SCHUNK SVP-2 User instructions

Translation of the original manual
Assembly and Operting Manual
Clamping Device SVP-2
Polygonal Clamping System

Imprint
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03.00 | Clamping Device SVP-2 | Assembly and Operting Manual | en | 0289021
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: 0289021
Version: 03.00|18/02/2020|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
Spann- und Greiftechnik
Bahnhofstr. 106 – 134
D-74348 Lauffen/Neckar
Tel. [phone]
Fax [phone]
[email protected]
schunk.com

Table of Contents
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Table of Contents
1 General.................................................................................................................... 5
1.1 About this manual ................................................................................................ 5
1.1.1 Presentation of Warning Labels ...............................................................5
1.1.2 Applicable documents ..............................................................................6
1.2 Warranty .............................................................................................................. 6
1.3 Scope of delivery .................................................................................................. 6
1.4 Accessories ........................................................................................................... 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 ........................................................................................................... 7
2.5 Environmental and operating conditions ............................................................. 8
2.6 Personnel qualification......................................................................................... 8
2.7 Transport .............................................................................................................. 8
2.8 Disposal ................................................................................................................ 8
2.9 Fundamental dangers........................................................................................... 9
2.9.1 Protection during handling and assembly ................................................9
2.10 Notes on particular risks....................................................................................... 9
3 Technical data.........................................................................................................11
3.1 Basic data ........................................................................................................... 11
3.2 Position of the type plate ................................................................................... 11
3.3 Content of the type plate ................................................................................... 11
4 Design and description............................................................................................12
4.1 Design ................................................................................................................. 12
4.2 Description ......................................................................................................... 12
5 Assembly and settings ............................................................................................13
5.1 Fastening the clamping device onto a work bench ............................................13
5.2 Assembly of the length adjustment.................................................................... 13
6 Operation ...............................................................................................................15
6.1 Reduction insert and toolholder......................................................................... 15
6.2 Notes on clamping and unclamping ...................................................................17
6.3 TRIBOS pressure table ........................................................................................ 19

Table of Contents
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7 Troubleshooting .....................................................................................................20
7.1 Tool shank cannot be inserted if pressure is built up......................................... 20
7.2 Tool shank can only be partially inserted into the toolholder............................ 22
7.3 Tool cannot be removed from the toolholder.................................................... 23
7.4 Tool shank can be inserted outside the pressure range if slight pressure is
applied................................................................................................................ 24
7.5 Tool shank can yet not be inserted at maximum pressure ................................ 24
7.6 Clamping device does not build up pressure...................................................... 24
7.7 Torque / clamping force / holding force too low ............................................... 25
7.8 Concentricity errors on the clamped tool .......................................................... 26
7.9 SVP-2 clamping device does not reach required pressure .................................27
7.10 Oil leaking out of the clamping device ............................................................... 28
8 Maintenance ..........................................................................................................29
8.1 Care and storage ................................................................................................ 29
8.2 Maintenance and service ................................................................................... 29
9 Transport and disposal............................................................................................30
9.1 Transport ............................................................................................................ 30
9.2 Disposal .............................................................................................................. 30
10 Short manual ..........................................................................................................31

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 [}6] 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 Applicable documents
• General terms of business *
• Catalog data sheet of the purchased product *
• Assembly and Operating manual "TRIBOS Polygonal Clamping
device" (Toolholder) *
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:
• Intended use in 1-shift operation
• Recommended operating and maintenance regulations
Basically tool and machine contacting components, and wear parts
(actuation screw and seal) are not part of the warranty.
1.3 Scope of delivery
The scope of delivery includes:
• TRIBOS clamping device SVP-2 Id No.: 0211760
• Documentation SVP-2 Id No.: 0289021
1.4 Accessories
• Cylindrical brush
(see catalog Toolholder systems "Accessories")
• Insert SRE (see catalog Toolholder systems "Accessories")
• Protective cover for TRIBOS clamping device SVP-2/2D
(ID number: 9935548)
• Length adjustment LMG-M (ID number: 0201961)
• Stacker (ID number: 0211768)
• Protective cover for Stacker (ID number: 9937963)

