SCHUNK ROTA TB-TBS-EP User instructions

Translation of Original Operating Manual
Pneumatic power chuck
ROTA TB-TBS-EP
Assembly and Operating Manual
Superior Clamping and Gripping

Imprint
2 02.00|0889073_ROTA TB-TBS-EP |en
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: 0889073
Version: 02.00 |27/02/2020|en
© H.-D. SCHUNK GmbH & Co.
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
H.-D. SCHUNK GmbH & Co.
Spanntechnik KG
Lothringer Str. 23
D-88512 Mengen
Tel. [phone]
Fax [phone]
[email protected]
schunk.com

Table of contents
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3
Table of contents
1
About this manual .................................................................................................... 5
1.1
Presentation of Warning Labels ............................................................................... 5
1.2
Applicable documents.............................................................................................. 6
2
Basic safety instructions ........................................................................................... 7
2.1
Intended use............................................................................................................. 7
2.2
Not intended use...................................................................................................... 7
2.3
Notes on particular risks........................................................................................... 8
2.4
Notes on safe operation......................................................................................... 11
2.4.1
Substantial modifications............................................................................ 14
2.5
Personnel qualification........................................................................................... 14
2.6
Organizational measures........................................................................................ 14
2.7
Using personal protective equipment.................................................................... 15
3
Warranty................................................................................................................. 16
4
Torques per screw ................................................................................................... 16
5
Scope of delivery ..................................................................................................... 16
6
Technical Data......................................................................................................... 17
6.1
Chuck data .............................................................................................................. 17
6.2
Clamping force / speed diagrams........................................................................... 20
6.3
Calculations for clamping force and speed ............................................................ 30
6.3.1
Calculation of the required clamping force in case of a given rpm............ 30
6.3.2
Calculation example: required initial clamping force for a given speed .... 32
6.3.3
Calculation of the permissible speed in case of a given initial clamping
force ............................................................................................................ 34
6.4
Grades of Accuracy................................................................................................. 35
6.5
Permissible imbalance DIN ISO 21940-11 .............................................................. 35
7
................................................................................................................................ 36
7.1
Pre-assembly measures.......................................................................................... 36
7.2
Distributor ring ....................................................................................................... 36
7.2.1
Mounting with bracket ............................................................................... 37
7.2.2
Mounting with 2-part clamping ring (D.R.M.B.) ......................................... 39
7.3
Attachment............................................................................................................. 40
7.3.1
All TB 400 – 850, TB-LH 400 – 850, TB/TB-LH 1000 (2010 or later*).......... 40
7.3.2
All TB/TB-LH 1000 (up to 2009*) and EP/EP-LH ......................................... 42
8
Function .................................................................................................................. 44
8.1
Principle of Operation ............................................................................................ 44

Table of contents
4 02.00|0889073_ROTA TB-TBS-EP |en
8.2
Air transmission system ......................................................................................... 44
8.3
Pilot controlled check valve.................................................................................... 46
8.4
Clamping or jaw actuation ..................................................................................... 47
9
Commissioning and maintenance ............................................................................ 48
9.1
Commissioning ....................................................................................................... 48
9.2
Maintenance........................................................................................................... 49
9.3
Maintenance intervals............................................................................................ 52
9.4
Hardened Reversible Jaws and Soft Top Jaws........................................................ 52
10
Disassembly and assembly ...................................................................................... 54
10.1
TB 400 - 850, TB-LH 400 - 850, TB/TB-LH 1000 (year of construction 2010 or later)
................................................................................................................................ 54
10.1.1
Disassembly................................................................................................. 54
10.1.2
Assembly ..................................................................................................... 55
10.2
All TB/ TB-LH up to size 1000 (until year of construction 2009) and all EP/EP-LH 56
10.2.1
Disassembly................................................................................................. 56
10.2.2
Assembly ..................................................................................................... 58
11
Control of types TB / TB-LH / EP / EP-LH .................................................................. 59
12
TBS, TBS-LH stationary power chucks ...................................................................... 59
13
Power Chuck with extended and standard jaw stroke (LH) ...................................... 60
14
Disposal .................................................................................................................. 61
15
Spare parts.............................................................................................................. 62
16
Assembly drawings.................................................................................................. 64
17
Translation of original EC declaration of incorporation ............................................ 71
18
Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B ..... 72

