Zimmer GSI Series User manual

INSTALLATION AND
OPERATING INSTRUCTIONS
Handling
technology
GSI series
O-ring assembly gripper
pneumatic
THE KNOW-HOW FACTORY
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●Phone: + 49 7844 9138-0 ● Fax: + 49 7844 9138-80 ●www.zimmer-group.de

DDOC00188 enu / 2016-08-31 / Index a
INSTALLATION AND OPERATING INSTRUCTIONS: Pneumatic GSI series O-Ring gripper
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●Phone: + 49 7844 9138-0 ● Fax: + 49 7844 9138-80 ●www.zimmer-group.de
Contents:
1. Supporting documents ............................................................................................................................ 3
2. Proper use ................................................................................................................................................. 3
3. Personnel qualications .......................................................................................................................... 3
4. Function ...................................................................................................................................................... 3
4.1 O-ring installation technological process ................................................................................................ 4
4.2 Flow chart ................................................................................................................................................... 5
5. Technical data ............................................................................................................................................ 5
6. Installation ................................................................................................................................................. 6
6.1 Installing the gripper .................................................................................................................................. 6
6.2 Power supply .............................................................................................................................................. 6
6.3 Stroke setting .............................................................................................................................................. 6
6.4 Installing the jaw set.................................................................................................................................... 7
6.5 Settings ....................................................................................................................................................... 9
6.6. Position sensing sensors............................................................................................................................ 10
7. Troubleshooting ........................................................................................................................................ 11
8. Maintenance .............................................................................................................................................. 12
9. Accessories ............................................................................................................................................... 12
10. Declaration of incorporation ................................................................................................................... 13
11. Your notes .................................................................................................................................................... 14
2

DDOC00188 enu / 2016-08-31 / Index a
INSTALLATION AND OPERATING INSTRUCTIONS: Pneumatic GSI series O-Ring gripper
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●Phone: + 49 7844 9138-0 ● Fax: + 49 7844 9138-80 ●www.zimmer-group.de
1. Supporting documents
• Catalog
• Drawings, performance data, information about accessory parts, etc.
• General Terms and Conditions of Business, including warranty information
Note: The following documents are available for download on our website.
Only the documents currently available on the website are valid.
Note: The gripper should only be used in its original state with its original accessories, with no unauthorized
changes and within the scope of its dened parameters for use.
Zimmer GmbH accepts no liability for any damage caused by improper use.
2. Proper use
The gripper is designed exclusively for pneumatic operation. The gripper is not suited for operation with any other media. The
gripper is used as dened under "Proper use" in enclosed rooms for temporarily gripping and handling O-rings.
The gripper is suited exclusively for the interior installation of O-rings. Its use for other applications is considered to be improper
use. Direct contact with perishable goods/food is not permitted.
3. Personnel qualications
Installation, commissioning and operation may be undertaken by trained specialists only. They must have read and understood the
installation and operating instructions in full.
4. Function
The gripper implements the movement sequence for picking
up, folding, inserting and wiping when installing O-rings in
inner annular grooves using three single-action pneumatic
cylinders dm dn do.
An adjustable stroke 6for the clamping jaws 4prevents
these jaws can overriding on the wiper 2
3three-part piston rod
dm Pistons for the clamping jaws
dn Pistons for the spread jaws
do Pistons for the wiper
The gripper can be adjusted to t the bore diameter of a
workpiece using an adjustable stroke 7for the spread jaws 1.
3
dm
dn
do
4
6
7
1
9
1
dm
dn
do
2
4
5
6
7
8
1Spread jaws
2Wiper
4Clamping jaws
5Force transmission (lever and connecting rod)
6Clamping jaw stroke setting
7Stroke setting on spread jaws
8Installation holes on the housing base
9Guides for magnetic eld sensors
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DDOC00188 enu / 2016-08-31 / Index a
INSTALLATION AND OPERATING INSTRUCTIONS: Pneumatic GSI series O-Ring gripper
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●Phone: + 49 7844 9138-0 ● Fax: + 49 7844 9138-80 ●www.zimmer-group.de
4.1 O-ring installation technological process
1 Home position .........................................................................►
Spread jaws 1Home position retracted
Clamping jaws 4Home position extended
Ejector 2Home position retracted
The gripper is ready to pickup an O-ring
2 Clamping ..................................................................................►
Retracting the clamping jaws 4gives the O-ring a clover shape.
(red arrow)
The spread jaws 1open and close 3 times in a row.
This is done to ensure a stress-free distribution of the O-ring on
the spread jaw (blue arrow).
Doing so also removes any potential loops that may occur.
3 Assembly ..................................................................................►
Once the gripper has reached the installation position in the
workpiece hole, the spread jaws 1spread apart and position
the O-ring in the annular groove of the workpiece
4 Wiping .......................................................................................►
The O-ring is pushed o of the clamping jaw pins 4by
extending the wiper 2.
5 Pressing in ...............................................................................►
The spread jaws 1now move back to the home position.
Additionally, the clamping jaws 4push the O-ring into the
annular groove of the workpiece again.
4
2
1
4