Basic safety notes
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2 Basic safety notes
2.1 Intended use
The clamping device has been designed to equip and replace tools
in TRIBOS toolholders.
TRIBOS toolholders are suitable to clamp rotationally symmetric
tools or work pieces. With shank tools, all shanks can be clamped
according to DIN 1835 Form A, B, E or DIN 6535 Form HA, HB, HE
(shank tolerance h6).
The polygon clamping system (clamping device, reduction inserts
and TRIBOS toolholders) may only be used within the framework
of its defined application parameters Technical data [}11].
• 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
It is an not intended use of the clamping device if toolholders were
used that are not SCHUNK TRIBOS toolholders.
2.3 Constructional changes
Implementation of structural changes
By conversions, changes, and reworking, e.g. additional threads,
holes, or safety devices can impair the functioning or safety of the
product or damage it.
• Structural changes should only be made with the written
approval of SCHUNK.
2.4 Spare parts
Use of unauthorized spare parts
Using unauthorized spare parts can endanger personnel and
damage the product or cause it to malfunction.
• Use only original spare parts or spares authorized by SCHUNK.

Basic safety notes
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2.5 Environmental and operating conditions
The TRIBOS clamping device may be stored and operated only in
clean, dust-free and dry rooms at a temperature of + 15°C till +
40°C.The relative humidity can be between 20 - 80%.
2.6 Personnel qualification
The initial commissioning, maintenance, and repair of the
clamping device may only be performed by trained specialist
personnel. Every person called upon by the operator to work on
the clamping device must have read and understood the complete
assembly and operating manual, especially the chapter "Basic
safety notes" Basic safety notes [}7]. This applies particularly to
personnel only used occasionally at the TRIBOS clamping device.
2.7 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.
2.8 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.

Basic safety notes
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2.9 Fundamental dangers
2.9.1 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.
2.10 Notes on particular risks
WARNING
Risk of injury due to lateral under high pressure escaping oil!
Lateral under high pressure escaping oil on seals or by opening
the vent screw can cause serious injuries.
•Wear protective gloves and safety goggles.
CAUTION
Material damage due to incorrect insertion of the toolholder /
reduction insert!
The gripping force of the TRIBOS clamping device SVP-2 goes up
to 800 000 N!
Incorrect insertion and positioning of the toolholder causes
plastically deformation and loss of function of the toolholder.
•Insert the toolholder till the stop into the reduction insert and
position correctly (via the flattened areas).
•Insert the reduction insert till the stop into the clamping
device.

Basic safety notes
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CAUTION
Material damage due to wear of the reduction insert.
Too high wear of the reduction insert causes loss of function of
the toolholder.
The wear of the reduction insert may be maximum of 0.04 mm.
•When exceeding the maximum wear replace reduction insert.
CAUTION
Material damage due to exceeding the permissible pressure!
Too high pressure causes deformation of the toolholder and loss
of function.
•Observe the pressure specifications of the toolholder.
CAUTION
Material damage due to false minimum clamping depth!
A too low minimum clamping depth causes loss of accuracy and
torque at the toolholder.
•Observe minimum clamping depth of the tool,
✓See Assembly and Operating manual Toolholder.

Technical data
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3 Technical data
3.1 Basic data
Reference value Value
Operating pressure [bar] 0 - 400
Pressing time (depending
on clamping pressure and
oil temperature)
approx. 8 sec at 400 bar
Hydraulic oil Mobile Vactra 2 (Viskosity 68)
Ambient temperature [°C] +15 to +40
Dimensions (L x W x H)
[mm]
300 x 370 x 347
Weight [kg] 37
Protection class IP 40
3.2 Position of the type plate
Type plate
3.3 Content of the type plate
Id-No. Type plate
Construction date
Technical data
Product designation and Id-No.
Consecutive No.

