ROTA THW plus Series,ROTA THW plus 165-43,ROTA THW plus 315-104,ROTA THW plus 185-52,ROTA THW plus 215-66,ROTA THW plus 260-81
SCHUNK ROTA THW plus Series,ROTA THW plus 165-43,ROTA THW plus 315-104,ROTA THW plus 185-52,ROTA THW plus 215-66,ROTA THW plus 260-81 Assembly And Operating Manual
Power chuck
Translation of original operating manual
ROTA THWplus
Assembly and operating manual
Superior Clamping and Gripping
Imprint
Imprint
Dear customer,
Kindest Regards
Your H.-D. SCHUNK GmbH & Co.
Copyright:
This manual remains the copyrighted property of SCHUNK GmbH & Co. KG. It is solely
supplied to our customers and operators of our products and forms part of the product.
This documentation may not be duplicated or made accessible to third parties, in particular competitive companies,
without our prior permission.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 0889020
Edition: 02.00 |24/04/2017|en
© SCHUNK GmbH & Co. KG
All rights reserved.
congratulations on choosing a SCHUNK product. By choosing SCHUNK, you have opted for
the highest precision, top quality and best service.
You are going to increase the process reliability of your production and achieve best
machining results – to the customer's complete satisfaction.
SCHUNK products are inspiring.
Our detailed assembly and operation manual will support you.
Do you have further questions? You may contact us at any time – even after purchase.
Spanntechnik KG
Lothringer Str. 23
D-88512 Mengen
Tel. +49–7572-7614-0
Fax +49-7572-7614-1099
info@de.schunk.com
www.schunk.com
2 01.00|ROTA THWplus |en
Table of contents
01.00|ROTA THWplus |en
Table of contents
1
General .................................................................................................................... 5
1.1
Warnings ................................................................................................................... 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 ................................................................................................... 17
5
Scope of delivery ..................................................................................................... 18
6
Technical data ......................................................................................................... 19
6.1
Chuck data .............................................................................................................. 19
6.2
Clamping force / speed diagrams ........................................................................... 19
6.3
Calculations for clamping force and speed ............................................................ 22
6.3.1
Calculation of the required clamping force in case of a given rpm ............ 22
6.3.2
Calculation example: Required initial clamping force Fsp0 for a given rpm n
..................................................................................................................... 24
6.3.3
Calculation of the permissible rpm nzul in case of a given initial clamping
force Fsp0 .................................................................................................... 26
6.4
Grades of Accuracy ................................................................................................. 26
6.5
Permissible imbalance ............................................................................................ 27
7
Attachment and disassembly of the chuck ............................................................... 28
7.1
Pre-assembly measures .......................................................................................... 28
7.2
Mounting of the Chuck to the Machine Spindle .................................................... 28
7.3
Disassembling and assembling the chuck .............................................................. 31
8
Function and handling ............................................................................................. 33
8.1
Function of the chuck ............................................................................................. 33
8.2
Handling the chuck and the base jaws ................................................................... 33
8.3
Base jaw position .................................................................................................... 34
8.4
Change or supplement of jaws ............................................................................... 34
3
Table of contents
9
Maintenance ........................................................................................................... 36
9.1
Lubrication .............................................................................................................. 36
9.2
Maintenance intervals ............................................................................................ 37
9.3
Technical condition ................................................................................................ 37
10
Disposal .................................................................................................................. 38
11
Chuck mounts and Spare parts ................................................................................ 39
11.1
Chuck mounts ......................................................................................................... 39
11.2
Spare parts .............................................................................................................. 39
12
Drawings ................................................................................................................. 41
13
Translation of the original declaration of incorporation ........................................... 43
14
Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B ..... 44
4 01.00|ROTA THWplus |en
General
01.00|ROTA THWplus |en
DANGER
Danger for persons!
WARNING
Dangers for persons!
CAUTION
Dangers for persons!
NOTICE
Material damage!
1
1.1
General
This operating manual is an integral component of the product and
contains important information on safe and proper assembly,
commissioning, operation, care, maintenance and disposal. This
manual must be stored in the immediate vicinity of the product
where it is accessible to all users at all times.
Before using the product, read and comply with this manual, especially the chapter “Basic safety notes”.( 2, Page 7)
If the product is passed on to a third party, these instructions must
also be passed on.
Illustrations in this manual are provided for basic understanding of
the product and may differ from the actual product design.
We accept no liability for damage resulting from the failure to
observe and comply with this operating manual.
Warnings
To make risks clear, the following signal words and symbols are
used for safety notes.
Non-observance will inevitably cause irreversible injury or death.
Non-observance can lead to irreversible injury and even death.
Non-observance can cause minor injuries.
Information about avoiding material damage.
5
General
WARNING
Warning about hand injuries
WARNING
Warning about hot surfaces
1.2
Applicable documents
• General terms of business *
• Catalog data sheet of the purchased product *
• Calculation of the jaw centrifugal forces, "Technology" chapter
in the lathe chuck catalog *
The documents marked with an asterisk (*) can be downloaded on
our homepage www.schunk.com.
6 01.00|ROTA THWplus |en
Basic safety instructions
01.00|ROTA THWplus |en
2
2.1
2.2
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, 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
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.
