Page 1
Original Manual
Installation and Operating Manual
SWS-001
Quick-Change
Page 2
Imprint
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: 389698
Version: 02.00|07/06/2019|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. +49-7133-103-0
Fax +49-7133-103-2399
info@de.schunk.com
schunk.com
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Table of contents
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
1.1.3 Sizes ..........................................................................................................6
1.2 Warranty .............................................................................................................. 6
1.3 Scope of delivery ..................................................................................................6
2 Basic safety notes .................................................................................................... 7
2.1 Intended use......................................................................................................... 7
2.2 Not intended use.................................................................................................. 7
2.3 Ambient conditions and operating conditions ..................................................... 7
2.4 Product safety ...................................................................................................... 7
2.4.1 Protective equipment...............................................................................8
2.4.2 Constructional changes, attachments, or modifications ..........................8
2.5 Personnel qualification......................................................................................... 8
2.6 Using personal protective equipment ..................................................................8
2.7 Notes on particular risks....................................................................................... 8
3 Technical Data ........................................................................................................11
4 Product Overview ...................................................................................................12
4.1 SWK Quick-Change Head.................................................................................... 12
4.2 Quick-Change Adapter SWA ............................................................................... 13
5 Assembly ................................................................................................................14
5.1 SWK Quick-Change Head Assembly.................................................................... 14
5.2 SWA Quick-Change Adapter Assembly............................................................... 15
5.3 Lock/Unlock Pneumatic Connections and Valving ............................................. 16
5.3.1 Air Requirements....................................................................................16
5.3.2 Valve Requirements and Connections....................................................17
5.3.3 Manual Uncouple SWK and SWA............................................................18
5.4 Wiring and Electrical Connections for Optional Modules .................................. 19
6 Operational Considerations ....................................................................................20
6.1 Coupling Sequence ............................................................................................. 20
6.2 Uncoupling Sequence......................................................................................... 21
6.3 Fail-Safe Operation............................................................................................. 22
6.4 Tool Stand Design ............................................................................................... 23
6.4.1 Tool Locating Features............................................................................25
6.4.2 Tool Stands Sensors................................................................................25
7 Troubleshooting .....................................................................................................26
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Table of contents
8 Maintenance ..........................................................................................................27
8.1 Preventive Maintenance .................................................................................... 28
8.2 Cleaning and Lubrication of the Locking Mechanism ......................................... 30
8.3 Rubber O-ring Inspection and Replacement ......................................................32
8.4 Spring Pin Replacement...................................................................................... 33
9 Recommended Spare Parts .....................................................................................35
10 Drawings.................................................................................................................36
10.1 Tool Changer ...................................................................................................... 36
10.2 E04 Electrical Module......................................................................................... 39
11 Translation of original declaration of incorporation ................................................40
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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
General
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.
NOTICE
Material damage!
Information about avoiding material damage.
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General
1.1.2 Applicable documents
• General terms of business*
• Catalog data sheet of the purchased product *
• Assembly and operating manuals of the accessories *
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
1.1.3 Sizes
This operating manual applies to the following sizes:
• SWS-001 001
1.2 Warranty
If the product is used as intended, the warranty is valid for 24
months from the ex-works delivery date under the following
conditions:
• Observe the maximum service life. Technical Data [}11]
• Observe the ambient conditions and operating conditions,
Ambient conditions and operating conditions [}7]
• Observe the specified maintenance and lubrication intervals,
Maintenance [}28]
Parts touching the workpiece and wear parts are not included in
the warranty.
1.3 Scope of delivery
The scope of delivery includes
• Quick-Change SWS-001 in the version ordered, containing the
following components:
– SWK quick-change head
– SWA quick-change adapter
• Accessory pack
Content of the accessory pack:
4x Screw DIN 7984 M3 x 14 mm
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Basic safety notes
2 Basic safety notes
2.1 Intended use
The produkt (SWS Quick-Change systems consisting of SWK QuickChange Head and SWA Quick-Change Adapter) was designed for
quick changing parts and automation components at a robot in
context of the technical data.
• The product is intended for installation in a machine/system or
for mounting to a robot. The applicable guidelines must be
observed and complied with.
• When implementing and operating components in safetyrelated parts of the control systems, the basic safety principles
in accordance with DIN EN ISO 13849-2 apply. The proven safety
principles in accordance with DIN EN ISO 13849-2 also apply to
categories 1, 2, 3 and 4.
• Make sure that the product is only used within its defined
application parameters.
• The product is intended for industrial use.
2.2 Not intended use
Use which is not specified as an intended use is for instance when
the product is for example used as a pressing tool, stamping tool,
lifting tool, guide for tools, cutting tool, tensioning mean, boring
tool.
2.3 Ambient conditions and operating conditions
• Make sure that the product is a sufficient size for the
application.
• Make sure that the environment is free from splash water and
vapors as well as from abrasion or processing dust. Exceptions
are products that are designed especially for contaminated
environments.
2.4 Product safety
Dangers arise from the product, if:
• the product is not used in accordance with its intended
purpose.