Design and description
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4 Design and description
4.1 Design
Actuation handle
Vent screw
Manometer
Lateral plate with type plate
Intermediate sleeve
Measuring system
Pressure release valve
Through bore for fastening
4.2 Description
• Clamping device for a safe and quick tool change.
• With the clamping device clamp TRIBOS tools quickly and
evenly.

Assembly and settings
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5 Assembly and settings
5.1 Fastening the clamping device onto a work bench
WARNING
Risk of injury due to tilting, falling of the clamping device!
Due to tilting, falling of the clamping device hands and feet may
be squeezed and jammed.
•Fix clamping device.
In the base plate of the TRIBOS clamping device SVP-2 are four
bore holes.
The SVP-2 has to be fastened to a work bench through the
mounting holes using four screws M8 and shims (preferably made
of plastic to avoid optical damages to the housing)!
5.2 Assembly of the length adjustment
Toolholder
Zero-point determination
Check that all the parts have been provided:
• 1 Caliper gauge (1)
• 2 Measuring legs (2)
• 2 Brackets for the measuring pins (3)
• 2 Knurled screws (4)
• 1 Safety pin (5)

Assembly and settings
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ØCarefully draw the movable side (6) of the caliper gauge (1)
away. Then guide the caliper gauge from left to right through
the two slotted bearings (7) of the bracket of the base body (8)
of the clamping device. Push the movable side (6) again onto
the caliper gauge and secure it with the safety pin (5) in the
bore on the rear of the caliper gauge.
ØIn order to reach the cutter of your tool (9), you will need an
extension of the caliper gauge side. Turn the knurled screw (4)
into the bracket (3). Push one bracket over each side of the
caliper gauge (1) and insert the measuring legs (2) into the
bracket with the slotted side facing the caliper gauge side (see
illustration)
ØAfter having inserted the measuring legs (2) into the required
position, fix the bracket (3) with the knurled screw (4).
ØTo determine the zero point of the caliper gauge, swivel up the
two measuring arms and slide towards one another. Set the
caliper gauge´s display to zero (see illustration).

Operation
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6 Operation
6.1 Reduction insert and toolholder
Valid for TRIBOS toolholder: Type S / Type R / Type Mini / Type
RM / Type SVL
toolholder type S pressure indication
flattened
toolholder type R
reduction insert
flattened
pressure segment
plastic ring
0! onto stop
pressure indication
Data Matrix Code
NOTE
Former versions of the toolholder type S haven´t been equipped
with a locking surface yet. To avoid damages at the toolholders
caused by wrong clamping operations please contact SCHUNK
([phone]), before clamping the toolholders in the
clamping device SVP-2.
CAUTION
Material damage due to exceeding the permissible pressure!
Too high pressure causes deformation of the toolholder and loss
of function.
•Observe the pressure specifications of the toolholder.

Operation
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CAUTION
Material damage due to incorrect handling!
Deformation of the intermediate sleeve by clamping without
reduction insert and TRIBOS toolholder.
•Intermediate sleeve clamp with reduction insert and TRIBOS
toolholder only.
CAUTION
Risk of injury due to sharp-edged tools.
•Wear protective gloves at tool change.
ØObserve the pressure specifications of the toolholder.
ØPush the reduction insert onto the toolholder until it snaps in
via the flattened areas. In order to eliminate possible play
between the flattened area and the reduction insert, turn the
toolholder, which is clamped into the reduction insert, to the
right (clockwise).
ØSlide the reduction insert and the toolholder into the clamping
device until the stop. The position is automatically determined
by the three segments of the reduction insert in the large
intermediate sleeve of the clamping device at an angle of 120°.
ØIMPORTANT!Check that the toolholder and the reduction
insert are correctly inserted to the stop and that any possible
toolholder play is eliminated.
ØClose the pressure release valve and actuate the manual pump
until the required pressure is achieved.
✓The tool/workpiece can be inserted or removed now.
ØTo unclamp the device, open the pressure release valve.
✔The reduction insert with the toolholder can be removed from
the clamping device. The toolholder is now ready for use.