7
Basic safety instructions
DANGER
Risk of fatal injury to operating personnel due to the workpiece
tential mechanical hazards.
DANGER
Possible risk of fatal injury to operating personnel if a jaw
measures to protect against possible mechanical hazards.
2.3
Notes on particular risks
This product may pose a danger to persons and property if, for example:
• It is not used as intended;
• It is not installed or maintained properly;
• The safety and installation instructions, local applicable safety
and accident prevention regulations or the EC Machinery Directive are not observed.
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 po-
falling down or being flung out in the event of a power failure
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.
breaks or if the lathe chuck fails because the technical data have
• 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
8 01.00|ROTA THWplus |en
Basic safety instructions
01.00|ROTA THWplus |en
DANGER
Possible risk of fatal injury to operating personnel from clothing
on the machine and the lathe chuck.
WARNING
Risk of injury due to dropping the chuck during transport, instal-
equipment.
CAUTION
Danger of slipping and falling in case of dirty environment
tools and other technical equipment.
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
or hair being caught on the lathe chuck and being dragged into
lation 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
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
9
Basic safety instructions
CAUTION
Danger of limbs being crushed by opening and closing of the
ing centers and other technical equipment.
CAUTION
Risk of burns due to workpieces with high temperatures.
• Automatic loading is preferred.
CAUTION
Danger of damage due to incorrectly selected clamping position
of the chuck base jaw.
placing 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 machin-
chuck jaws during manual loading and unloading or when re-
• Wear protective gloves when removing the workpieces.
An incorrectly selected clamping position of the clamping jaws to
the workpiece can result in damage to the base and top jaws.
• Make sure that the workpiece clamping is concentric.
• In the case of a chuck with a quick-change jaw system the top
jaws must not protrude radially beyond the base jaws used.
Exception: The supporting jaw variant 3 protrudes beyond the
chuck base jaw due to the construction of the jaw. In this case,
the T-nuts must always be inserted completely into the groove
of the clamping jaws to the workpiece.
10 01.00|ROTA THWplus |en
Basic safety instructions
01.00|ROTA THWplus |en
CAUTION
Hazard from vibration due to imbalanced rotating parts and
• Wear hearing protection.
2.4
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.
noise generation.
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! The clamping force of the chuck must be
achieved at max. operating force/pressure.
• Stroke control! The stroke of the clamping piston must allow a
safety zone at the front and rear end position. The machine
spindle may only be started when the clamping piston has
passed through the safety zone. Only limit switches that meet
the requirements for safety limit switches specified in DIN EN
60204-1 may be used.
When determining the necessary clamping force to machine a
workpiece, take the centrifugal force acting on the chuck jaws into
account (according to VDI 3106).
11
Basic safety instructions
If the chuck jaws are changed, adjust the stroke control to the new
DANGER
Possible risk of fatal injury to operating personnel if the chuck's
effective.
situation.
Speed
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
top speed is exceeded and a workpiece is released or parts fly
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. 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, 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
12 01.00|ROTA THWplus |en
Basic safety instructions
01.00|ROTA THWplus |en
lubricant back to the surfaces of the force transmission. This
DANGER
Possible risk of fatal injury to operating personnel due to chuck
the relevant safety training.
means that the clamping force is retained for longer).
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.
ed!
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
failure if the servicing instructions for the chuck are disregard-
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.
• 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.
13
Basic safety instructions
2.4.1
2.5
2.6
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.
14 01.00|ROTA THWplus |en
Faults
If a fault occurs on the chuck and this fault endangers safety or if a
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.
Basic safety instructions
01.00|ROTA THWplus |en
Spare parts
2.7
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).
15
Warranty
3
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
,
Page 19)
• Observe the specified maintenance and lubrication intervals
( 9, Page 36)
Parts touching the workpiece and wear parts are not included in
the warranty.
16 01.00|ROTA THWplus |en
Torques per screw
01.00|ROTA THWplus |en
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
Screw size
M6
M8
M10
M12
M14
M16
M20
M24
Max. admissible torque MA (Nm)
16
30
50
70
130
150
220
450
4
Torques per screw
Tightening torques for mounting screws used to clamp the chuck
on lathes or other suitable technical equipment (screw quality
10.9)
Tightening torques for mounting screws used to attach top jaws
onto the chuck (screw quality 12.9)
17
Scope of delivery
1
Power chuck
1
Set of base jaws
3
Mounting screws
1
Jaw change key
1
Operating manual
1
Short operating manual
1
Power chuck
1
Set of base jaws
3
Mounting screws
1
Jaw change key
1
Operating manual
1
Short operating manual
1
Mounting wrench
5
Scope of delivery
ROTA THW plus 165, 185, 215:
ROTA THW plus 260, 315:
18 01.00|ROTA THWplus |en
Technical data
01.00|ROTA THWplus |en
ROTA THW plus
165-43
185-52
215-66
260-81
315-104
Max. actuating force [kN]
30
36
46
65
90
Max. clamping force [kN]
45
64
82
115
160
Max. rotation speed [min-1]
6000
5700
5400
4000
3600
Stroke per jaw [mm]
5.9
6.7
7.4
8.2
8.6
Piston stroke [mm]
20
23
25
28
28
Through hole [mm]
43
52
66
81
104
Weight [kg]
14
18
26
45
70
Operating temperature
15 - 60 °C
Centrifugal torque of the base
For the chuck THW plus it's necessary to determine those
catalog or in the
load at www.de.schunk.com.