• the product is not installed or maintained properly.
• the safety and installation notes are not observed.
Avoid any manner of working that may interfere with the function
and operational safety of the product.
Wear protective equipment.
NOTE
More information is contained in the relevant chapters.
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Basic safety notes
2.4.1 Protective equipment
Provide protective equipment per EC Machinery Directive.
2.4.2 Constructional changes, attachments, or modifications
Additional drill holes, threads, or attachments that are not offered
as accessories by SCHUNK may be attached only with permission
of SCHUNK.
2.5 Personnel qualification
The assembly, initial commissioning, maintenance, and repair of
the product may be performed only by trained specialist
personnel. Every person called upon by the operator to work on
the product 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, such as maintenance personnel.
2.6 Using personal protective equipment
When using this product, you must comply with the relevant
health and safety at work rules and you must use the required
personal safety equipment (minimum: category 2).
2.7 Notes on particular risks
Generally valid:
• Remove the energy supplies before installation, modification,
maintenance, or adjustment work.
• Make sure that no residual energy remains in the system.
• Do not move parts by hand when the energy supply is
connected.
• Do not reach into the open mechanism or the movement area
of the module.
• Perform maintenance, modifications, and additions outside of
the danger zone.
• For all work, secure the unit against accidental operation.
• Take a precautionary approach by maintenance and
disassembly.
• Only specially trained staff should disassemble the module.
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Basic safety notes
CAUTION
Possible risk of injury due to electrostatic energy!
Components or assembly groups may become electrostatically
charged. When touched, the electrostatic discharge can trigger a
startle response, which can result in injuries.
• The operator must ensure that all components and assembly
groups are included in the local equipotential bonding in line
with the applicable regulations.
NOTE
• The equipotential bonding must be installed by a specialist
electrician in line with the applicable regulations, paying
particular attention to the actual conditions in the working
environment.
• The effectiveness of the equipotential bonding must be verified
by a specialist electrician through regular safety measurements.
WARNING
Risk of injury from objects falling and being ejected!
Falling and ejected objects during operation can lead to serious
injury or death.
• Take appropriate protective measures to secure the danger
zone.
WARNING
Risk of injury due to unexpected movement of the machine/
system!
• Switch off the energy supply.
WARNING
Remove all temporary protective materials (caps, plugs, tape,
etc.) on the locking face of Tool Changer and modules prior to
operation.
Failure to do so will result in damage to Tool Changers, modules,
and end-of-arm tooling and could cause injury to personnel.
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Basic safety notes
WARNING
Injury or equipment damage can occur with power or air on.
• Do not perform maintenance or repair on Tool Changer or
modules with power or air on.
• Turn off power and air before performing maintenance or
repair on Tool Changer or modules.
WARNING
Failure to keep area clear will result in damage to Tool Changer,
modules, or end-of-arm tooling and could cause injury to
personnel.
• During operation, the area between the quick-change master
SWK and quick-change tool SWA must be kept clear.
WARNING
Using the Tool Changer in applications other than intended will
result in damage to Tool Changer, modules, or end-of-arm
tooling and could cause injury to personnel.
• The Tool Changer is only to be used for intended applications
and applications approved by the manufacturer.
CAUTION
The quick-change master SWK locking mechanism must not be
actuated without being mounted to the robot interface plate.
Damage to the Cover Plate and O-ring may result.
• Always attach the quick-change master SWK to the robot
interface plate prior to attempting any operations.
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Technical Data
3 Technical Data
Specifications such the as payload, moment capacity, repeatability,
and weight for model can found in the product catalog and on our
website.
Drawings also can found in the product catalog and on our
website. 2-D and 3-D models are also available on our website.
Contact SCHUNK for specific information and drawings regarding
your installation. We encourage you to use our service department
to review your designs and answer your questions.
SWK Quick-Change Head and SWA Quick-Change Adapter
Suggested Payload Limit 1.4 kg The mass attached to the Tool
Changer.
Operating Pressure Range 4.5 - 6.9 bar Locking mechanism supply pressure
operating range. Supply to be clean,
dry, and filtered.
Coupling Force @ 5 bar 170 N Axial holding force.
Static Moment Capacity: (x, y) 2.8 Nm Maximum recommended working
load for optimum performance of the
Tool Changer.
(z) 3.45 Nm Torsion
Positional Repeatability 0.01 mm Repeatability tested at rated load at
one million cycles.
Weight 0.03 kg
0.02 kg
Max. Recommended distance
1.0 mm No-TouchTM locking technology
between SWK and SWA
SWK
SWA
allows the SWK and SWA to lock with
separation when coupling.
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Product Overview
4 Product Overview
The Tool Changer consists of two primary parts: The quick-change
head SWK and the quick-change adapter SWA. The quick-change
head is attached to a robot while end-effectors such as grippers,
material handlers, etc. are attached to one or more quick-change
adapter SWA.
