Transcript
Translation of the original manual
Portal Actuator PMP 16 - 25 Assembly and Operating Manual
Superior Clamping and Gripping
Translation of the original manual
Imprint: 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 unit. 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: 0389313 Edition: 02.01 |18/12/2012|en © SCHUNK GmbH & Co. KG, Lauffen/Neckar All rights reserved
Dear customer, congratulation 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. Kindest Regards Yours SCHUNK GmbH & Co. KG Precision Workholding Systems Bahnhofstr. 106 – 134 D-74348 Lauffen/Neckar Tel. +49-7133-103-2503 Fax +49-7133-103-2189
[email protected] www.schunk.com
02.01|PMP 16 - 25|en
Table of contents
Table of contents 1
About this manual .................................................................................................... 5 1.1 Warnings ................................................................................................................... 5 1.1.1 Signal words .................................................................................................. 5 1.1.2 Symbols ......................................................................................................... 5 1.2 Applicable documents .............................................................................................. 6
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Basic safety notes .................................................................................................... 6 2.1 Appropriate use ........................................................................................................ 6 2.2 Not intended use ...................................................................................................... 6 2.3 Environmental and operating conditions................................................................. 7 2.4 Product safety........................................................................................................... 7 2.4.1 Protective equipment ................................................................................... 7 2.4.2 Constructional changes, attachments, or modifications .............................. 7 2.5 Personnel qualification ............................................................................................. 8 2.6 Using personal protective equipment...................................................................... 8 2.7 Information about special dangers .......................................................................... 8
3
Warranty ................................................................................................................. 10
4
Scope of delivery ..................................................................................................... 10
5
Accessories .............................................................................................................. 10 5.1 Variable end stop.................................................................................................... 10 5.2 Intermediate stops AS/ZA ...................................................................................... 11 5.3 Bellows.................................................................................................................... 11 5.4 Cable track .............................................................................................................. 11 5.5 Columns and mounting material ............................................................................ 11 5.6 T-nuts ..................................................................................................................... 11
6
Technical data ......................................................................................................... 12
7
Assembly and Installation........................................................................................ 13 7.1 Mechanical connection .......................................................................................... 13 7.2 Compressed air supply ........................................................................................... 15 7.3 End position - sets .................................................................................................. 16 7.3.1 End position adjustment "X" ....................................................................... 16 7.3.2 Variable end stop VE ................................................................................... 17 7.3.3 Damping adjustment “Z” ............................................................................ 17 7.4 Intermediate stops AS/ZA ...................................................................................... 18 7.4.1 Stop collar AS …. .......................................................................................... 19
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Table of contents 7.4.2 Intermediate stop ZA .................................................................................. 20 7.4.3 Handling ...................................................................................................... 21 7.5 Cable track .............................................................................................................. 22 7.5.1 Cable track horizontal KSH... ....................................................................... 22 7.5.2 Vertical KSV... cable drag chain ................................................................... 23 8
Commissioning ........................................................................................................ 24
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Troubleshooting ...................................................................................................... 25 9.1 Module does not move? ........................................................................................ 25 9.2 Power / speed / power of the module is declining? .............................................. 25 9.3 End position signal not present? ............................................................................ 25 9.4 Module impacts on end position? ........................................................................ 26 9.5 Service load vibrates in end position?.................................................................... 26
10 Maintenance and Care ............................................................................................ 27 10.1 Notes....................................................................................................................... 27 10.2 Maintenance and lubrication intervals .................................................................. 27 10.3 Lubricants/Lubrication points (basic lubrication) ................................................. 28 10.4 Dismantling the module ......................................................................................... 28 10.5 Assembling the module .......................................................................................... 29 11 Assembly / spare parts ............................................................................................ 29 11.1 PMPS/F 16 .............................................................................................................. 30 11.2 PMPS/F 25 .............................................................................................................. 31 12 Translation of original declaration of incorporation ................................................. 32
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Basic safety notes
1 About this manual This instruction is an integral part of the product and contains important information for a safe and proper assembly, comissioning, operation, maintenance and helps for an easier trouble shooting. Before using the product, read and note the instruction, especially the chapter "Basic safety notes".