Length of warranty
24 Months
Maximum clamping cycle number
500 000 Cycles
6
6.1
6.2
jaw with
fine serration
M
[kgm]
cGB
Technical data
Chuck data
data specific. Calculation examples are in the chapter
"Technology" in the SCHUNK-lathe-chuckchapter "Special jaws/Technology" in the SCHUNK-powerchuck-catalog. Those catalogs are also available as down-
The maximum permissible speed for special machining has to be
defined by the user on the basis of the required clamping forces.
This speed must not exceed the maximum speed of the chuck.
Warranty and maximum clamping cycles
Ensure minimal weight for all jaws.
For unhardened top jaws or chuck jaws in special design, the permissible RPM according to VDI 3106 must be calculated for the respective machining job. Whereby the recommended maximum
speed must not be exceeded. The values calculated must be
checked by means of dynamic measurement using a clamping
force tester.
Clamping force / speed diagrams
The diagrams refer to 3-jaw-chuck.
Clamping force/rpm curves have been determined by using hard
jaws. In the determination process, the maximum actuating force
19
Technical data
was applied and the jaws were set flush with the outer diameter of
F/3
Clamping force per jaw
F
max
Max. actuating force
rs
Center of gravity radius
S
Center of gravity
the chuck.
The chuck is in perfect condition and lubricated with SCHUNK
LINOMAX special grease.
If one or more of these prerequisites is modified, the graphs will
no longer be valid.
Chuck setup for clamping force/rpm graph
Clamping force / speed diagrams ROTA THW plus 165-43
Clamping force / speed diagrams ROTA THW plus 185-52
20 01.00|ROTA THWplus |en
Technical data
01.00|ROTA THWplus |en
Clamping force / speed diagrams ROTA THW plus 215-66
Clamping force / speed diagrams ROTA THW plus 260-81
Clamping force / speed diagrams ROTA THW plus 315-104
21
Technical data
Legend
Fc
Total centrifugal force [N]
M
cAB
Centrifugal torque of top jaws [kgm]
Fsp
Effective clamping force [N]
M
cGB
Centrifugal torque of base jaws [kgm]
F
Required minimum clamping force
[N]
n
RPM [min-1]
F
sp0
Initial clamping force [N]
rs
Center of gravity radius [m]
F
spz
Machining force [N]
r
sAB
Center of gravity radius of top jaw [m]
mAB
Mass of one top jaw [kg]
ssp
Clamping force safety factor
mB
Mass of clamping jaw set [kg]
sz
Machining safety factor
Mc
Centrifugal force torque [kgm]
Σs
Max. clamping force of the chuck [N]
6.3
6.3.1
Calculations for clamping force and speed
Missing information or specifications can be requested from the
manufacturer!
spmin
Calculation of the required clamping force in case of a given rpm
The initial clamping force F
on the workpiece via the jaws due to actuation of the lathe chuck
during shutdown. Under the influence of rotation, the jaw mass
generates an additional centrifugal force. The centrifugal force reduces or increases the initial clamping force depending on whether gripping is from the outside inwards or from the inside outwards.
The sum of the initial clamping force F
force F
22 01.00|ROTA THWplus |en
is the total force impacting radially
sp0
sp0
is the effective clamping force Fsp.
c
and the total centrifugal
Technical data
01.00|ROTA THWplus |en
(–) for gripping from the outside inwards
DANGER
Risk to life and limb of the operating personnel and significant
• Do not fall below the necessary minimum clamping force.
(+) for gripping from the inside outwards
ping from the outside inwards, and with increasing RPM, the
effective clamping force is reduced by the magnitude of the increasing centrifugal force (the forces are opposed). When the
RPM limit is exceeded, the clamping force drops below the re-
property damage when the RPM limit is exceeded! With grip-
quired minimum clamping force F
. Consequently, the work-
spmin
piece is released spontaneously.
• Do not exceed the calculated RPM.
Reduction in effective clamping force by the magnitude of the total centrifugal force, for gripping from the outside inwards.
The required effective clamping force for machining Fsp is calculated from the product of the machining force F
factor S
. This factor takes into account uncertainties in the calcu-
z
lation of the machining force. According to VDI 3106: S
From this we can derive the calculation of the initial clamping
force during shutdown:
(+) for gripping from the outside inwards
(–) for gripping from the inside outwards
and the safety
spZ
≥ 1.5.
z
23
Technical data
NOTICE
This calculated force must not be larger than the maximum
See also "Chuck data" table ( 6.1, Page 19)
NOTICE
For safety reasons, in accordance with DIN EN 1550, the centrif-
force.
6.3.2
clamping force ΣS engraved on the chuck.