The locking mechanism consists of a cam, alignment posts, and
chrome-steel balls. Tapered pins located on the SWK mate with
alignment locking posts in the SWA to ensure repeatable
alignment during the coupling process. Extreme pressure grease is
applied to the posts on the SWA to enhance performance and
maximize the life of the locking mechanism.
The Tool Changer has four M5 integrated pneumatic only passthrough ports and is equipped with M5 elbow fittings for 6mm
diameter tubing.
Both the SWK and the SWA have two mounting pockets that
support optional modules for support of various utility passthrough connections. An electrical module E04 module provides
four signal connections, providing the capability of up to eight
signal connections to the Tool Changer.
4.1 SWK Quick-Change Head
The SWK quick-change head includes an anodized aluminum body,
hardened stainless-steel locking mechanism and hardened steel
alignment pins. The SWK is attached to the robot using four
mounting holes for M3 flathead screws. The four M3 x 14 socket
flathead cap screws are included with the Tool Changer.
The SWK is equipped with four M5 ports for pass-through air only
and two M3 threaded ports for Lock and Unlock air. The four Orings seal the pneumatic connection between the SWK and SWA.
The Lock and Unlock air ports are equipped with M3 adjustable
elbow fittings for 4mm diameter tubing. The SWK has two
mounting pockets that support optional modules for electrical or
other pass-through connections.
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M3 Adjustable Elbow Fittings
for 4mm Dia. Tubing (2x)
Optional Modules
(2x)
Pneumatic M5
Pass-through
Ports (4x)
M5 Elbow Fittings
for 6 mm Dia.
Tubing
(4x)
Alignment Pins
(2x)
Coupling Orientation
Pocket
Visual Alignment
Indicators (4x)
M3
Lock Air Port
O-ring Pneumatic
Seals (4x)
Locking Mechanism
Mounting holes (4x)
M3 x 14 Socket
Screws (4x)
Optional Modules
E04-A Electrical
Modules Shown
quick-change head SWK
3 mm H8 Through
Mounting Holes (2x)
M3 Through
Mounting Holes
Optional Modules
E04-M Electrical
Modules Shown
Coupling Orientation
Dowel Pin
Interface for
Optional Tool Stand
Alignment
Locking Posts (2x)
Pneumatic M5
Pass-through
Ports (4x)
M5 Elbow Fittings
for 6 mm Dia.
Tubing (4x)
Interface for
Optional Tool Stand
Visual Alignment
Indicators (4x)
Optional
Modules (2x)
Product Overview
4.2 Quick-Change Adapter SWA
The SWA quick-change adapter is made of an anodized aluminum
body. Harden stainless-steel alignment locking posts provide
reliable and repeatable coupling of the SWA. An end-effector can
be mounted with mounting holes on the bottom of the SWA.
quick-change adapter SWA
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The SWA is equipped with four M5 x 0.8 ports for pass through air
only and is equipped with four M5 elbow fittings for 6mm
diameter tubing. The SWA has two mounting pockets that support
optional modules for electrical or other pass-through connections.
Grooves are provided for interfacing with an optional tool stand.
A dowel pin on the SWA aligns with a pocket in the master plate to
ensure proper coupling orientation.
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Page 14
Assembly
M3 x 14 screws
(supplied by SCHUNK)
Mounting Fasteners
(supplied by user)
End-Effector
SWK-001
SWA-001
Adapter Plate if Required
(supplied by user)
SWA
Mating Surface
Mounting Fasteners
Must Not Protude
Above Mating Surface
5 Assembly
5.1 SWK Quick-Change Head Assembly
Typical Installation
Ø Clean the debris from the robot wrist and SWK mounting
surface prior to installation.
Ø Apply Loctite 222® to the four M3 x 14 socket flat head cap
screws supplied.
Ø Assemble SWK to robot wrist, align the four mounting holes in
the SWK to the holes in the robot wrist and attach with the four
M3 x 14 socket flat head cap screws. Torque to 0.8 Nm.
Ø Pneumatic lines and electrical cables can be installed after the
SWK is attached. The pneumatic lines and electrical cables must
be bundled, and strain-relieved in a manner that allows for
freedom of movement during operation Wiring and Electrical
Connections for Optional Modules [}19].
CAUTION
Failure of some critical electrical and/or pneumatic lines to
function properly may result in injury to personnel and
equipment.
• All pneumatic fittings and tubing must be capable of
withstanding the repetitive motions of the application without
failing.
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• The routing of electrical and pneumatic lines must minimize
the possibility of stress pullout, kinking, rupture, etc.
Page 15
5.2 SWA Quick-Change Adapter Assembly
Ø Clean the debris from the end-effector and SWA mounting
surfaces prior to installation.
Ø The end-effector is attached to the SWA using the four M3 x 0.5
mounting holes with mounting fasteners supplied by the user.
Removable thread locker (Loctite 222®) or fasteners with preapplied adhesive should be used for all mounting fasteners.
NOTICE
Fasteners that extend beyond the mating surface will create a
gap between the SWK and SWA and not allow the locking
mechanism to fully engage.
This could cause damage to the equipment.