1.1 Warnings The following signal words and symbols are used to highlight dangers. 1.1.1 Signal words DANGER
Dangers for persons. Non-compliance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons. Non-compliance may cause irreversible injury or death.
CAUTION
Dangers for persons. Non-observance may cause minor injuries.
CAUTION
Information about avoiding material damage 1.1.2 Symbols Warning about a danger point Warning about hand injuries General mandatory sign to prevent material damage
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Basic safety notes
1.2 Applicable documents • General terms of business • SCHUNK catalog Modular Assembly Automation • Assembly and Operating Manuals for sensors The documents listed up here, can be download on our homepage www.schunk.com.
2 Basic safety notes 2.1 Appropriate use The module is exclusively designed for linear movement of useful loads into any desired position. The module is intended for installation in a machine/system. The requirements of the applicable guidelines must be observed and complied with. The module may be used only in the context of its defined application parameters ( 6, Page 12). To use this unit as intended, it is also essential to observe the technical data and installation and operation notes in this manual and to comply with the maintenance intervals.
2.2 Not intended use It is not an intended use if the module is used, for example, as a pressing tool, stamping tool, lifting gear, guide for tools, cutting tool, clamping device or a drilling tool.
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Basic safety notes
2.3 Environmental and operating conditions • The module may be used only within its defined application parameters. • Ensure that the environment is clean. Observe the lubrication intervals. ( 10.2, Page 27) • Ensure that the environment is free of splashing water and vapors, and also of abrasive dust and process dust. This does not apply to modules designed especially for unclean environments. • Do not subject the module to excessive vibrations and/or mechanical shocks. • Strong magnetic fields can impair the function of the module. If the product is to be used in strong magnetic fields, contact your SCHUNK partner.
2.4 Product safety Dangers arise from the module, if e.g.: • the module is not used in accordance with its intended purpose. • the module 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 module. Wear protective equipment. NOTE
More information are contained in the relevant chapters. 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.
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Basic safety notes
2.5 Personnel qualification The assembly, initial commissioning, maintenance, and repair of the module may be performed only by trained specialist personnel. Every person called upon by the operator to work on the module must have read and understood the complete assembly and operating manual especially the chapter "Basic safety notes" ( 2, Page 6). This applies particularly to personnel only used occasionally, such as maintenance personnel.
2.6 Using personal protective equipment When using this product, observe the relevant industrial safety regulations and use the personal protective equipment (PPE) required! • Use protective gloves, safety shoes and safety goggles. • Observe safe distances. • Minimal safety requirements for the use of equipment.
2.7 Information about special dangers 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 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
WARNING Risk of injury due to squeezing and bumping during movement of the Unit or attachment parts! Risk of injury due to breaking or loosening of the attachment parts!
WARNING Risk of injury from objects falling and being ejected • The danger zone must be surrounded by a safety fence during operation.
WARNING While disassembling uncontrollable moves of parts of the gripper possible!
WARNING Danger of injury due to unexpected movements of the machine/system due to failure of the energy supply or malfunction of the controller! Apply a holding break at the linear axis.
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Accessories
3 Warranty The warranty is valid for 24 months from the delivery date to the production facility under the following conditions: • Intended use in 1-shift operation • Observe the mandatory maintenance and lubrication intervals. • Observe the environmental and operating conditions. Parts touching the work piece and wearing parts are not part of the warranty.
4 Scope of delivery The scope of delivery includes: • Portal module PMPS/F in the ordered model.
5 Accessories A wide range of accessories is available for this module. To get information about which accessories can be used with the appropriate product variant, ☞ catalog.
5.1 Variable end stop The stroke and its position along the entire stroke length of the portal module can be adjusted using the variable VE end stops ( 7.3.2, Page 17). For further information, consult the latest catalog.
