SCHUNK SWS-001 User instructions

Translation of the original manual
Assembly and Operating Manual
SWS
Quick-Change System

Imprint
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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: 12.00|10/09/2020|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
Clamping and gripping technology
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 Definition of Terms...................................................................................7
1.1.3 Applicable documents ..............................................................................7
1.2 Warranty .............................................................................................................. 7
1.3 Scope of delivery .................................................................................................. 7
1.4 Accessories ........................................................................................................... 8
1.4.1 Seal kit ......................................................................................................8
2 Basic safety notes ................................................................................................... 9
2.1 Intended use......................................................................................................... 9
2.2 Not intended use.................................................................................................. 9
2.3 Constructional changes ...................................................................................... 10
2.4 Spare parts ......................................................................................................... 10
2.5 Ambient conditions and operating conditions ...................................................10
2.6 Personnel qualification....................................................................................... 11
2.7 Personal protective equipment.......................................................................... 12
2.8 Notes on safe operation .....................................................................................12
2.9 Transport ............................................................................................................ 13
2.10 Malfunctions....................................................................................................... 13
2.11 Disposal .............................................................................................................. 13
2.12 Fundamental dangers......................................................................................... 13
2.12.1 Protection during handling and assembly ..............................................14
2.12.2 Protection during commissioning and operation ...................................14
2.12.3 Protection against dangerous movements.............................................15
2.13 Notes on particular risks..................................................................................... 16
3 Technical data.........................................................................................................17
3.1 Basic data ........................................................................................................... 17
3.2 Ambient conditions and operating conditions ...................................................18
3.3 Max. permissible offset when mounting the SWA with end effector ................19
4 Design and description............................................................................................20
4.1 Description ......................................................................................................... 20
4.1.1 Functional principle ................................................................................21
4.2 Design ................................................................................................................. 22
4.2.1 SWS 001..................................................................................................22
4.2.2 SWS 005..................................................................................................23
4.2.3 SWS 007..................................................................................................24
4.2.4 SWS 011..................................................................................................25
4.2.5 SWS 011HM............................................................................................26

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4.2.6 SWS 020 / 021 / 041 / 060......................................................................27
4.2.7 SWS 020HM / 021HM.............................................................................28
4.2.8 SWS 040Q / 071......................................................................................29
4.2.9 SWS 046..................................................................................................30
4.2.10 SWS 076 / 110 / 160 ...............................................................................31
5 Assembly ................................................................................................................32
5.1 Installing and connecting.................................................................................... 32
5.2 Mechanical connection ...................................................................................... 33
5.2.1 SWS 001..................................................................................................34
5.2.2 SWS 005 / 011 ........................................................................................36
5.2.3 SWS 007..................................................................................................38
5.2.4 SWS 011HM............................................................................................40
5.2.5 SWS 020 / 021 / 041 / 060......................................................................43
5.2.6 SWS 020HM / 021HM.............................................................................46
5.2.7 SWS 040Q / 071......................................................................................49
5.2.8 SWS 046..................................................................................................54
5.2.9 SWS 076 / 110 / 160 ...............................................................................56
5.3 Pneumatic connection........................................................................................ 58
5.3.1 Example for pneumatic control ..............................................................58
5.3.2 SWS 001..................................................................................................59
5.3.3 SWS 005..................................................................................................60
5.3.4 SWS 007..................................................................................................61
5.3.5 SWS 011..................................................................................................63
5.3.6 SWS 011HM............................................................................................64
5.3.7 SWS 020 / 021 / 041 / 060......................................................................65
5.3.8 SWS 020HM / 021HM.............................................................................66
5.3.9 SWS 040Q / 071......................................................................................67
5.3.10 SWS 046..................................................................................................68
5.3.11 SWS 076 / 110 / 160 ...............................................................................69
5.4 Mounting the sensor .......................................................................................... 70
5.4.1 Overview of sensors ...............................................................................70
5.4.2 Check integrated piston stroke control ..................................................71
5.4.3 Mount and check external piston stroke control ...................................74
5.4.4 Mount sensor ready-to-lock ...................................................................83
5.4.5 Wrench sizes and tightening torques .....................................................84
5.5 Mount the optional module ............................................................................... 85
6 Troubleshooting .....................................................................................................86
6.1 Product does not lock or unlock......................................................................... 86
6.2 Electrical signals are not transmitted ................................................................. 87
6.3 Locking or unlocking signal faulty....................................................................... 87
6.4 Tool presence monitoring faulty ........................................................................ 87