• Make sure the mounting fasteners are flush or below the
mating surface of the SWA.
• Do not use mounting fastener that extend beyond the SWA
mating surface.
Assembly
Ø Pneumatic lines and electrical cables are attached, bundled, and
must be strain-relieved in a manner that allows for freedom of
movement during operation. For electrical cabling instructions:
Wiring and Electrical Connections for Optional Modules [}19].
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Assembly
5.3 Lock/Unlock Pneumatic Connections and Valving
CAUTION
Failure to use a 4-way valve and properly vent to atmosphere
may cause the locking mechanism to operate incorrectly and
may cause the Tool Changer to not lock or unlock as expected.
This could result in damage to the product, attached tooling, or
personnel.
Air must be supplied to the “Lock” air port on the SWK to move
the internal piston, which moves the cam, and forces the locking
balls outward. The locking balls move outward until they contact
the alignment locking post on the mating SWA. This will rigidly
engage the SWK and SWA providing high load capacity and
positional accuracy. In a fail-safe condition the cam profile
prevents the SWA from becoming disengaged in the event that
there is a loss of air in the locked state. To unlock the SWA from
the SWK, lock air must be vented and air supplied to the “Unlock”
air port on the SWK.
5.3.1 Air Requirements
For proper operation of the Tool Changer, the SWK must be
supplied with clean, dry, non-lubricated air supplied between 4.5 –
5.5 bar.
NOTICE
Possible damage to the locking mechanism could occur.
• Do not use the Tool Changer in the fail-safe condition for
extended periods of time.
• Do not transport the Tool Changer in the fail-safe condition.
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Lock Port
Unlock Port
4-way Valve
Supply Clean, Dry,
Non-Iubricated Air
4.5 - 5.5 bar
Exhaust
Open to Atmosphere
Pneumatic Connections
Assembly
5.3.2 Valve Requirements and Connections
As with all pneumatic piston arrangements, smooth operation
requires proper porting of the supplied and vented air. It is
recommended that a single 4-way valve be used to actuate the
locking mechanism in the SWK. The valve may be of either 4-port
or 5-port configuration. It is imperative that when air is supplied to
the Lock or Unlock Port on the SWK, that the opposite port be
vented to atmosphere (i.e., when air is supplied to the Lock Port,
the Unlock Port must be open to the atmosphere.) Failure to vent
trapped air or vacuum on the inactive port will negate the locking
force of the Tool Changer mechanism. The Lock and Unlock Ports
are threaded for M3 connections.
NOTICE
The Tool Changer locking mechanism will not function properly
when connected to a single 3-way valve as this type of valve is
incapable of venting trapped air pressure from within the Tool
Changer.
Connect the Lock and Unlock supply air to a single 4-way valve
with either 4 or 5 port configuration.
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Assembly
1.5mm Ball End
Allen Wrench
Remove M3 Elbow Fitting
Support Tool Plate and Tool if attached
Remove
Pneumatic
Tubing
5.3.3 Manual Uncouple SWK and SWA
It is possible to manually uncouple the SWK and SWA if air is
completely lost. This is not standard procedure and should only be
use when no other alternative is available.
NOTICE
If the tool is attached to the master it must be secured in the
tool stand or in a location where the tool weight is supported
before manually uncoupling. Use of manually uncoupling is
restricted to contingency situations.
Using the manual override will release the tool and may cause
damage to equipment.
• Do not manually uncouple the SWK and SWA if the tool is not
secured.
Manual Uncouple Master and Tool Plates
Ø Remove the Unlock air tubing.
Ø Unscrew the M3 elbow fitting from the SWK.
Ø Using a 1.5mm Ball end Allen wrench, insert it through the
Unlock air port and push the locking piston to the unlocked
position.
Ø Separate the SWA from the SWK, supporting the SWA and tool
if attached.
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Assembly
SWK
Optional Module
E04-K Shown
M2 screw
1.5 mm Allen Wrench
Optional Module
E04-A Shown
SWA
Notch in pin
Heat Shrink
Strip wire the same
length as notch in pin
Solder wire to pin
Slide heat
shrink
over wire
Slide heat shrink
over solder
connection and
apply heat
Optional Module
E04-K Shown
Optional Module
E04-A Shown
5.4 Wiring and Electrical Connections for Optional Modules
Removable Optional Module
Ø Both the SWK and SWA have removable optional modules for
Ø Remove the M2 screw from the optional module using a 1.5mm
Ø Remove the optional module from the SWK or SWA
Soldering the Electrical Connections
Ø Strip the wire the same length as the notch in the pin.
electrical pass-through connections. The electrical connections
have to be soldered to the connection pins.
Allen wrench.
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Ø Slide a piece of heat shrink tubing over the wire.
Ø Solder the wire to the pin.
Ø Slide the heat shrink tubing over the soldered connections and
apply heat using a heat gun until the heat shrink restricts tightly
over the connection.
Ø Repeat this for all the connections.