1
4
2
4
1

DDOC00188 enu / 2016-08-31 / Index a
INSTALLATION AND OPERATING INSTRUCTIONS: Pneumatic GSI series O-Ring gripper
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●Phone: + 49 7844 9138-0 ● Fax: + 49 7844 9138-80 ●www.zimmer-group.de
4.2 Flow chart
Action on the O-ring: Pick up O-ring Space out
evenly
Position the
wiper
Re-press
O-ring
Valve Status Step 12 3 4 5 6 1 23 4 5 6 1 2 34 5 6 1 2 3 45 6 1 2 3 4 56 1 2 3 4 5 6
Aa
b
t=0.4
Ba
b
t=0.4
Ca
b
Operating situation:
Movement to
the installation
position
In installation
position
Extend from
installation
position
Information:
Be sure to observe the description of the pneumatic connections in Chapter 6.2 "Power Supply."
5
5. Technical data
Parameters Values
GSI206
Minimum adjustable clamping jaw stroke for each gripper
jaw [mm] 6
Maximum adjustable clamping jaw stroke for each grip-
per jaw [mm] 20
Minimum adjustable spread jaw stroke for each gripper
jaw [mm] 1
Minimum adjustable spread jaw stroke for each gripper
jaw [mm] 6
Wiper stroke [mm] 5
Expanding force [N] 240
Possible O-ring Ø for thickness 1 [mm] 11 to 45
Possible O-ring Ø for thickness 2 [mm] 20 to 130
Possible O-ring Ø for thickness 3 [mm] 32 to 130
Possible O-ring Ø for thickness 4 [mm] 42 to 100
Number of gripper ngers [total] 6
Clamping jaws 3
Spread jaws 3
Min. operating pressure [bar] 3
Max. operating pressure [bar] 8
Min. operating temperature [°C] 5
Max. operating temperature [°C] +80
Weight [kg] 1.1

DDOC00188 enu / 2016-08-31 / Index a
INSTALLATION AND OPERATING INSTRUCTIONS: Pneumatic GSI series O-Ring gripper
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●Phone: + 49 7844 9138-0 ● Fax: + 49 7844 9138-80 ●www.zimmer-group.de
6. Installation
6.1 Installing the gripper
8
bl
The gripper is fastened via the 3 tapped holes 8
•Screws with a screw class of 8.8 are to be used.
•Permitted tightening torque
The orientation is determined using straight pins in both
alignment holes bl.
The dimensions of the connection structure are refer data sheet
under www.zimmer-group.de
6.2 Power supply
A
B
C
ababab
ABC
The pneumatic ttings for connecting to the power supply can be
mounted directly on the gripper.
Clamping jaws 4Connection A - Extended in a depressurized state
Spread jaws 1Connection B - Retracted in a depressurized state
Ejector 2Connection C - Retracted in a depressurized state
The activation of the gripper is displayed in the image below with
three 3/2 way valves.
The chronological activation process is displayed in a ow chart in
Chapter 4.2.
4
1
2
6.3 Settings
The clamping jaw and spread jaw stroke can be t to the respective
O-ring by twisting the two adjustment rings, 6and 7.
To prevent an unintentional adjustment of the stroke limitation, the
rings have to be secured with locking screws bm.
6Adjustment ring clamping jaw stroke
7Adjustment ring spread jaw stroke
bm Safety screws
Both adjustment rings can be turned a maximum of 3.5 revolutions.
Adjustment ring 6
Turning clockwise ►Stroke becomes smaller (gripper in its
position, as shown in the adjacent image)
Adjustment ring 7
Turning counterclockwise ►Stroke becomes smaller (gripper in its
position, as shown in the adjacent image)
6
7
bm
6

DDOC00188 enu / 2016-08-31 / Index a
INSTALLATION AND OPERATING INSTRUCTIONS: Pneumatic GSI series O-Ring gripper
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●Phone: + 49 7844 9138-0 ● Fax: + 49 7844 9138-80 ●www.zimmer-group.de
6.4 Installing the jaw set
The jaw set consists of 3 component groups.
The expanding and clamping jaws as well as the corresponding wiper are designed dierently depending on the size of the O-rings
to be installed.
Type Image / Description
3 spread jaws each for picking
up and spreading the O-rings
3 clamping jaws each for
clamping the O-rings
(clover shape)
1 wiper each for removing the
O-ring from clamping jaw pins
The following steps must be performed to install the jaw set:
Wiper
►Insert wiper2
►Secure wiper with strength class 8.8 cylinder screws
►Tighten the screws manually, the wiper must be aligned based on the
clamping jaws
Note:
Before installing the jaw set, both stroke setting rings have
to be turned in opposite directions until the limit stop is
reached to set the smallest possible stroke.
(to do so, see also Chapter 6.3)
2
7