About this manual
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5
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
(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.
CAUTION
Material damage!
Information about avoiding material damage.
1
1.1

About this manual
6 02.00|0889073_ROTA TB-TBS-EP |en
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 schunk.com
1.2

Basic safety instructions
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7
Basic safety instructions
Improper handling, assembly and maintenance of this product may
result in risk to persons and equipment if this operating manual is
not observed.
Report any failures and damage immediately and repair without
delay to keep the extent of the damage to a minimum and prevent
compromising the safety of the product.
Only original SCHUNK spare parts may be used.
Intended use
The chuck is used to clamp workpieces on machine tools and other
suitable technical facilities, paying particular attention to the
technical data specified by the manufacturer. The technical data
specified by the manufacturer must never be exceeded.
The product is intended for industrial use.
Intended use also means that the user has read and understood
this operating manual in its entirety, especially the chapter “Basic
safety notes”.
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”). (6.1, Page 19)
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.
(6.1, Page 19)
• 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.
2
2.1
2.2

Basic safety instructions
8 02.00|0889073_ROTA TB-TBS-EP |en
Notes on particular risks
This product may cause danger to persons and damage to
property if, for example
- is not used as intended,
- is improperly installed or maintained;
- the safety and assembly instructions, the safety and accident
prevention regulations valid at the place of use and the EC
Machinery Directive are not observed.
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
automated 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
maintain 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
requirements of the EC Machinery Directive; specifically, they
must have effective technical measures to protect against
potential mechanical hazards.
2.3

Basic safety instructions
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9
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.
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
requirements of the EC Machinery Directive; specifically, they
must have effective technical measures to protect against
potential mechanical hazards.
• Always wear tight-fitting clothing and a hairnet when working
on the machine and the lathe chuck.
WARNING
Risk of injury due to dropping the chuck during transport,
installation or removal.
• Take special care in the danger zone when transporting,
installing or removing the chuck.
• Note the relevant load securing regulations for working safely
with cranes, ground conveyors, lifting gear and load-handling
equipment.

Basic safety instructions
10 02.00|0889073_ROTA TB-TBS-EP |en
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
replacing moving parts.
• Do not reach between the jaws.
• Wear safety gloves.
• Observe the safety and accident prevention regulations during
operation of the chuck, especially in connection with
machining centers and other technical equipment.
CAUTION
Risk of burns due to workpieces with high temperatures.
• Wear protective gloves when removing the workpieces.
• Automatic loading is preferred.
CAUTION
Risk of damages 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 the top jaws may be damaged.
• The T-nuts combine the top jaws with the base jaws and they
should never protude over the base jaws in radial direction.
• The outer diameter of the screwed top jaws must not exceed
the outer diameter of the chuck by more than 10%.

Basic safety instructions
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11
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.
Notes on safe operation
• The machine spindle may only be started up when clamping
pressure has built up in the cylinder and clamping has followed
in the permitted work area.
• Unclamping may only be possible when the machine spindle
has come to a standstill.
• If the clamping energy fails, the workpiece must remain firmly
clamped until the spindle is shut down and the workpiece is
secured.
• The technical safety requirements in the respective operating
instructions must be observed exactly.
Functional test
After installation of the chuck, its function must be checked prior
to start-up.
Two important points are:
• Clamping force At max. actuating force/pressure, the clamping
force specified for the chuck must be reached.
• Stroke control The stroke of the clamping piston must have a
margin of safety at the front and back end positions. The
spindle must not start up until the clamping piston has passed
through the safety margin.
When determining the clamping force required to machine a
workpiece, the centrifugal force acting on the chuck jaws must be
taken into account (according to VDI 3106).
If the chuck jaws are changed, adjust the stroke control to the new
situation.
2.4

