm nzul in case of a given
initial clamping force Fsp0 .......................................................................... 25
3.4
Grades of Accuracy................................................................................................. 26
3.5
Permissible imbalance............................................................................................ 26

Table of Contents
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4
Torques per screw ................................................................................................... 26
5
Mounting ................................................................................................................ 27
5.1
Installing and connecting ....................................................................................... 27
5.2
Checking the chuck mounting ................................................................................ 27
5.3
Assembly of the chuck on the machine ................................................................. 28
5.3.1
Mounting the chuck with a reduction or extension flange ........................ 30
5.3.2
Mounting the chuck by means of a direct mount ...................................... 31
5.4
Replacing or adding to jaws ................................................................................... 32
5.5
Switching the compensating clamping on and off................................................. 32
5.6
Option with bearing plate ...................................................................................... 33
6
Function .................................................................................................................. 34
6.1
Function and handling............................................................................................ 34
6.2
Functional testing ................................................................................................... 34
7
Maintenance ........................................................................................................... 36
7.1
Lubrication.............................................................................................................. 36
7.2
Maintenance intervals............................................................................................ 36
7.3
Disassembly and assembly of the Chuck................................................................ 37
7.4
Disassembling and assembling the piston ............................................................. 38
8
Spare parts.............................................................................................................. 39
9
Assembly drawings.................................................................................................. 41
10
Translation of the original declaration of incorporation........................................... 43

General
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5
General
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
accessible 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
(1.1.2, Page 6) are applicable.
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.
1
1.1
1.1.1

General
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Applicable documents
• General terms of business *
• Catalog data sheet of the purchased product *
• Calculation of the jaw centrifugal forces, "Technology" chapter
in the lathe chuck catalog *
The documents marked with an asterisk (*) can be downloaded on
our homepage www.schunk.com.
Sizes
This operating manual applies to the following sizes:
• ROTA NCR
165; 200; 250; 315; 400; 500; 630; 800; 1000; 1250; 1600
• ROTA NCR with centrifugal force compensation
200; 250; 315; 400; 500; 630
Warranty
The warranty period is 24 months after delivery date from factory
or 500 000 cycles*, if it is used as intended, under the following
conditions:
• Observe the applicable documents (1.1.2, Page 6)
• Observe the ambient conditions and operating conditions
(2.6, Page 9)
• Observe the specified maintenance and lubrication intervals
(7, Page 36)
Parts touching the workpiece and wear parts are not included in
the warranty.
* A cycle consists of a complete clamping process
("Open" and "Close").
Scope of delivery
1
Power Chuck
3
Fastening screws (up to size 400)
6
Fastening screws (from size 500 on)
12
T-nuts for fine serration
12
Screws for tongue and groove
1
Eye bolt from size 250 and up
1
Operating manual
1.1.2
1.1.3
1.2
1.3

Basic safety notes
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7
Basic safety notes
Intended use
This product is intended for clamping workpieces on machine tools
and other suitable technical devices.
• The product may only be used within the scope of its technical
data, (3, Page 17).
• The product is intended for industrial and industry-oriented
use.
• Appropriate use of the product includes compliance with all
instructions in this manual.
• The maximum RPM of the chuck and the required clamping
force must be determined by the user for the respective
clamping task based on the applicable standards and technical
specifications of the manufacturer.
(See also “Calculations for clamping force and RPM” in the
chapter “Technical data”). (3, Page 17)
Not intended use
A not intended use of the product is for example:
• It is used as a press, a punch, a toolholder, a load-handling
device or as lifting equipment.
• the product is used for unintended machines or workpieces.
• the technical data is exceeded when using the product. (3,
Page 17)
• if workpieces are not clamped properly, paying particular
attention to the clamping forces specified by the manufacturer.
• if it is used in working environments that are not permissible.
• if the product is operated without a protective cover.
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
2.1
2.2
2.3

Basic safety notes
8 02.00|ROTA NCR |en
Spare parts
Use of unauthorised spare parts
Using unauthorised spare parts can endanger personnel and
damage the product or cause it to malfunction.
• Use only original spare parts or spares authorised by SCHUNK.
Chuck jaws
Requirements of the chuck jaws
Stored energy can make the product unsafe and risk the danger of
serious injuries and considerable material damage.
• Only replace chuck jaws if no residual energy can be released.
• Do not use welded jaws.
• The jaws should be designed as light and as low as possible.
The clamping point must be as close as possible to the chuck
face (clamping points at a greater distance lead to greater
surface pressure in the jaw guidance and can significantly
reduce the clamping force).
• If for constructional reasons the special chuck jaws are
heavier than the top jaws assigned to the lathe chuck, greater
centrifugal forces must be accounted for when defining the
required clamping force and the recommended speed.
• The maximum recommended speed may only be operated in
conjunction with maximum actuating force and only with the
lathe chuck in optimal, fully functioning condition.
• After a collision, the lathe chuck and the chuck jaws must be
subjected to a crack test before being used again. Damaged
parts must be replaced with original SCHUNK spare parts.
• Screw the jaw mounting screws into the bore holes furthest
apart.
• The jaw fastening screws must be replaced if they show
any signs of wear or damage. Only use screws with a quality
of 12.9.
2.4
2.5