From the above formula it is evident that the sum of the effective
clamping force F
the safety factor for the clamping force S
3106, the following also applies here: S
The total centrifugal force F
and the total centrifugal force Fc is multiplied by
sp
. According to VDI
sp
≥ 1.5.
sp
is dependent on both the sum of the
c
masses of all jaws and on the center of gravity radius and the rpm.
ugal force may be a maximum of 67% of the initial clamping
The formula for the calculation of the total centrifugal force Fc is:
RPM
For this, n is the given speed of rotation in
is referred to as the centrifugal force torque M
. The product mB ∙ rs
.
c
In case of toolholders with split chuck jaws, i.e., with base jaws and
top jaws, for which the base jaws change their radial position only
by the stroke amount, the centrifugal torque of the base jaws
M
and the centrifugal torque of the top jaws M
cGB
need to be
cAB
added:
The centrifugal torque of the base jaws M
table "Chuck data"( 6.1, Page 19)
top jaws M
is calculated as per:
cAB
. The centrifugal torque of the
can be found in the
cGB
Calculation example: Required initial clamping force Fsp0 for a
given rpm n
The following data is known for the machining job:
• Gripping from the outside in (application-specific)
• Machining force F
24 01.00|ROTA THWplus |en
= 3000 N (application-specific)
spz
Technical data
01.00|ROTA THWplus |en
• max. speed of rotation n
rpm
• RPM n = 1200
(application-specific)
= 3200
max
rpm
("Chuck data" table)
• Mass of one (!) top jaw m
= 5.33 kg (application-
AB
specific)
• Center of gravity radius of top jaw r
= 0.107 m (application-
sAB
specific)
• Safety factor S
• Safety factor S
= 1.5 (according to VDI 3106)
z
= 1.5 (according to VDI 3106)
sp
Note:Masses of the jaw mounting screws and T-nuts are not taken
into account.
First the required effective clamping force F
is calculated using
sp
the machining force stated:
Initial clamping force during shutdown:
Calculation of total centrifugal force:
For two-part chuck jaws, the following applies:
Centrifugal torque of base jaw and top jaw specified in "Chuck data" table:
For the centrifugal torque of the top jaw, the following applies:
Centrifugal torque for one jaw:
The chuck has 3 jaws, the total centrifugal torque is:
The total centrifugal force can now be calculated:
Initial clamping force during shutdown that was sought:
25
Technical data
NOTICE
The calculated permissible RPM may not exceed the maximum
6.3.3
6.4
Calculation of the permissible rpm nzul in case of a given initial
clamping force Fsp0
The following formula can be used to calculate the permissible
RPM for a given initial clamping force during shutdown:
RPM inscribed on the chuck for safety reasons!
Example of calculation: Permissible RPM for a given effective
clamping force
The following data is known from previous calculations:
• Initial clamping force during shutdown F
• Machining force for machining job F
spz
= 17723 N
sp0
3000 N (application-
specific)
• Total centrifugal torque of all jaws ∑M
• Safety factor S
• Safety factor S
= 1.5 (according to VDI 3106)
z
= 1.5 (according to VDI 3106)
sp
= 2,668 kgm
c
NOTE:
Masses of the jaw mounting screws and T-nuts are not taken into
account.
Identifying the permissible RPM:
The calculated RPM n
= 1495
zul
permissible RPM of the chuck n
ble ( 6.1, Page 19)
This calculated RPM may be used.
).
rpm
is smaller than the maximum
= 3200
max
rpm
(see "Chuck data" ta-
Grades of Accuracy
Tolerances for run-out accuracy and axial run-out accuracy correspond to the Technical Supply Terms for lathe chucks as per DIN
ISO 3089.
26 01.00|ROTA THWplus |en
Technical data
01.00|ROTA THWplus |en
6.5
Permissible imbalance
The permissible imbalance for lathe chucks is quality class
G 6.3 as per DIN ISO 1940-1.
27
Attachment and disassembly of the chuck
CAUTION
Danger of injury due to sharp edges and rough or slippery sur-
Use personal protective gear, especially safety gloves.
7
7.1
7.2
Attachment and disassembly of the chuck
The item numbers specified for the corresponding individual components relate to chapter drawings.( 12, Page 41)
Pre-assembly measures
Carefully lift the product (e.g. using suitable lifting gear) from the
packaging.
Check the delivery for completeness and for transport damage.
Mounting of the Chuck to the Machine Spindle
Checking the chuck mounting
• Check the machine spindle head or the finish machined adapter
plate for concentricity and face runout. The permissible limit is
0.005 mm as per DIN 6386-1.
• The contact surface must be clean and deburred.
Mounting the ROTA THW plus chuck
• Push the tension rod into its foremost position (see Fig. 2).
faces
Piston in foremost position
R1 = Push the chuck piston to its foremost position and measure
28 01.00|ROTA THWplus |en
Attachment and disassembly of the chuck
01.00|ROTA THWplus |en
with a depth gauge
R2 = R1 + 0.3 mm (max. + 0.5 mm)
You have to ensure that the piston can be moved to the foremost
(jaw change) position. To do this, ensure that the dimensions for
the attachment (see Fig. 2) are complied with.
• Move the chuck piston (item 3) to its foremost position.
Chucks in sizes 165, 185 and 215
• Offset the base jaws so that they do not project over the outer
edge of the chuck.
• The entire chuck has to be rotated on the draw tube (rod).
• Alternately tighten the mounting screws supplied to fix the
chuck to the spindle nose.
• Check radial and axial runout at the checking edge.
• Check the function and the size of the operating force.