Basic safety instructions
12 02.00|0889073_ROTA TB-TBS-EP |en
Speed
DANGER
Possible risk of fatal injury to operating personnel if the chuck's
top speed is exceeded and a workpiece is released or parts fly
off.
If the machine tool or technical equipment can reach a higher
speed than the chuck's top speed, a reliable speed limiter must
be installed and proof must be provided that the speed limiter is
effective.
Maintenance instructions
The chuck's reliability and safety can only be guaranteed if the
operator complies with the manufacturer's maintenance
instructions.
• For lubrication, we recommend our tried and tested special
grease, LINOMAX plus. Unsuitable lubricants can have a
negative impact on the functioning of the chuck (clamping
force, coefficient of friction, wear characteristics).
(For product information about LINOMAX plus, see the
"Accessories" chapter of the SCHUNK lathe chuck catalog or
contact SCHUNK).
• Use a suitable high-pressure grease gun to ensure that you
reach all the greasing areas.
• To ensure correct distribution of the grease, move the clamping
piston to its end positions several times, lubricate again, and
then check the clamping force.
• We recommend checking the clamping force using a clamping
force tester before starting a new production run and between
maintenance intervals. "Only regular checks can guarantee
optimal safety."
• The clamping force should always be measured in the state of
the chuck as used for the current clamping situation. If top jaws
with clamping steps are used, measuring must be performed in
the same step as for the respective clamping task. In the event
of high operating speeds, clamping force losses must be
accounted for due to the centrifugal force acting on the chuck
jaws. The operating clamping force must in this case be
determined by means of dynamic measurement.
• Move the clamping piston through to its end position several
times after 500 clamping strokes, at the latest. (This moves the

Basic safety instructions
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13
lubricant back to the surfaces of the force transmission. This
means that the clamping force is retained for longer).
Caution
Following a longer shutdown period (more than 6 hours), always
retension the clamped lathe chuck in order to compensate for the
setting properties of the clamping situation or possible pressure
losses and the resulting loss of clamping force.
Safety notes for servicing
Follow all the applicable legal norms for health and safety during
servicing. Use suitable personal protective equipment, especially
protective gloves, goggles and safety boots, paying particular
attention to the operating system and hazard assessment.
DANGER
Possible risk of fatal injury to operating personnel due to chuck
failure if the servicing instructions for the chuck are
disregarded!
The servicing instructions specified by the manufacturer must be
complied with to ensure safe operation of the chuck.
Work must be carried out by qualified specialist personnel with
the relevant safety training.
Use of special chuck jaws
When using special chuck jaws, please observe the following rules:
• The chuck jaws should be designed to be 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).
• Do not use welded jaws.
• If for constructional reasons the chuck jaws in special design
are heavier than the top jaws assigned to the clamping device,
greater centrifugal forces must be accounted for when defining
the required clamping force and the recommended speed.
• Screw the jaw mounting screws into the bore holes furthest
apart.
• The maximum recommended speed may only be operated in
conjunction with maximum actuating force and only with the
chuck in optimal, fully functioning condition.