Ø Replace the optional module to the SWK or SWA and secure
with the M2 screw using a 1.5mm Allen Wrench. Torque to
approximately 0.24 Nm.
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Operational Considerations
6 Operational Considerations
The SWK locking mechanism is pneumatically driven to couple and
uncouple with the alignment Locking Posts on the SWA. The SWK
utilizes air ports to provide Lock and Unlock pressure to the locking
mechanism.
During operation, the area between the SWK and SWA must be
kept clear.
Failure to keep area clear will result in damage to Tool Changer,
modules, or end-of-arm tooling and could cause injury to
personnel.
NOTICE
Safe, reliable operation of the Tool Changer is dependent on a
continuous supply of compressed air at a pressure of 4.5 - 5.5
bar.
WARNING
Robot motion should be halted if the air supply pressure drops
below 4 bar for any reason.
6.1 Coupling Sequence
NOTICE
Before attempting to couple or uncouple, ensure that passthrough air pressure and electrical signals are off.
Equipment could be damaged if air pressure and electrical signals
are not turned off.
Ø Prior to coupling and with air supplied to the Unlock Port,
position the SWK above the SWA.
Ø Move the SWK toward the SWA so that the two SWA alignment
locking posts enter the alignment holes on the SWK.
Note: Take care to program the robot so that the SWK and SWA
are aligned axially and are parallel to each other as closely as
possible. This will minimize tool movement and subsequent
wear during lock-up.
Note: Make sure the visual alignment indicators on the SWK
and the SWA are aligned properly before coupling to ensure
proper orientation.
Ø When the two faces are within the specified No-Touch™
distance, release the pressure from the Unlock Port and supply
air to the Lock Port
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Operational Considerations
Note: The SWA will be drawn toward the SWK and coupled. Air
must be maintained on the Lock Port during operation to assure
rigid coupling.
Ø A sufficient delay must be programmed between locking valve
actuation and robot motion so that the locking process is
complete before moving the robot.
The fail-safe design prevents the SWA from being released in the
event of air-pressure loss to the Lock Port, thereby increasing
safety and reliability. Positional accuracy may not be maintained
during air loss, but will be regained once air pressure is reestablished to the Lock Port.
6.2 Uncoupling Sequence
Ø Position the SWA in the Tool Stand such that there is little or no
contact force between the SWA and Tool Stand.
Ø Release air on the Lock Port and apply air to the Unlock Port.
NOTICE!The air will cause the locking mechanism to be
released and the weight of the SWA and attached tooling will
assist in its removal. Tool weight assists in uncoupling if the
Tool is released in the vertical position only.
Ø Move the SWK axially away from the SWA.
Ø A sufficient delay must be programmed between unlocking
valve actuation and robot motion so that the unlocking process
is complete and the SWA is fully released before moving the
robot.
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Operational Considerations
6.3 Fail-Safe Operation
A fail-safe condition occurs, when there is an unintended loss of air
pressure to the SWK. When air pressure is lost, the Tool Changer
relaxes and there may be a slight separation between the SWK and
the SWA. The lock sensor may indicate that the unit is not locked.
The fail-safe feature utilizes a multi-tapered cam to trap the ball
bearings and prevent unintended release of the SWA. Positional
accuracy of the tooling is not maintained during this fail-safe
condition. Do not operate the Tool Changer in the fail-safe
condition. If source air is lost to the unit, movement should be
halted until air pressure is restored.
After air pressure is re-established to the SWK, the locking
mechanism will energize and securely lock the SWK and the SWA
together. In some cases when to load on the Tool Changer is
significantly off center, it may be necessary to position the load
underneath the Tool Changer or return the tool to the tool storage
location to ensure a secure lock condition. If equipped, make sure
the lock sensor indicates the Tool Changer is in the locked position
before resuming normal operations. Consult your Control/Signal
Module manual for specific error recovery information.
CAUTION
Do not use the Tool Changer in a fail-safe condition.
Damage to the locking mechanism could occur.
• Re-establish air pressure and ensure the Tool Changer is in a
secure lock position before returning to normal operations.
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Page 23
Operational Considerations
6.4 Tool Stand Design
NOTICE
During coupling and lock-up, the Tool Stand must allow for
movement (float) in a plane parallel to the mating surfaces of
the SWK and SWA, and in a direction perpendicular to this
plane, towards the SWK.
In most cases, the Tools are stored in a Tool Stand when not being
used by the robot. During coupling and lock-up, the Tool Stand
must allow for movement (float) in a plane parallel with the
mating surfaces of the SWK and SWA (X and Y), and also in a
direction towards the SWK (Z). Even slight misalignment between
the SWK and SWA can generate high forces during lock-up if the
SWA is not allowed to float into place during lock-up. These high
forces can cause excessive wear and even jamming of the endeffector and robot. The degree of float required depends on the
accuracy of the robot’s positioning and the repeatability of the
Tool location in the Tool Stand during lock-up. See the following
figure and table for recommended maximum allowable float
(offsets) prior to coupling. The Tool Stand should be designed to
minimize misalignment during coupling and uncoupling. In some
cases, greater offsets than shown in the following table can be
accommodated by the SWK and the SWA, but will increase wear.