• Move the cylinder into the front position. Unlock the wedge
bars with the jaw change key supplied and insert or offset the
base jaws into the chuck's jaw guidance as shown on markings
1, 2 or 3.
• Check that the base jaw and jaw stroke are easy to move.
Chucks in sizes 260 and 315
• Offset the base jaws to the outermost marking (see drawings,
chapter 11).
• Remove the screws (item 43) and use the threaded extraction
hole to push off the protection sleeve (item 4) away from the
chuck body (item 1), and then pull it out completely.
• Lift the chuck to in front of the spindle lug using an eye bolt
flush to the center of the spindle.
• Screw the rotating center sleeve (item 18) onto the draw tube
using the enclosed assembly tool as far as this will go.
• Alternately tighten the mounting screws supplied to fix the
chuck to the spindle nose.
• Check radial and axial runout at the checking edge.
• Check the function and the size of the operating force.
• Insert and fasten the protection sleeve (item 4) in the chuck
body with the screws (item 43).
• Move the cylinder to the front position. Unlock the wedge bars
with the jaw change key supplied and insert or offset the base
29
Attachment and disassembly of the chuck
jaws into the chuck's jaw guidance as shown on markings 1, 2
A B C D E F
O-ring
ROTA THW plus 165-43
M54 x 1.5
15.0
43
50.8
2.8
47
50.47 x 2.62
ROTA THW plus 185-52
M64 x 1.5
15.0
52
62.0
2.4
58
60 x 2
ROTA THW plus 215-66
M78 x 1.5
17.0
66
76.0
2.4
70
76 x 2
ROTA THW plus 260-81
M90 x 2.0
20.3
81
87.0
2.4
84
86 x 2
ROTA THW plus 315-104
M115 x 2.0
22.5
104
110.0
3.2
107
110 x 3
or 3.
• Check that the base jaw and jaw stroke are easy to move.
Dismounting of the spindle is carried out in reverse order.
At regular intervals, check that the retainer ring (item 17) is seated firmly (see Fig. 3).
Lubricate before commissioning the chuck
Before commissioning, move the chuck in the open position. Press
three strokes SCHUNK special grease LINOMAX into each of the
grease nipples using a high-pressure grease gun. To achieve the
optimal grease distribution and the maximum clamping force,
close and open the chuck several times over the entire clamping
stroke. Check the clamping force and, if necessary, repeat the lubrication process.
30 01.00|ROTA THWplus |en
Attachment and disassembly of the chuck
01.00|ROTA THWplus |en
7.3
Disassembling and assembling the chuck
The chuck may only be disassembled once it has been uninstalled
(see Mounting the chuck, chapter 7.2).
• You can leave the base jaws (item 2) in the chuck. Move them
to the outermost permissible position. To do this, push the
chuck piston (item 3) to its front end position.
• Remove the screws (item 43) and use the threaded extraction
hole to push off the protection sleeve (item 4) away from the
chuck body (item 1), and then pull it out completely.
• Remove the screws (item 42/44) from the mount (item 7).
• Mark the position of the mount (item 7) in relation to the chuck
body (item 1).
• Undo the screws (item 40/41) several thread turns and hammer gently on the screw heads using a rubber mallet. This allows the mount (item 7) to be released from the centering for
the chuck body (item 1). Remove the screws and take off the
mount.
• Remove the safety bolt (item 14) with compression spring (item
35) and spring bolt (item 13).
• Use a suitable tool to push out and remove the jaw-change bolt
(item 8) with the balls (item 37) through the bore hole for the
safety bolt. Check the seal (item 33) for damage and wear, and
replace it if necessary.
NOTE: The bearing mechanism may cause metallic noise.
• Pull the chuck piston (item 3) together with the three wedge
bars (item 9) out of the chuck body (item 1). The individual
wedge bars (item 9) are identified in position in the chuck body
(item 1) in accordance with the numbering on the perimeter.
The piston has a point marking at the radial front side on the
piston wedge hook. This is assigned to base jaw guide 1 during
assembly.
• Push the base jaws (item 2) out of the chuck body (item 1).
• Check the seal (item 31) in the chuck piston (item 3) for the
protection sleeve (item 4) and the seal (item 32) for the draw
tube for damage and wear, and replace it if necessary.
• A wedge bar (item 9) consists of nine parts in total. Spring tension pre-loads the thrust bolt (item 12) and the pressure pieces
(item 16). Remove the wedge bar (item 9) using the appropriate safety measures and using safety goggles.
31
Attachment and disassembly of the chuck
• With its slot for the jaw-change bolt (item 8), the eccentric bolt
CAUTION
Allergic reactions due to grease in contact with skin!
(item 10) is joined to the wedge bar (item 9) in extension of the
groove. This is the position for operation and assembly of the
chuck. For disassembly, the eccentric bolt (item 10) has to be
turned clockwise by approx. 15° using a suitable tool.
• Push out the eccentric bolt (item 10) from the diagonal pull side
of the wedge bar (item 9) up to approx. 6 mm. The thrust bolt
(item 12) then becomes visible. The displacement force is reduced through slight pressure on the serration.
• Secure the thrust bolt (item 12) against flying off and then
completely remove the eccentric bolt (item 10) out of the
wedge bar (item 9).