Basic safety instructions
14 02.00|0889073_ROTA TB-TBS-EP |en
• If the chuck is involved in a collision, it must be subjected to a
crack test before using it again. Replace damaged parts with
original SCHUNK spare parts.
• Replace the chuck jaw mounting screws if there are signs of
wear or damage. Only use screws with a quality of 12.9.
Substantial modifications
No substantial modifications may be made to the chuck.
If the operator carries out a substantial modification to the
chuck, the product shall no longer conform to the EC Machinery
Directive 2006/42/EC.
Personnel qualification
Assembly and disassembly, commissioning, operation and repair of
the chuck may be performed only by qualified specialists who have
been instructed with respect to safety.
All persons who are assigned to operate, maintain and repair our
chuck must have access to the operating manual, especially the
chapter “Fundamental safety instructions”. We recommend that
the operator create in-house safety operating instructions.
Persons in training may be assigned to machines and technical
equipment in which a chuck is mounted only if they are under the
constant guidance and supervision of qualified specialists.
Organizational measures
Obeying the rules
Via suitable organizational measures and instructions, the
operator must ensure that the relevant safety rules are obeyed by
the persons asked to operate, maintain and repair the chuck.
Checking the behavior of personnel
The operator must at least occasionally check that the personnel
are behaving in a safety conscious manner and are aware of the
potential hazards.
Danger signs
The operator must ensure that the signs concerning safety and
hazards mounted on the machine where the chuck is mounted are
clearly legible and are observed.
Faults
If a fault occurs on the chuck and this fault endangers safety or if a
2.4.1
2.5
2.6

Basic safety instructions
02.00|0889073_ROTA TB-TBS-
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15
problem is suspected due to production characteristics, the
machine tool where the chuck is mounted must be immediately
stopped and remain shut down until the fault has been located
and remedied. Only allow specialists to remedy faults.
Spare parts
Only ever use original SCHUNK spare parts.
Environmental regulations
Comply with the applicable legal norms when disposing of waste.
Using personal protective equipment
When using this product, you must comply with the relevant
health and safety at work rules and you must use the required
personal safety equipment (minimum: category 2).
2.7

Scope of delivery
16 02.00|0889073_ROTA TB-TBS-EP |en
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 applicable documents, (1.2, Page 6)
• Observe the ambient conditions and operating conditions
• Observe the maximum number of clamping cycles
(6.1, Page 19)
• Observe the specified maintenance and lubrication intervals,
(9, Page 48)
Parts touching the workpiece and wear parts are not included in
the warranty.
Torques per screw
Tightening torques for mounting screws used to clamp the chuck
on lathes or other suitable technical equipment (screw quality
10.9)
Screw size
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
Admissible torque
MA(Nm)
13
28
50
88
120
160
200
290
400
500
1050
1500
Tightening torques for mounting screws used to attach top jaws
onto the chuck (screw quality 12.9)
Screw size
M6
M8
M10
M12
M14
M16
M20
M24
Max. admissible torque MA(Nm)
16
30
50
70
130
150
220
450
Scope of delivery
1
ROTA TB chuck
6
T-Nuts
2
Elbow connectors
2
Straight connectors
1
Eye bolt
Mounting screws
1
Operating manual
3
4
5

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17
Technical Data
Chuck data
ROTA TB
Size
400-115
400-140
470-185
500-160
500-205
500-230
600-275
630-265
Chuck Ø
400
422
470
500
540
570
610
630
Chuck through
bore [mm]
115
140
185
160
205
230
260
265
Max. clamping
force [kN]
200
180
115
300
240
230
190
330
Max. rotation
speed [min-1]
1700
1700
1700
1300
1300
1300
1300
1000
Stroke per jaw
[mm]
7
7
7
8.5
8.5
8.5
12
10
Serration of the
jaws [mm]
3/32" x 90°
Distributor ring
Ø [mm]
467
467
470
570
570
570
570
685
Centrifugal
torque of base
jaw [kgm] McGB
0.497
0.535
0.626
0.749
0.847
0.891
1.300
1.624
Max. jaw
eccentricity of
center of gravity
in axial direction
[mm] amax
36
ROTA TB
Size
630-310
630-330
800-365
800-410
1000-
534
400-
140-LH
470-
185-LH
500-
205-LH
Chuck Ø
662
685
800
800
1000
467
470
570
Chuck through
bore [mm]
310
330
365
410
534
140
185
205
Max. clamping
force [kN]
280
280
420
400
280
180
115
240
Max. rotation
speed [min-1]
1000
700
750
750
450
1300
1300
1100
Stroke per jaw
[mm]
10
10
12
12
12
19
20
25.4
6
6.1