Ideally, the Tool should be hanging vertically in the Tool Stand so
that gravity acts to uncouple the SWA from the SWK during
unlocking. It is possible to design Tool Stands that hold Tools in the
horizontal position, but care must be taken that the necessary
compliance is provided during coupling and uncoupling. In general,
“horizontal-position” SWA cause more wear on the locking
mechanism and locating features of the Tool and Tool Stand.
Lock-up should occur with the SWK in the No-Touch™ locking zone
(see the following table), but not touching the SWA. When air is
supplied to the lock port, the SWK should draw the SWA into the
locked position.
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Operational Considerations
SWK
SWA
Twisting Offset
(About Z)
X, Y, and Z Offset
Cocking Offset
(About X and Y)
NOTICE
Tool Stand design is critical to proper operation of the Tool
Changer. Improperly designed Tool Stands can cause
misalignments that will cause jamming and/or excessive wear
of Tool Changer components.
Improperly designed Tool Stands can cause misalignments that
will cause jamming and/or excessive wear of Tool Changer
components.
Tool Stands may also need to incorporate means for covering
Tools and electrical modules to protect them in dirty
environments, such as grinding or welding.
Offset Prior to Coupling
Maximum Recommended Offsets Prior to Coupling
No-Touch Zone Z Offset
(Max)* (mm)
X and Y Offset
(Max)** (mm)
Cocking Offset
(Max) (degrees)
Twisting Offset
(Max) (degrees)
+1 ±1 ±0.7 ±3
* Maximum values shown. Decreasing actual values will
minimize wear during coupling/uncoupling.
** Actual allowable values may be higher in some cases, but
higher offsets will increase wear during coupling.
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6.4.1 Tool Locating Features
The Tool must be positively located in the Tool Stand. A variety of
methods may be used to accomplish this. Whatever method is
chosen, it is important that the required compliance or “float” be
built into the locating system.
Other Tool locating feature methods include balls and detents,
dowel pins in notched V-grooves, etc. Please consult SCHUNK for
recommendations or assistance with locating feature design for
your particular tooling.
Cylindrical (not tapered) dowel pins should not be used as they
provide too much surface engagement. During coupling and
uncoupling, the Tool can bind on these straight (cylindrical) pins
due to misalignment of the SWK and the SWA.
Robot programming and locational repeatability are important in
Tool pick-up and drop-off.
6.4.2 Tool Stands Sensors
Operational Considerations
It is suggested that the customer provide a sensor that detects the
presence of a properly seated Tool in the Tool Stand. The sensor
may be used prior to coupling to ensure there is a Tool properly
seated in the stand. Sensors may also be used as the robot starts
to move away after uncoupling. This provides a fail-safe measure
in the event that a Tool should become jammed in the stand or if
the Tool should fail to release properly from the robot.
Proximity sensors should be located so that the sensing face is
vertical to prevent swarf or other debris from falling on the sensor
and creating false readings.
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Troubleshooting
7 Troubleshooting
The system contains few components and provides trouble-free
operation once properly installed. The following table is provided
to assist with troubleshooting the system.
Symptom Possible cause Correction
If Tool Changer is not
operating properly check
the following conditions
prior to any further
troubleshooting.
SWK will not Lock or
Unlock to Tool (locking
piston does not move)
Unlock switch fails to
operate.
Pneumatic connections
incorrect or air supplied is
insufficient.
Air or vacuum trapped in
a de-energized Lock or
Unlock port or incorrect
valve type.
SWK and SWA not within
specified No-Touch
distance.
Debris caught between
SWK and SWA
Air supplied to Unlock (U)
port is insufficient.
Ensure that the Tool Changer has
proper pneumatic connections and
air is supplied at a minimum of 4.5
bar. Lock/Unlock Pneumatic
Connections and Valving [}16]
Ensure that no air or vacuum can be
trapped in a de-energized Lock or
Unlock Port and 4 way type valve is
used (pressure must be vented to
atmosphere). Lock/Unlock
Pneumatic Connections and Valving
[}16]
Adjust position to be within
specified No-Touch distance. Tool
Stand Design [}23]
Inspect and remove any debris
between SWK and SWA and retry.
Ensure that air is supplied at a
minimum of 4.5 bar to the Tool
Changer Unlock (U) port.
Lock/Unlock Pneumatic Connections
and Valving [}16]
Air or vacuum trapped in
a Lock (L) air port.
Ensure that the SWK cam is fully
retracted and that there is no air
trapped in the Lock (L) air port.
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8 Maintenance
Maintenance
General
Under normal conditions, no special maintenance is necessary,
however it is recommended that periodic inspections be
performed to assure long-lasting performance and to assure that
unexpected damage has not occurred. For a schedule and items
that should be visually inspected at regular intervals Preventive
Maintenance [}28].
Spare parts are available from SCHUNK. Please call for
recommendations.