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Accessories
5.2 Intermediate stops AS/ZA The intermediate stop consists of a AS... stop guide which is mounted on the traversing slide and of the actual ZA stops. These can be controlled independently and any number can be distributed along the axis. The intermediate stop can be supplied for all types and sizes of the portal module ( 7.4, Page 18).
5.3 Bellows The module is optionally available with a bellow. This increases the protection against penetrating materials. This option is only available for fixed stroke variants ( 11, Page 29). For further information, consult the latest catalog.
5.4 Cable track For guiding electric and pneumatic lines The cable track is available for "horizontal slide" and "vertical slide" versions. Several attachment variants are possible ( 7.5, Page 22).
5.5 Columns and mounting material Columns, adapter plates and mounting materials are available for the portal modules( 7.1, Page 13). For further information, consult the latest catalog.
5.6 T-nuts For mounting the linear module on the machine / system. Overview of T-nuts
Designation
Type / ID number
T-nut for PMPS/F 16
NT-M5 / 03136073
T-nut for PMPS/F 25
NT-M5 / 03136078
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Technical data
6 Technical data ambient temperature [°C] IP rating Noise emission [dB(A)] Pressure medium
5 - 60 40 ≤ 70 compressed air, standard for quality of the compressed air according to ISO 8573-1: 6 4 4
Min. pressure [bar]
3
Max. pressure [bar]
10
Nominal working pressure
6
Repeatability [mm]
± 0.02
Further technical data can be found in our catalog. The most recent version applies.
NOTICE The portal modules may not under any circumstances have been operated with oiled air before operation with unoiled air.
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Assembly and Installation
7 Assembly and Installation NOTICE Assembly measures • During the mounting of loads, do not allow the system to be subjected to impermissible forces or moments. • Select a suitable screw tightening torque for mounting of the linear actuator or loads on the linear actuator in accordance with the generally valid guidelines for screw connections. • Secure all screw connections with an appropriated chemical securing screw.
WARNING Risk of injury when the machine/system moves unexpectedly! Remove the energy supplies.
7.1 Mechanical connection Check the evenness The values relate to the entire bolting surface. of the bolting surface Requirements for levelness of the bolting surface
Diameter [mm]
Permissible unevenness [mm]
< 100
< 0.02
> 100
< 0.05
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Assembly and Installation Mounting Grooves fasten the module underneath on the profile, the load can be mounted and fastened on the slide using bore holes and threads. Position dimensions, etc. ☞ Catalog.
Fig. 1 PMPS/F 16 connection geometries
Fig. 2 PMPS/F 25 connection geometries PMPS/F 16 / 25 connection geometries
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PMPS/F 16
PMPS/F 25
A [mm]
M6 / 11 (2x)
M8 / 16 (6x)
B [mm]
Ø5F7 / 10 (2x)
Ø5F7 / 8 (2x)
C
X
M6 / 12 (4x)
D [mm]
5
8
E [mm]
11.77
20.5
F [mm]
1.8
3.5
G [mm]
4.55
7.95
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Assembly and Installation
Fig. 3 Fitting example PMPS/F on pillar profile modular system, horizontal and vertical
Additional information on the pillar profile modular system and mounting elements for attachment ☞ Catalog.
7.2 Compressed air supply NOTE
• Use connecting pipes of a cross-section that is larger than or identical to that of the connector thread. • Observe the requirements for the air supply ( 6, Page 12)
Fig. 4 Compressed air supply PMPS/F ....axis Thread diameter of the air connections
Air supply thread
PMPS/F 16
PMPS/F 25
M5
G 1/8"
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Assembly and Installation
7.3 End position - sets For stroke limiting, damping and query of the end positions the following components are available: • VE (Variable end stop) • LMST-...(shock absorber - stop collar) • NI 30 (proximity switch) Hereinafter the assembly of LMST- and NI 30 in the portal module with and without variable end stop VE is shown.