• Take the angle with plunger pin (item 15) and pressure piece
(item 16) with compression spring (item 34) off the wedge bar.
• The pin (item 11) is securely glued into the eccentric bolt (item
10).
Clean all individual components and check them for damage and
wear.
Only original SCHUNK spare parts may be used.
The chuck is assembled in the same way but in the reverse order.
Before installation, lubricate parts well with LINO MAX special
grease.
Wear gloves.
See also
Mounting of the Chuck to the Machine Spindle [ 28]
32 01.00|ROTA THWplus |en
Function and handling
01.00|ROTA THWplus |en
CAUTION
There is a risk of crushing during manual loading due to the
with one of the jaws.
8
8.1
8.2
Function and handling
The item numbers specified for the corresponding individual components relate to chapter drawings.( 12, Page 41)
Function of the chuck
The type THW plus quick-change power chucks are actuated using
a rotating solid or through-hole cylinder. The axial tensile or compressive forces are converted to the radial jaw clamping force via
wedge bars positioned tangentially to the chuck body.
Handling the chuck and the base jaws
The clamping and opening path of the chuck jaws is prescribed by
the clamping cylinder. The base jaws with screwed-on top jaws are
moved or changed in the open clamping position. For safety reasons, the serration for the base jaws is still engaged in this chuck
piston position. The base jaws are unlocked manually.
large jaw stroke.
We recommend automatic loading.
If manual loading is used, set up the jaw position so that there is
no risk of injury when inserting the parts. The maximum opening
gap must be less than 4 mm when the workpiece is in contact
For each jaw guidance, a jaw-change bolt (item 8) with hexagon
socket (which can be turned using the jaw change key (item 90)) is
arranged on the chuck perimeter. Turning the jaw-change bolt
moves the serration for the wedge bar (item 9) axially against
spring pressure out of the serration for the base jaw (item 2). In
this position, the base jaws can be moved or changed radially inwards or outwards. It is not possible to pull out the jaw change key
in this position.
Der Ausklinkschlüssel wird verriegelt, solange keine Spannbacken
in den Funktionsbereich gebracht wurden! Der Funktionsbereich
bedeutet, dass die Grundbacke im Eingriff der Verzahnung des
Winkels ist.
33
Function and handling
NOTICE
The chuck piston (item 3) must not be moved so long as the jaw
Risk of damage to the chuck.
NOTICE
The mechanical system of the chuck is opened when the protec-
Risk of damage to the chuck.
CAUTION
Risk of crushing due to mechanical system of the chuck being
Wear protective gloves.
8.3
8.4
change key (item 90) is located in one of the jaw-change bolts
(item 8) for the chuck.
tion sleeve (item 4) is changed. No chips may penetrate into the
mechanical system of the chuck. If no protection sleeve is installed in the chuck, then the chuck must not be actuated and
the chuck piston (item 5) must not be moved!
Do not reach into the open mechanical system of the chuck!
Base jaw position
open when the protection sleeve is being changed.
A marking line between the jaw guides is milled on the face side of
the chuck (see drawing( 12, Page 41)
). This marking line is the
positioning aid for the base jaws or top jaws. The outermost base
jaw or monoblock position is reached when the front face of the
base jaw or the unsplit top jaw agrees with the marking line in the
jaw change position (chuck open).
It is vital that this jaw position is adhered to so that all teeth are
engaged for the force transmission from the wedge bars to the
base jaws or top jaws.
Change or supplement of jaws
Jaws for highest repeatability must be bored and ground in the
chuck under clamping pressure.
• When boring and grinding it is important that the boring ring or
the boring bolts are clamped by the top jaws – and not by the
base jaws. Keep base and top jaws screwed together for later
34 01.00|ROTA THWplus |en
tasks.
Function and handling
01.00|ROTA THWplus |en
• Keep the base jaws and top jaws screwed in place for recurring
work. Tighten the jaw mounting screws to the specified torque
( 4, Page 17)
.
Tighten the jaw mounting screws with a torque wrench. On no
account tighten the screws with an extension pipe or with hammer blows.
35
Maintenance
A
Three lubrication nipples on the chuck perimeter (3 x
120°)
Chuck size
165
185
215
260
315
400
Number of strokes
2 2 4 4 4
6
CAUTION
Allergic reactions due to grease in contact with skin!
9
9.1
Maintenance
Lubrication
To maintain the safe function and high quality of the chuck, it has
to be regularly lubricated.
Move the chuck into the open position. Lubricate the chuck at the
three lubrication nipples (A - see Fig. 4) using a high-pressure
grease gun with two to six strokes (depending on the chuck side)
of SCHUNK LINO MAX special grease at each nipple.
For optimum grease distribution, the clamping piston must travel
the entire clamping stroke several times after lubrication.
Check the clamping force, repeat the procedure if necessary.
Lubricate all three segments evenly in order to avoid imbalances.
(For product information about LINO MAX, see the "Accessories"
chapter of the SCHUNK lathe chuck catalog or contact SCHUNK).
Wear gloves.