Operation
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6.2 Notes on clamping and unclamping
• Due to the manufacturing and material tolerances, it is possible
to insert or loosen tools or work pieces even at a pressure
below that indicated on the TRIBOS toolholder.
•This lower pressure value may be significantly less than that
stipulated on the toolholder.
However, this has no influence on the transmissible torque of
the toolholder (see operating manual TRIBOS polygonal tool
holder).
• Please make sure that the tool/work piece is still clamped in the
toolholder at this time, if the actual unclamping pressure of the
clamping device was exceeded! It is also possible that the tool
can no longer be inserted into the toolholder at the indicated
pressure, but instead at a value that is a few bars below it!
• Continually check the pressure in the clamping device at which
the tool/workpiece can be inserted or removed from the
toolholder.
• If it proves impossible to loosen or insert the tool or work piece
from or into the toolholder until the indicated pressure is
achieved, stop the clamping procedure. Release the pressure of
the clamping device first and then check that any play between
the flattened area of the toolholder and the reduction insert is
eliminated by turning the toolholder to the right
(clockwise).Repeat the clamping procedure.
• If it proves impossible to loosen or insert the tool/work piece,
even though the toolholder is inserted correctly in the reduction
insert, unclamp the device and remove the reduction insert and
the toolholder. Turn the reduction insert on the toolholder by
120°, push it into the clamping device again and repeat the
clamping procedure. It should now be possible to loosen the
tool/work piece.
• The tool can become stuck in the toolholder as a result of fine
particles in the cooling lubricant. If this is the case, insert a
piercer through the rear opening of the TRIBOS toolholder and
loosen the tool by pushing or gently hitting it with this piercer.
• Sometimes, the tool shanks are marked. These markings are
often "wrapped". This impairs the insertion of the TRIBOS
toolholder or even makes an insertion impossible. In this case,
re-move the wrapping.

Operation
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• Tool shanks with clearances, especially DIN 1835 shape E or DIN
6535 shape HE are often twisted and can therefore frequently
not be inserted into the TRIBOS toolholder or quickly lead to
poor run-out accuracy. The same is also true of tool shanks that
fall below h6 quality (no torque) or exceed it (not joinable).
For clamping shanks of shape E or HE, please consider the position
of the flattening to the pressure segments:
SRE-Pressure segment
Toolholder
Shank
DIN 1835 E
DIN 6535 HE
At this shank position in the TRIBOS toolholder the clamping faces
are positioned at the round shank and thus achieve the effect of a
"round shank clamp". The hardness at the tool shank should be
min. HRC 50 (shank stiffness min. 1000 N/mm2) in order to avoid a
deformation of the tool shank. If the degree of hardness or
stiffness should be lower, the compression joint is not properly
covered and therefore results a reduced force transmission of the
clamping system.

Operation
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6.3 TRIBOS pressure table
Generally the following applies: Observe TRIBOS pressure table

Troubleshooting
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7 Troubleshooting
7.1 Tool shank cannot be inserted if pressure is built up
Possible cause Corrective action
Toolholder has not fully engaged with the
engaging areas of the reduction insert.
Toolholder not placed on end stop.
Engage toolholder properly and place on end
stop.
Wrong toolholder/reduction insert angle.
Too much pressure could have been
applied to toolholder/reduction insert
causing constant deformation.
Ensure correct angle position of toolholder/
reduction insert (engaging surface must be
aligned with the segment).
TRIBOS toolholder not turned to right-
hand stop.
Turn TRIBOS toolholder to right-hand stop