Fig. 5 Portal module with and without variable end stop VE
7.3.1 End position adjustment "X" The end positions can be finely adjusted by the shock absorbers stop collar LMST the maximum possible setting range X is included in the catalog modular assembly automation
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Assembly and Installation
7.3.2 Variable end stop VE The stroke and its location along the entire stroke of the portal module can be adjusted by the variable end stops. For the assembly remove the cover caps and the fastening screws of the profiled rail guide in the selected area.
NOTICE Ensure that the slots residual in the nots don´t move.
After placing the variable end stop with the supplied centering sleeves it must be screwed together with the profiled rail guides. Further information ☞ catalog modular assembly automation 7.3.3 Damping adjustment “Z” The adjustment screw of the damper adjustment mechanism can be used to adjust the stroke of the shock absorber and thereby the damping curve to the kinetic energy occur-ring. The counternut is loosened and the appropriate setting value is adjusted by turning the adjustment screw. The permissible setting values Z are given in the SCHUNK standard catalog modular assembly automation.
Fig. 6 damping adjustment dimension "Z"
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Assembly and Installation
7.4 Intermediate stops AS/ZA The stop slide AS-... is mounted on the carriage of the portal actuator and, depending on the design, is suitable for approaching the intermediate position from one side or both sides.
Fig. 7 Installation of AS and ZA
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Assembly and Installation
7.4.1 Stop collar AS …. The stop collar AS-... is mounted at the guide carriage of the portal module. • Depending on the model suitable for one-or two-sided to approach the intermediate position. • The stop collar (Pos.5) can be used for precision adjustment of the intermediate position within a ±3mm range. • With an appropriate version and setting, the intermediate position can be approached from both sides without a loss of position. • Independently of this, it is also possible to match the end position damping to the specific mass by adjusting the shock absorber (11). • The cover plate (6 and 7) is prepared for installation of a proximity switch NI 30 that interrogates the precision position of the stop slide
Fig. 8 : Section drawing stop collar AS
In accordance with the section drawing above, all parts can be ordered individually. Ordering numbers are as indicated in the following example • Part-No.: AS 25-02
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Assembly and Installation
7.4.2 Intermediate stop ZA The intermediate stop ZA-... is located by means of the slots in the support rail. • It can be moved steplessly. • It is thereby possible to approach several intermediate positions CAUTION Observe minimum distance. • The position at which the portal actuator (2) is actually located is determined by the proximity switch NI 40 (15a). Query of the interactive position by the proximity switch NI40 (15b) is optionally possible.
Fig. 9 Section drawing and installation of the sensors ZA...
In accordance with the section drawing all parts can be ordered individually. Ordering numbers are as indicated in the following example: • Part-No: 2 ZA 25-02 As standardized wear part sets, seal sets are available under the following ordering numbers: • ZADI 16 for intermediate stop ZA 16 • ZADI 25 for intermediate stop ZA 25
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Assembly and Installation
7.4.3 Handling Controlling Further movement from the intermediate position is possible at the portal of corresponding control module via a 5/3-way valve without repeating stroke (center position = both chambers ventilated). ( 8, Page 24). determination of the To determine the position of several intermediate positions in position / sensors which the portal module is currently a installation of the proximity switch NI 30 is intended. It will be fixed with the clamping screw (20). A switch cam will be requested at the stop slide. Achieving a precise end position is sensed by the sensors NI30 on the stop slide. Thus any intermediate position and end position can be requested exactly.
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Assembly and Installation
7.5 Cable track There are different possibilities to mount the cable tracks on the module. In the following chapter there is always only one variant mapped exemplarily. Detailed information about the attachment variants you can get form of the contact person.
7.5.1 Cable track horizontal KSH...
Fig. 10 Cable track horizontal KSH...