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7 Maintenance ..........................................................................................................88
7.1 Notes .................................................................................................................. 88
7.2 Maintenance intervals........................................................................................ 88
7.3 Lubricants/greasing areas .................................................................................. 89
7.4 Removing the product from the robot arm........................................................ 90
7.5 Clean and lubricate product ............................................................................... 91
7.6 Replace seals ...................................................................................................... 96
7.6.1 Overview of the seals .............................................................................96
7.6.2 Change O-ring.........................................................................................97
7.6.3 Change rubber bushing ..........................................................................98
7.6.4 Replace rubber bushing with sleeve.......................................................99
7.7 Change alignment pins ..................................................................................... 100
7.7.1 External alignment pins ........................................................................100
7.7.2 Internal alignment pins.........................................................................102
7.8 Change sensors................................................................................................. 103
7.8.1 Change integrated piston stroke control..............................................103
7.8.2 Change external piston stroke control .................................................109
7.8.3 Change sensor ready-to-lock ................................................................113
7.9 Maintain option modules ................................................................................. 114
7.9.1 Clean electric feed-through module.....................................................114
7.9.2 Replace V-ring seal on electric feed-through module ..........................115
7.9.3 Change rubber bushing on the fluid feed-through module..................116
7.10 Assembly drawings ........................................................................................... 117
7.10.1 SWS 001................................................................................................117
7.10.2 SWS 005................................................................................................118
7.10.3 SWS 007................................................................................................119
7.10.4 SWS 011................................................................................................120
7.10.5 SWS 011HM..........................................................................................121
7.10.6 SWS 020................................................................................................122
7.10.7 SWS 020HM..........................................................................................123
7.10.8 SWS 021................................................................................................124
7.10.9 SWS 021HM..........................................................................................125
7.10.10 SWS 040Q .............................................................................................126
7.10.11 SWS 041................................................................................................127
7.10.12 SWS 046................................................................................................128
7.10.13 SWS 060................................................................................................129
7.10.14 SWS 071................................................................................................130
7.10.15 SWS 076................................................................................................131
7.10.16 SWS 110................................................................................................132
7.10.17 SWS-160 ...............................................................................................133
8 Translation of original declaration of incorporation ..............................................134
8.1 Annex to Declaration of Incorporation............................................................. 135

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.
CAUTION
Material damage!
Information about avoiding material damage.

General
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1.1.2 Definition of Terms
The term "product" replaces the product name on the title page in
this manual.
1.1.3 Applicable documents
• General terms of business *
• Catalog data sheet of the purchased product *
• Catalog data sheet for electric feed-through modules SWO-E
and for fluid feed-through modules SWO-F
• Catalog data sheet for SWM storage racks
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
1.2 Warranty
If the product is used as intended, the warranty is valid for
24 months from the ex-works delivery date under the following
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.
1.3 Scope of delivery
The scope of delivery includes
• Quick-Change System SWS in the version ordered,
consisting of the following components
– Quick-change master SWK
– Quick-change adapter SWA
• Assembly and Operating Manual
• Accessory pack

General
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1.4 Accessories
The following accessories are available for the product, which
must be ordered separately:
• Electric modules SWO-E and fluid modules SWO-F
• Modular storage rack SWM
• Sensors for piston stroke control and presence monitoring of
the SWA
• Dust cover SWD for quick-change adapter SWA
• Seal kit
• Cable connectors and cable extensions
• Adapter plates for screwing to the robot
For information regarding which accessory articles can be used
with the corresponding product variants, see catalog data sheet.
1.4.1 Seal kit
Size ID.-No. of the seal kit
SWS001 available from SCHUNK on request
SWS005 0370819
SWS007 1371094
SWS011 0370977
SWS011HM available from SCHUNK on request
SWK020 0370821
SWA020 0370822
SWS020HM available from SCHUNK on request
SWS021 0370978
SWS021HM available from SCHUNK on request
SWS040Q 0370949
SWS041 0370979
SWS046 1371095
SWS060 0370824
SWS071 0370980
SWS076 0370948
SWS110 0370806
SWS160 0370992

Basic safety notes
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2 Basic safety notes
2.1 Intended use
• The quick-change system SWS consists of a quick-change master
SWK and a quick-change adapter SWA. It is exclusively intended
for the automated changing of tools, e.g. grippers or other end
effectors on robots.
• The quick-change master SWK is mounted on a robot. An end
effector is mounted on the quick-change adapter SWA. By using
an optionally available storage rack and several tools with quick-
change adapters, the possibilities for automation are extended.
• 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/system.
The applicable guidelines must be observed and complied with.
• The product may only be used within the scope of its technical
data, Technical data [}17].
Operating conditions • Use only in covered or closed areas.
• Use in non-explosive areas.
• Only the substances permitted for the respective product
should be fed through (fluids, electricity). All substances are
only to be fed through the modules provided for this purpose.
Never feed through corrosive or flammable gases.
• Only use the accessories permitted for the respective product.
• The product is intended for industrial and industry-oriented use.
• Appropriate use of the product includes compliance with all
instructions in this manual.
2.2 Not intended use
Any use that exceeds or differs from the appropriate use is
regarded as misuse. This includes in particular:
• Assembly on products that are not robots
• Use of the product as lifting equipment
• Outdoor use
• Use in potentially explosive areas

Basic safety notes
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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.
2.5 Ambient conditions and operating conditions
Required ambient conditions and operating conditions
Incorrect ambient and operating conditions can make the product
unsafe, leading to the risk of serious injuries, considerable material
damage and/or a significant reduction to the product's life span.
• Make sure that the product is used only in the context of its
defined application parameters, Technical data [}17].