18 02.00|0889073_ROTA TB-TBS-EP |en
Size
630-310
630-330
800-365
800-410
1000-
534
400-
140-LH
470-
185-LH
500-
205-LH
Serration of the
jaws [mm]
3/32" x 90°
Distributor ring
Ø [mm]
685
685
850
850
850
467
470
570
Centrifugal
torque of base
jaw [kgm] McGB
1.745
1.815
3.031
3.172
4.292
0.866
0.823
1.399
Max. jaw
eccentricity of
center of gravity
in axial direction
[mm] amax
36
42
36
ROTA TB
Size
500-230-
LH
600-275-
LH
630-265-
LH
630-325-
LH
850-375-
LH
1000-
560-LH
1200-
640-LH
Chuck Ø
570
610
685
720
850
1000
1200
Chuck through
bore [mm]
230
275
265
325
375
560
640
Max. clamping
force [kN]
220
180
330
280
330
170
170
Max. rotation
speed [min-1]
1100
1100
900
900
750
450
180
Stroke per jaw
[mm]
25.4
25.4
38
25.4
25.4
25.4
38
Serration of the
jaws [mm]
3/32" x 90°
Distributor ring Ø
[mm]
570
570
685
685
850
850
925
Centrifugal torque
of base jaw [kgm]
McGB
1.312
1.349
2.251
2.641
4.806
5.189
9.062
Max. jaw
eccentricity of
center of gravity in
axial direction
[mm] amax
36
42

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19
ROTA EP
Size
380-127
460-165
460-185
500-260
460-165-
LH
460-185-
LH
Chuck Ø
380
460
460
500
460
460
Chuck through bore [mm]
127
165
185
26
165
185
Max. clamping force [kN]
160
230
230
80
230
220
Max. rotation speed
[min-1]
2300
1600
1600
1000
1600
1600
Stroke per jaw [mm]
7
7
7
15
19
19
Serration of the jaws
[mm]
3/32" x 90°
1/16" x
90°
3/32" x 90°
Distributor ring Ø [mm]
380
460
460
467
460
460
Centrifugal torque of
base jaw [kgm] McGB
0.432
0.622
0.640
0.343
0.787
0.816
Max. jaw eccentricity of
center of gravity in axial
direction [mm] amax
36
32
36
40
The specified maximum speed of rotation stated only applies when
using the maximum clamping force and the SHB-type, hard,
standard stepped jaws that go with the chuck.
WARNING
Risk of personal injury and property damage due to parts flying
off in the event of a screw breakage on unhardened top jaws!
Soft standard top jaws must be hardened in the countersink
region.
They should only be depth-hardened, not surface-hardened.
If unhardened top jaws or chuck jaws in a special design are used,
ensure that the jaws weigh as little as possible. For soft top jaws or
chuck jaws in special design, the permissible speed of rotation
according to VDI 3106 must be calculated for the machining job in
question. The recommended maximum speed must not be
exceeded. The calculations must be checked using dynamic
measurement. Function monitoring (piston movement and
actuating pressure) must be performed in accordance with the
guidelines of the Berufsgenossenschaft (employers' mutual
insurance association).
Warranty and maximum clamping cycles
Duration of warranty
24 Months
Maximum clamping cycles
500 000

20 02.00|0889073_ROTA TB-TBS-EP |en
Clamping force / speed diagrams
The diagrams refer to 3-jaw-chuck.
Clamping force/speed curves were determined with hard standard
stepped jaws SHB, SWB and SWB-AL. The maximum actuating
force was introduced and the jaws were placed flush with the base
jaw outer edge.
The chuck is in perfect condition and lubricated with SCHUNK LINO
MAX 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
center of gravity in axial
direction
F
max
Max. actuating force
Clamping force-RPM-diagram ROTA TB 400-115
6.2