36 01.00|ROTA THWplus |en
Maintenance
01.00|ROTA THWplus |en
Lubrication interval
Strain
every 25 hours
normal / coolant utilization
every 8 hours
high / coolant utilization
after 1200 hours or
Total cleaning with disassembly of the
contamination
9.2
9.3
Maintenance intervals
Lubrication of the grease areas:
as needed
chuck, depending on type and degree of
Technical condition
With the smallest possible actuating pressure (clamping cylinder),
the base jaws should move evenly. This method only provides a
limited indication and does not replace the measurement of the
clamping force.
If the clamping force has dropped too far or if the base jaws and
clamping piston no longer move properly, the chuck has to be disassembled, cleaned, and relubricated.
Only original SCHUNK spare parts may be used.
37
Disposal
10
Disposal
After decommissioning, place the chuck in a position that enables
any liquids in the chuck to drain out.
• Collect the escaping liquids and dispose of them properly in line
with the statutory provisions.
• Remove any identifiable plastic or aluminum parts installed in
or on the chuck and dispose of them properly in line with the
statutory provisions.
• Dispose of the chuck's metal parts as scrap metal.
Alternatively, you can return the chuck to SCHUNK for proper disposal.
38 01.00|ROTA THWplus |en
Chuck mounts and Spare parts
0|ROTA THWplus |en
SCHUNK type
Chuck mount
Id-No.
ROTA THW plus 165-43
Z 140
A6
0800600
0800602
ROTA THW plus 185-52
Z 140
A6
0800610
0800613
ROTA THW plus 215-66
Z 170
A8
0800620
800622
ROTA THW plus 260-81
Z 170
A8
0800630
0800633
ROTA THW plus 315-104
Z 220
A11
0800640
0800642
Item
Designation
Quantity
1
Chuck body
1
2
Base jaws
3 3 Piston
1 4 Standard protection sleeve
1 7 Mount
1 8 Jaw-change bolt
3 9 Complete wedge bar
3
10
Eccentric bolt
3
11
11.1
11.2
Chuck mounts and Spare parts
Chuck mounts
A5
Z 170
A5
A6
Z 220
A6
0800601
0800611
0800612
0800621
0800631
0800632
A8
0800641
Spare parts
When ordering spare parts, it is imperative to specify the type,
size and above all the manufacturing no of the chuck.
Seals, sealing elements, screw connections, springs, bearings,
screws and wiper bars plus parts coming into contact with the
workpiece are not covered by the warranty.
01.0
39
Chuck mounts and Spare parts
Item
Designation
Quantity
11
Pin 3 12
Thrust bolt
3
13
Spring bolt
3
14
Safety bolt
3
15
Plunger pin
3
16
Pressure piece
6
17
Retainer ring (size 260/315 only)
1
18
Center sleeve (size 260/315 only)
1
19
Assembly tool
1
20
Lever for assembly tool
1
29
Center sleeve seal (from size 250)
1
31
Piston seal
1
32
Adapter seal
1
33
Jaw-change bolt seal
3
34
Compression spring for pressure piece
6
35
Compression spring for safety bolt
3
36
Compression spring for thrust bolt
3
37
Steel ball for jaw-change bolt
3
39
Tapered lubricating nipple
3
40
Mounting screws DIN EN ISO 4762-10.9
3
41
Mounting screws DIN EN ISO 4762-10.9
3
42
Mounting screws DIN EN ISO 4762-10.9
3
43
Mounting screws DIN 7984-8.8
3
44
Mounting screws DIN EN ISO 4762-10.9
3
47
Compression spring for grid
2
48
Steel ball for grid
2
60
Eye bolt
1
90
Jaw change key
1
91
Cross handle for jaw change key
1
93
Holding piece
1
94
Spring sleeve
1
95
Pressure sleeve
1
96
Compression spring for jaw change key
1
40 01.00|ROTA THWplus |en
Drawings
01.00|ROTA THWplus |en
12
Drawings
41
Drawings
42 01.00|ROTA THWplus |en
Translation of the original declaration of incorporation
01.00|ROTA THWplus |en
in terms of the Directive 2006/42/EG, Annex II, Part 1.B of the European Parliament and of
the Council on machinery.
Manufacturer/
H.-D. SCHUNK GmbH & Co. Spanntechnik KG
D-88512 Mengen
We hereby declare that on the date of the declaration the following incomplete machine
invalid if modifications are made to the product.
Product designation:
Power-actuated chuck with quick jaw change
THW plus in sizes 165-43, 185-52, 215-66, 260-81, 315-104
ID number
0800600, 0800601, 0800602, 0800610, 0800611, 0800612,
0800632, 0800633, 0800640, 0800641, 0800642
The incomplete machine may not be put into operation until conformity of the machine
Directive (2006/42/EC) is confirmed.
Applied harmonized standards, especially:
DIN EN ISO
12100:2011-03
Safety of machinery - General principles for design Risk assessment and risk reduction
EN 1550:
1997+A1:2008
Machine-tools safety - Safety requirements for the design and construction of work holding chucks
Other related technical standards and specifications:
DIN ISO
702-1:2010-04
Machine tools - Connecting dimensions of spindle noses and work
holding chucks - Part 1: Conical connection
DIN ISO
702-4:2010-04
Machine tools - Connecting dimensions of spindle noses and work
holding chucks - Part 2: Cylindrical connection
VDI 3106:2004-04
Determination of permissible speed (rpm) of lathe chucks (jaw chucks)
The manufacturer agrees to forward on demand the relevant technical documentation for
partly completed machinery, has been created.