Basic safety notes
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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.

Basic safety notes
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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.
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.

Basic safety notes
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2.12.1 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
swiveling range.
• Never move loads without supervision.
• Do not leave suspended loads unattended.
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.

Basic safety notes
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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 due to unexpected movements!
If the power supply is switched on or residual energy remains in
the system, components can move unexpectedly and cause
serious injuries.
•Before starting any work on the product: Switch off the power
supply and secure against restarting.
•Make sure, that no residual energy remains in the system.
WARNING
Risk of crushing from objects falling and being ejected!
During operation, the load can no longer be held if the maximum
permissible load is exceeded, if a component breaks or if the
pressure drops.
•Check product for damage before operation. Arrange for
repairs if necessary.
•Observe maintenance intervals.
•Take suitable protective measures to secure the danger zone.

Technical data
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3 Technical data
3.1 Basic data
SWS Weight [kg] Recommended
handling
weight [kg]
Max. moment [Nm]
SWK SWA Mx and MyMZ
001 0.03 0.02 1.4 2.8 3.45
005 0.27 0.09 8 37.5 51
007 0.16 0.08 16 75 102
011 0.13 0.09 16 75 102
011HM 0.29 0.09 16 20.3 12.4
020 0.69 0.32 25 169.5 220
020HM 0.68 0.32 25 56.5 78
021 0.5 0.3 25 169.5 230
021HM 0.7 0.3 25 56.5 78
040Q 1.27 0.6 50 471 648
041 1.4 0.7 50 471 648
046 1.95 1.03 50 678 882
060 1.3 0.7 75 591 326
071 1.8 1.3 79 1185 378
076 2.25 1.4 100 1626 2103
110 4 2.2 150 2352 2352
160 6.44 2.86 300 7170 3800
More technical data is included in the catalog data sheet.
Whichever is the latest version.

Technical data
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3.2 Ambient conditions and operating conditions
All SWS sizes
Designation SWS
Ambient temperature [°C]
min.
max.
+5
+60
Pressure medium Compressed air, compressed air
quality according to
ISO 8573-1:7 4 4
Permissible pressure range
[bar]
4.5-6.9
* 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.

Technical data
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3.3 Max. permissible offset when mounting the SWA with end
effector
Axial offset Z Angular offset X/Y
Lateral offset X/Y
Torsional offset Z
SWK
SWA
Offset definition
SWS Max.
torsional
offset Z [°]
Max. axial
offset Z
[mm]*
Max. lateral
offset XY
[mm]**
Max. angular
offset XY [°]
001 ±1 3 ±2 ±0.7
005 ±2 2 ±1 ±1.1
007 ±2 1.5 ±1 ±1.5
011 ±2 1.5 ±1 ±0.8
011HM ±2 1.5 ±1 ±0.8
020 ±2 2 ±1 ±0.8
020HM ±2 2 ±1 ±0.8
021 ±2 2 ±1 ±0.8
021HM ±2 2 ±1 ±0.8
040Q ±2 5 ±2 ±1.0
041 ±2 3 ±2 ±1.0
046 ±2 2.5 ±1.5 ±1.0
060 ±1 3 ±2 ±0.6
071 ±1 3 ±2 ±0.6
076 ±1 2 ±1 ±1.0
110 ±1 3 ±1 ±0.7
160 ±1 2.5 ±2 ±0.7
* Maximum values specified. By reducing the actual values, the
wear and tear during coupling/decoupling is minimized.
** The actual values may be higher in some cases. However,
higher offset values increase the wear and tear during
coupling/decoupling.

Design and description
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4 Design and description
4.1 Description
Quick-change systems (SWS) enable automated tool change and
consist of two components:
• Quick-change master SWK: The SWK is connected to the robot
and, together with the SWA, forms the interface between the
robot and the end effector.
• Quick-change adapter SWA: The SWA is connected to the end
effector. If different tools are used with an SWK, each end
effector is equipped with an SWA. The unused tools are stored
by the robot in a storage rack during when not being used.
Storage racks are optionally available as accessories from
SCHUNK.