DDOC00188 enu / 2016-08-31 / Index a
INSTALLATION AND OPERATING INSTRUCTIONS: Pneumatic GSI series O-Ring gripper
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●Phone: + 49 7844 9138-0 ● Fax: + 49 7844 9138-80 ●www.zimmer-group.de
► Inserting the centering rings prepares the gripper jaws for the installation of
the spread jaw.
Clamping jaws
►Reduce stroke to the minimum dimension (as described in Chapter 6.3)
►Position the clamping jaws 4on the gripper jaws,
•Pins in the direction of the wiper.
•Insert screws into the tapped holes
►Secure the clamping jaws with strength class 8.8 cylinder screws
• Install the gripper jaws so that they can still be moved manually
• The gripper jaws must lay ush against the contact surface
• The clamping jaw pins may not touch the spread jaws, which will
be installed in the next step (arrow)
Spread jaws
►Reduce stroke to the minimum dimension (as described in Chapter 6.3)
►Position the spread jaws 1on the centering sleeves and align them. The
gripper jaws must be centered.
►Secure the spread jaws with strength class 8.8 cylinder screws
4
1
8

DDOC00188 enu / 2016-08-31 / Index a
INSTALLATION AND OPERATING INSTRUCTIONS: Pneumatic GSI series O-Ring gripper
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●Phone: + 49 7844 9138-0 ● Fax: + 49 7844 9138-80 ●www.zimmer-group.de
6.5 Settings
Wiper:
►Move the clamping jaws together manually / press inward
►Align wiper so, that the clamping jaws can move in and out without
contact.
►Secure the wiper in this position
Clamping jaws:
►Position the gripper axially to the O-ring pickup station
►Approach the program the pickup position of the gripper
• The contact surface of spread jaw Amust be in the same plane as
the contact surface for O-ring Bin the pickup station
►Position and secure any clamping jaw 4at a distance of 1 - 2 mm
to the O-ring
The two other clamping jaws can still be moved.
►Move the gripper away from the O-ring pickup station.
►Move the clamping jaws 4together using compressed air.
► Reduce the decient stroke of the fastened clamping jaw to the wiper by
twisting the adjustment ring 6.
The clamping jaw pin must be at least 0.2 mm away from the end of
the wiper's slot
The clamping jaw must not make contact with the wiper.
Twisting the adjustment ring 6is only possible in a depressurized
state.
►Clamp the adjustment ring with the safety screw bm
►Align and secure the clamping jaws that have not been fastened.
The distance to the end of the wiper's slot must also be 0.2 mm
►Move the clamping jaws together manually / press together and check to
ensure that they can be moved over the entire length of the stroke without
contacting the wiper
►Retract the clamping jaws using compressed air
►Check the wiper function in this position.
It mist be able to extend and retract without making contact.
1 to 2 mm
A B 4
Correct O-ring position
Correct wiper position - clamping jaws
Note:
The stroke limitation of the piston must occur via the
internal limit stop of the gripper (adjustment ring),
► not indirectly via the ejector!
9

DDOC00188 enu / 2016-08-31 / Index a
INSTALLATION AND OPERATING INSTRUCTIONS: Pneumatic GSI series O-Ring gripper
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●Phone: + 49 7844 9138-0 ● Fax: + 49 7844 9138-80 ●www.zimmer-group.de
Spread jaws:
►Retract clamping jaws 4,
No interference contour when retracting them into the workpiece.
►Adjust the immersion depth of the spread jaws into the workpiece
Contact surface Aon the spread jaw 1must be the
same height as the bottom edge Cof the annular
groove in the workpiece.
►Retract the gripper from the installation position.
►Increase the stroke of the spread jaw 1until it touches the workpiece using
adjustment ring 7.
►After, reduce the stroke by approximately 0.5 mm.
Check the distance by pushing in a workpiece.
Twisting the adjustment ring 7is only possible in a depressurized
state.
The gripper jaws must not touch the workpiece when they are
extended.
►The jaw set and the retraction depth are not set,
 some fine adjustments using the adjustment rings may be neces-
sary after a test.
►Attach the sensors.
►Perform a test run in a single step procedure
Please adhere strictly to the gripper's flow diagram
A 1 C
0.5 mm
Note:
The stroke limitation of the piston must occur via the
internal limit stop of the gripper (adjustment ring),
► not indirectly via the workpiece!
6.6. Position sensing sensors
em
en
eo
em Piston position query dm
for clamping jaws
en Piston position query dn
for spread jaws
eo Piston position query do
for wiper
The clamping position query via magnetic eld sensors takes place indirectly via
a magnet xed to the piston.
The magnetic eld sensor cr is inserted into the integrated slot (9) to set the
switch point.
► Insert the magnetic eld sensor cr into the integrated slot 9
► Turn the mounting screw cq using an Allen key
Observe the maximum tightening torque;
refer also to the magnetic eld sensor operating instructions
► Move the respective pistons into the respective end position and adjust the
magnetic eld sensor there
2 positions for each piston
► Push the magnetic eld sensor cr until it reaches the switch-on point (LED on).
► Mark the point
► Push the magnetic eld sensor cr until it reaches the switch-o point (LED o).
► Mark the point
► Then push the sensor back again until it reaches the switch-on point (LED on).
 The optimum magnetic eld sensor position cr is between the two
tagged points.
► Repeat the process for each piston end position
cq
cr
9
10