NOTICE
The cleanliness of the work environment strongly influences the
trouble-free operation of the changer. The dirtier the
environment, the greater the need for protection against
debris.
Protection of the entire End of Arm Tooling, the SWK, the SWA
and all of the modules may be necessary. Protective measures
include the following:
• Placement of Tools Stands away from debris generators.
• Covers incorporated into the Tool Stands, guards, deflectors,
air curtains, and similar devices the End of Arm Tooling and
the Tool Stand Design.
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Maintenance
8.1 Preventive Maintenance
The Tool Changer and optional modules are designed to provide a
long life with regular maintenance. A visual inspection and
preventive maintenance schedule is provided in the following
Table below depending upon the application. Assembly details are
provided in Drawings [}36] of this manual.
Preventative Maintenance Checklist
Application(s) Tool Change Frequency Inspection Schedule
General Usage, Material Handling,
Docking Station
More than 1 per minute Weekly
Less than 1 per minute Monthly
Wet or Humid Environments All Weekly
Welding/Servo/Deburring, Foundry
All Weekly
Operations (Dirty Environments)
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Maintenance
Locking Mechanism
Mounting Fasteners
Interface Connections
NOTE
Locking mechanism components are subject to corrosion from
water.
If these components get wet, they must be dried and greased
immediately.
• Inspect and lubricate Locking Mechanism (Alignment locking
posts). Over time lubricants can become contaminated with
process debris. Therefore, it is recommended to thoroughly
clean the existing grease and replace with new as needed
Cleaning and Lubrication of the Locking Mechanism [}30]
• Inspect alignment locking posts for wear. Excessive wear may
be an indication of poor robot position during pickup/drop-off.
Adjust robot position as needed.
• Inspect alignment locking post ball sockets race for wear. Wear
on the ball sockets could be an indication of excessive loading.
• Inspect mounting fasteners, verify they are tight and have the
proper torque.
• Inspect pneumatic connections for cuts in hoses, abrasions, or
wear. If signs of wear are apparent, tighten connections and
secure lines so that they allow freedom of movement during
operation and do not rub or obstruct other components.
Rubber O-rings
Electrical Contacts
• Inspect electrical cables for cuts, abrasions, or wear. If signs of
wear are apparent, check connections and secure cables so that
they allow freedom of movement during operation and do not
rub or obstruct other components.
• Inspect for wear, abrasion, and cuts. If worn or damaged,
replace Rubber O-ring Inspection and Replacement [}32]
• Clear debris from area of the contacts using compressed air. Do
not directly clean contacts as abrasion may occur and the
performance of the contact may be compromised.
• Inspect electrical contacts for wear or damage Spring Pin
Replacement [}33]
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Maintenance
Ball socket
Inner surface
Outer surface of the
Alignment Locking Posts
Alignment Pin
Inner surface
8.2 Cleaning and Lubrication of the Locking Mechanism
Clean Outer and Inner Surfaces of Alignment Locking posts on the Tool Plate
Ø The locking mechanism must be in the Unlock state before
cleaning.
Ø Use a clean rag to thoroughly remove the existing lubricant and
debris from the outer surface of the alignment locking posts on
the SWA. Clean the inner surfaces and ball sockets of the
alignment locking posts by pushing the rag through in the
narrow passages with a small shaft.
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Clean Inner Surface and Alignment Pins of the Master Plate
Ø Clean the inner surfaces, balls, and alignment pins of the SWK
by pushing the rag into the narrow socket with a small shaft.
Page 31
Maintenance
Apply greases to inner surfaces
of the alignment locking posts
Apply greases to ball socket
of the alignment locking posts
Apply Lubricant to the Alignment Locking Posts on the Tool Plate
Ø Apply a moderate coating of lubricant to the alignment locking
posts inside and out.
NOTICE
Special grease to lubricate the locking mechanism.
Tubes of lubricant for this purpose are shipped with every Tool
Changer.
• Use MobilGrease® XHP222 Special grease.
MobilGrease® XHP222 Special is a NLGI #2 lithium complex
grease with molybdenum disulfide.
Ø No application of lubrication is necessary on the SWK
components
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Maintenance
o-ring
Master Plate
8.3 Rubber O-ring Inspection and Replacement
Rubber O-ring Replacement
Ø The rubber O-ring seals the air passage from the SWK to the
SWA. If the O-rings become cut or damaged they need to be
replaced.
Ø Remove damaged rubber O-ring by pinching with finger tips or
prying with finger nail and pulling the O-ring out of the body.
Ø Dip new O-ring in water to aid in installation.
Ø Insert the rubber O-ring into the bore.
Ø Press the O-ring in by hand until it is seated completely in the
bore.
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8.4 Spring Pin Replacement
SWK
Spring Pin
Spring Pin Head
Pin Insertion Tool
Spring Pin
Pin Insertion Tool
Replacing spring pins may be necessary if they become damaged
or worn. The following procedure describes the replacement of
the spring pins.
Spring Pin Removal
Maintenance
Ø Using your finger nails, catch the spring pin under the head.