Basic safety notes
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9
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.
• Make sure that the product is used only in the context of its
defined application parameters, (3, Page 17).
• Make sure that the product is a sufficient size for the application.
• Only use high-quality cooling emulsions with anti-corrosive ad-
ditives during processing.
Clamping force tester
Depending on the operating conditions, the function and clamping
force must be checked after a certain period of operation (7.2,
Page 36). Only use a calibrated clamping force tester for measur-
ing during the clamping force test.
With the smallest possible actuating pressure (clamping cylinder),
the base jaws should move evenly. This method only provides a
limited indication and is not a substitute for measuring the clamp-
ing force.
If the clamping force has dropped too much or if the base jaws and
pistons no longer move properly, the chuck must be disassembled,
cleaned, and relubricated (7, Page 36).
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:
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.
2.6
2.7
Trained electrician

Basic safety notes
10 02.00|ROTA NCR |en
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 persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behaviour.
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.
Personal protective equipment
Using personal protective equipment
Not wearing personal protective equipment while working with
the product, may result in dangers that impact the personnel's
safety and health.
• While working with the product, observe the health and safety
regulations and wear the required personal safety equipment.
• Observe the valid safety and accident prevention regulations.
• In case of sharp edges and corners and rough surfaces, wear
protection gloves.
• In case of hot surfaces, wear heat-resistant protection gloves.
• When dealing with hazardous substances, wear protection
gloves and goggles.
• In case of moving parts, wear tight protection clothes.
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 environ-
ments.
• Eliminate any malfunction immediately.
Qualified personnel
Instructed person
Service personnel of
the manufacturer
2.8
2.9

Basic safety notes
02.00|ROTA NCR |en
11
• Observe the care and maintenance instructions.
• Observe the current safety, accident prevention and
environmental protection regulations regarding the product's
appli-cation field.
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.
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 mal-
function.
• 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.
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.
2.10
2.11
2.12

Basic safety notes
12 02.00|ROTA NCR |en
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.
Protection during handling and assembly
Incorrect handling and assembly
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Have all work carried out by appropriately qualified personnel.
• For all work, secure the product against accidental operation.
• Observe the relevant accident prevention rules.
• Use suitable assembly and transport equipment and take
precautions to prevent jamming and crushing.
Incorrect lifting of loads
Falling loads may cause serious injuries and even death.
• Stand clear of suspended loads and do not step into their swiv-
eling range.
• Never move loads without supervision.
• Do not leave suspended loads unattended.
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.
2.13
2.13.1
2.13.2

Basic safety notes
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13
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 ac-
tion being dependent on the control unit and the current oper-
ating condition of the drive. Perform maintenance work, modi-
fications, 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.
Restrict unintentional access by persons to this range e.g. via a
protective cover, protective fence or photoelectric barrier. The
protective cover and protective fence must be rigid enough to
withstand the maximum possible movement energy. EMER-
GENCY STOP switches must be easily and quickly accessible.
Check the function of the EMREGENCY STOP before starting up
the machine or system. If this protective equipment is not
working properly, prevent the operation of the machine.
Notes on particular risks
DANGER
Risk of fatal injury from suspended loads!
Falling loads can cause serious injuries and even death.
• Stand clear of suspended loads and do not step within their
swiveling range.
• Never move loads without supervision.
• Do not leave suspended loads unattended.
• Wear suitable protective equipment.
2.13.3
2.13.4

Basic safety notes
14 02.00|ROTA NCR |en
DANGER
Risk of fatal injury to operating personnel due to the workpiece
falling down or being flung out in the event of a power failure
In the event of a power failure, the lathe chuck's clamping force
may fail immediately and the workpiece may be released in an
uncontrolled manner. This poses a risk of death or injury to the
operating personnel and can result in serious damage to the au-
tomated system.
• The machine manufacturer and the operator of the machine
must carry out and document a hazard assessment and risk
analysis to ensure that suitable measures are taken to main-
tain the lathe chuck's clamping force until the machine comes
to a standstill and the workpiece can be secured (e.g. using a
crane or suitable lifting equipment).
• The machines and equipment must fulfill the minimum re-
quirements of the EC Machinery Directive; specifically, they
must have effective technical measures to protect against po-
tential mechanical hazards.
DANGER
Possible risk of fatal injury to operating personnel if a jaw
breaks or if the lathe chuck fails because the technical data have
been exceeded and a workpiece is released or parts fly off
• The technical data specified by the manufacturer for using the
lathe chuck must never be exceeded.
• The lathe chuck may only be used on machines and facilities
that fulfill the minimum requirements of the EC Machinery
Directive; specifically, they must have effective technical
measures to protect against possible mechanical hazards.