Person authorized to compile the technical documentation:
Philipp Schräder, Address: see manufacturer's address
Mengen, January2017
p.p. Philipp Schräder; Head of Engineering Design
13
Distributor
Translation of the original declaration of incorporation
Lothringer Str. 23
complied with all basic safety and health regulations found in the directive 2006/42/EC of
the European Parliament and of the Council on machinery. The declaration is rendered
0800613, 0800620, 0800621, 0800622, 0800630, 0800631,
into which the incomplete machine is to be installed with the provisions of the Machinery
the partly completed machinery in electronic form to national authorities.
The relevant technical documentation according to Annex VII, Part B, belonging to the
43
Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B
Product designation
Power-actuated chuck with quick jaw change
Type designation
THW plus in sizes 165-43, 185-52, 215-66, 260-81, 315-104
ID number
0800600, 0800601, 0800602, 0800610, 0800611, 0800612, 0800613, 0800620, 0800621,
0800622, 0800630, 0800631, 0800632, 0800633, 0800640, 0800641, 0800642
To be provided by the System Integrator for the overall machine
⇓
Fulfilled for the scope of the incomplete machine
⇓
Not relevant
⇓
1.1
Essential Requirements
1.1.1
Definitions
X
1.1.2
Principles of safety integration
X
1.1.3
Materials and products
X
1.1.4
Lighting
X
1.1.5
Design of machinery to facilitate its handling
X
1.1.6
Ergonomics
X
1.1.7
Operating positions
X
1.1.8
Seating
X
1.2
Control Systems
1.2.1
Safety and reliability of control systems
X
1.2.2
Control devices
X
1.2.3
Starting
X
1.2.4
Stopping
X
1.2.4.1
Normal stop
X
1.2.4.2
Operational stop
X
1.2.4.3
Emergency stop
X
1.2.4.4
Assembly of machinery
X
1.2.5
Selection of control or operating modes
X
1.2.6
Failure of the power supply
X
1.3
Protection against mechanical hazards
1.3.1
Risk of loss of stability
X
1.3.2
Risk of break-up during operation
X
1.3.3
Risks due to falling or ejected objects
X
1.3.4
Risks due to surfaces, edges or angles
X
1.3.5
Risks related to combined machinery
X
1.3.6
Risks related to variations in operating conditions
X
1.3.7
Risks related to moving parts
X
1.3.8
Choice of protection against risks arising from moving parts
X
1.3.8.1
Moving transmission parts
X
1.3.8.2
Moving parts involved in the process
X
1.3.9
Risks of uncontrolled movements
X
1.4
Required characteristics of guards and protective devices
1.4.1
General requirements
X
1.4.2
Special requirements for guards
X
1.4.2.1
Fixed guards
X
1.4.2.2
Interlocking movable guards
X
1.4.2.3
Adjustable guards restricting access
X
1.4.3
Special requirements for protective devices
X
14
Appendix on Declaration of Incorporation,
as per 2006/42/EC, annex II, No. 1 B
44 01.00|ROTA THWplus |en
Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B
01.00|ROTA THWplus |en
1.5
Risks due to other hazards
1.5.1
Electricity supply
X
1.5.2
Static electricity
X
1.5.3
Energy supply other than electricity
X
1.5.4
Errors of fitting
X
1.5.5
Extreme temperatures
X
1.45.6
Fire X 1.5.7
Explosion
X
1.5.8
Noise
X
1.5.9
Vibrations
X
1.5.10
Radiation
X
1.5.11
External radiation
X
1.5.12
Laser radiation
X
1.5.13
Emissions of hazardous materials and substances
X
1.5.14
Risk of being trapped in a machine
X
1.5.15
Risk of slipping, tripping or falling
X
1.5.16
Lightning
X
1.6
Maintenance
1.6.1
Machinery maintenance
X
1.6.2
Access to operating positions and servicing points
X
1.6.3
Isolation of energy sources
X
1.6.4
Operator intervention
X
1.6.5
Cleaning of internal parts
X
1.7
Information
1.7.1
Information and warnings on the machinery
X
1.7.1.1
Information and information devices
X
1.7.1.2
Warning devices
X
1.7.2
Warning of residual risks
X
1.7.3
Marking of machinery
X
1.7.4
Instructions
X
1.7.4.1
General principles for the drafting of instructions
X
1.7.4.2
Contents of the instructions
X
1.7.4.3
Sales literature
X
The classification from Annex 1 is to be supplemented from here forward.
2 Supplementary essential health and safety requirements for certain categories of machinery
X
2.1
Foodstuffs machinery and machinery for cosmetics or pharmaceutical products
X
2.2
Portable hand-held and/or guided machinery
X
2.2.1
Portable fixing and other impact machinery
X
2.3
Machinery for working wood and material with similar physical characteristics
X
3
Supplementary essential health and safety requirements to offset hazards due to the mobility of machinery
X
4
Supplementary essential health and safety requirements to offset hazards due to lifting operations
X 5 Supplementary essential health and safety requirements for machinery intended for under-
ground work
X
6
Supplementary essential health and safety requirements for machinery presenting particular
hazards due to the lifting of persons
X
45
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