Ø Gently and evenly pull the spring pin out until it clears the pin
block. Gently and evenly pull the spring pin out until it clears the
pin block.
Spring Pin Insertion
Ø Start new spring pin into the pin block by hand.
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Maintenance
NOTICE
Use of excessive force can cause socket to move in pin block and
damage pin block assembly.
This may require the replacement of entire pin block assembly.
• Gently push spring pin into the block until you feel a click.
• Do not use excessive force to push spring pin into pin socket.
Ø Using the Pin pusher tool gently push the pin into the block until
you feel a click.
NOTICE!The pin socket has two sets of dimples that the spring
pin will click into.
Ø Check to see if the spring pin is at the proper height by
comparing it to other original spring pins. If not continue to
push the pin into the block until you feel a click or the pin is at
the proper height.
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Recommended Spare Parts
9 Recommended Spare Parts
Assembly Part Number Description
SWK 0302290 SWK-001-000-000
SWA 0302291 SWA-001-000-000
Electrical modules 9960359 Electrical Module, E04-K,
4-Pin, 3Amp/50VAC Master
9960360 Electrical Module, E04-A,
4-Pin, 3Amp/50VAC Tool
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Drawings
45°
B.C.Ø20
M3
Lock Port
Ø45
4X M5
Pneumatic Thru
Ports
4X SWK/SWA
Alignment Mark
2X 30.6
SWK
(Protection Only)
4X Thru Holes for
M3 x 14
C'sunk from Far Side
Equally Spaced
Customer Interface
Note 2
2X 20
M3
Unlock Port
Note 4
2X Ø3 g6
Customer Interface
Note 3
5.5
Customer
Interface
Electrical
Note 2
2X 2.5
Dowel, Note 3
10.9
SWK
8
Pin
6
SWA
4.8
Unlock Port
(Lock Port Opposite Side)
Ø1.5
Note 5
2.2
6.1
Side View
(Uncoupled)
45°
B.C.Ø20
2XØ
3.014
3
Thru
(Ø3 H8)
Customer Interface
4X M5
Pneumatic
Thru Ports
2X 30.6
SWA
(Projection Only)
4.3
Customer Interface
Electrical
Note 2
4X SWK/SWA
Alignment Mark
4X M3 Thru
Customer Interface
Note 2
Ø 14 H7
Customer Interface
Ø45
2X 20
2.9
1.8
Note 5
37.3
[.67]
16.9
Coupled
Notes:
1. SWS-001 is designed for extremely light payloads.
2. Optional E04 Electrical Modules shown. Total 8 pins @ 3 Amp / 50 VAC. Electrical connections not shown for clarity. Wires attached will rewuire additional clearance.
3. Master Plate includes 2X Ø3mm dowel pins are integral to the machanical function of the Master Plate and should not be tampered with or damage will occur.
4. Master Plate can be manually set in the Unlock state. Remove fitting and using a Ø2mm rod, push the internal Locking Mechanism until Unlock state is achieved.
5. Dowel and grooves serve as an interface for an optional Tool Stands.
10 Drawings
10.1 Tool Changer
SWS-001 Tool Changer
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Drawings
quick-change head SWK-001
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Drawings
quick change adapter SWA-001
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10.2 E04 Electrical Module
Loctite 222 / 0.25 Nm
Loctite 222 / 0.25 Nm
23.4
7.2
0.2
4X Contacts
E04 Tool Module
E04-K
E04-A
13.9
Coupled
(Approx.)
Tool
E04-A
23.4
6.4
1.3
4X Spring Probes
E04 Master Module
Notes:
1. The E04 is a customer configurable 4-pin module designed to fit the SWS-001.
2. Provides gold plated contacts with solder connections in a miniature size. Contacts are rated at 3A/50V.
3. Maximum recommended wire gauge is Ø 0.5 mm.
Master
E04-K
Drawings
Electrical Module
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Translation of original declaration of incorporation
11 Translation of original declaration of incorporation
in terms of the Directive 2006/42/EG, Annex II, Part 1.B of the European Parliament and of
the Council on machinery.
Manufacturer/
Distributor
SCHUNK GmbH & Co. KG Spann- und Greiftechnik
Bahnhofstr. 106 – 134
D-74348 Lauffen/Neckar
We hereby declare that on the date of the declaration the following partly completed
machine 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 invalid if modifications are made to the product.
Product designation: Quick-Change / SWS-001 / pneumatic
ID number
The partly completed machine may not be put into operation until conformity of the
machine into which the partly completed machine is to be installed with the provisions of
the Machinery Directive (2006/42/EC) is confirmed.
The manufacturer agrees to forward on demand the relevant technical documentation for
the partly completed machinery in electronic form to national authorities.
The relevant technical documentation according to AnnexVII, Part B, belonging to the
partly completed machinery, has been created.
Person authorized to compile the technical documentation:
Robert Leuthner, Address: see manufacturer's address
Lauffen/Neckar, June 2019 p.p. Ralf Winkler,
Manager for development
of gripping system components
40
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