Basic safety notes
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15
DANGER
Possible risk of fatal injury to operating personnel from clothing
or hair being caught on the lathe chuck and being dragged into
the machine
Loose clothing or long hair may become caught on projecting
parts of the lathe chuck and be drawn into the machine.
• The machines and equipment must fulfill the minimum re-
quirements of the EC Machinery Directive; specifically, they
must have effective technical measures to protect against po-
tential mechanical hazards.
• Always wear tight-fitting clothing and a hairnet when working
on the machine and the lathe chuck.
CAUTION
Danger of slipping and falling in case of dirty environment
where the chuck is used (e.g. by cooling lubricants or oil).
• Ensure that the working environment is clean before starting
assembly and installation work.
• Wear suitable safety shoes.
• Follow the safety and accident-prevention regulations when
operating the chuck, especially when working with machine
tools and other technical equipment.
CAUTION
Danger of limbs being crushed by opening and closing of the
chuck jaws during manual loading and unloading or when re-
placing moving parts.
• Do not reach between the chuck jaws.
• Automatic loading is preferred.
• If manual loading is used, adjust the jaw position so that the
opening gap between the jaw and the workpiece is less than 4
mm.
• Wear protective gloves.
• Observe the safety and accident prevention regulations during
operation of the chuck, especially in connection with machin-
ing centers and other technical equipment.

Basic safety notes
16 02.00|ROTA NCR |en
CAUTION
Risk of burns due to workpieces with high temperatures.
• Wear protective gloves when removing the workpieces.
• Automatic loading is preferred.
CAUTION
Risk of damage due to incorrect choice of clamping position for
chuck jaws on workpiece.
If an incorrect clamping position is chosen for the chuck jaws on
workpiece, the base and top jaws may become damaged.
• The T-nuts for connecting the top jaws to the base jaws must
not protrude beyond the base jaws in the radial direction.
• The diameter of the workpiece may not be bigger than the
chuck diameter.
CAUTION
Hazard from vibration due to imbalanced rotating parts and
noise generation.
Physical and mental strains due to imbalanced workpieces and
noise during the machining process on the clamped and rotating
workpiece.
• Ensure the chuck's axial and concentric runout.
• Check options for remedying imbalances on special top jaws
and workpieces.
• Reduce the speed.
• Wear hearing protection.

Technical data
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17
Technical data
Chuck data
ROTA NCR
165
200
250
315
400
500
630
800
1000
Max. actuating
force [kN]
20
25
38
40
54
65
80
80
150
Max. clamping
force [kN]
36
50
64
80
100
125
160
160
300
Max. speed [rpm]
4000
3500
3000
2500
1400
1200
1000
700
600
Stroke per jaw
[mm]
6
6
8
8
12
12
16
16
25
Piston stroke
[mm]
13.5
15.0
18.5
20.0
30.0
30.0
40.0
40.0
60.0
Pendular com-
pensation
1+1
1+1
2+2
2+2
2.5+2.5
2.5+2.5
3.5+3.5
3.5+3.5
6+6
Moment of inertia
[kg m
2
]
0.04
0.09
0.31
0.71
2.4
5.6
19.1
31.7
143
Weight [kg]
11.5
17.5
35
54
118
175
375
480
1250
Centrifugal force
of the base jaw
McGB [kgm]
0.009
0.015
0.041
0.063
0.216
0.338
0.935
1.491
3.360
Max. jaw eccen-
tricity of center of
gravity in axial
direction amax
[mm]
12
24
24
24
32
32
32
32
40
Sizes 1200 to 2500 upon request
The maximum RPM stated is only valid with the maximum clamp-
ing force and when using the hard standard chuck jaws that go
with the chuck.
If unhardened top jaws or special chuck jaws are used, ensure that
the jaws weigh as little as possible.
For soft top jaws or special chuck jaws, the permissible speed of rota-
tion according to VDI 3106 must be calculated for the machining job
in question. The recommended maximum speed must not be ex-
ceeded. The calculations must be checked using dynamic measure-
ment. Function monitoring (piston movement and actuating pres-
sure) must be performed in accordance with the guidelines of the
Berufsgenossenschaft (employers' mutual insurance association).
3
3.1

Technical data
18 02.00|ROTA NCR |en
Clamping force / speed diagrams
Clamping force/RPM curves have been calculated using hard jaws.
The chucks were operated with the max. permissable force and
the jaws were located exactly on line with the chuck O.D.
The chuck is in perfect condition and lubricated with SCHUNK
LINOMAX special grease.
Should one or several of the above mentioned parameters be
changed the diagrams are no longer valid.
Chuck set-up for clamping force / speed diagram
F/3
Clamping force per jaw
S
Center of gravity
rs
Center of gravity radius
a
max
Max. jaw eccentricity of cen-
ter of gravity in axial direction
Fmax
Max. actuating force
Clamping force/RPM graph for ROTA NCR 165
3.2

Technical data
02.00|ROTA NCR |en
19
Clamping force/RPM graph for ROTA NCR 200
Clamping force/RPM graph for ROTA NCR 250
Clamping force/RPM graph for ROTA NCR 315

Technical data
20 02.00|ROTA NCR |en
Clamping force/RPM graph for ROTA NCR 400
Clamping force/RPM graph for ROTA NCR 500
Clamping force/RPM graph for ROTA NCR 630