In accordance with the drawing all wear parts and individual parts are available as single items. Ordering numbers are as indicated in the following example • Part-No1: KSH...-01 NOTE
Always quote the stroke or the Id.-No. of the axis at part 05 ( 11, Page 29)
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Assembly and Installation
7.5.2 Vertical KSV... cable drag chain
Fig. 11 Vertical KSV... cable drag chain
All parts can be ordered individually in accordance with the figure. Order numbers as given in the following example: • • Part no. 1: KSV...-01 NOTE
For part 05, always specify the stroke or the axis Id-No. ( 11, Page 29).
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Commissioning
8 Commissioning NOTICE Prior to commissioning. Carefully read this operating manual. Faults can be avoided and problem-free operation can be ensured only with the knowledge contained in this operating manual. • Check the technical specifications ( 6, Page 12). • Do not use the device until perfect operation has been checked taking all permissible operating parameters into account. • For operation, use only a 5/3-directional control valve which ventilates both chambers of the drive cylinder in center position. This ensures, each time the system is started up, that both cylinder chambers are filled equally and thus prevents the slide from shooting out. • The movement speed is ideally regulated via throttle check valves ( 7.2, Page 15). The speed is always set so that it starts at a low speed, and increases to a higher speed until the desired operating speed is reached. • Do not load the portal module beyond the operating range limit. Excessive loading can cause damage or result in guide unit inaccuracies. The maximum permissible loads are listed in the catalog.
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Troubleshooting
9 Troubleshooting 9.1 Module does not move? Possible cause
Corrective action
Pressure drops below minimum.
Check the air supply.( 7.2, Page 15)
Compressed air lines switched
Check compressed air lines.
Mechanical damage
Check mechanical parts
9.2 Power / speed / power of the module is declining? Possible cause
Corrective action
Pressure drops below minimum.
Check the air supply.( 7.2, Page 15)
compressed air line is leaking
Check compressed air lines.
rodless cylinder is leaking
Check the cylinder for leakproofness - exchange if necessary ( 10.4, Page 28)
guide- rail carriage is defective
Send the axis to the manufacturer for repair service
guide- rail carriage is strongly contaminated Clean the rail carriages, grease the guiderail carriages again ( 10.2, Page 27)
9.3 End position signal not present? Possible cause
Corrective action
Initiator incorrectly set in relation to stop
Readjust initiator ( 7.3, Page 16)( 7.4, Page 18)
Initiator defective
Replace initiator
Broken cable
Replace initiator cable
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Troubleshooting
9.4 Module impacts on end position? Possible cause
Corrective action
Damping incorrectly adjusted
Adjust damping ( 7.3.3, Page 17)( 7.4.1, Page 19)
Shock absorber defective
Change shock absorber ( 7.3.3, Page 17)( 7.4.1, Page 19)
Stroke speed too high
Check / reduce stroke speed with ventilation valves. If necessary, replace defect ventilation valves.
9.5 Service load vibrates in end position? Possible cause
Corrective action
Stroke speed too high
Check / reduce stroke speed with ventilation valves If necessary, replace defect ventilation valves.
Inadequate damping
Optimise damper stroke ( 7.3.3, Page 17)( 7.4.1, Page 19)
Unfavourable installation
Check design
Unfavourable PMP type
Use larger PMPS/F type
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Assembly / spare parts
10 Maintenance and Care 10.1 Notes The following recommendations apply if the unit is operated as intended in compliance with the specified operating parameters, operating conditions and settings. Original spare parts When replacing damaged parts (wearing parts/spare parts) only use SCHUNK original spares.
10.2 Maintenance and lubrication intervals NOTICE Environmental temperatures of more than 60 °C/ 140 °F can harden the used lubricants faster! Lubrication and maintenance works have to be carried out more often.
interval
Component
Activity
every 3 months
Guide rails / Carriage
Clean it with an oil-soaked cloth
/ 500km
Remove all incrustations of dust and grease residues Visual inspection for traces of wear. Mechanical testing on backlash and ease of movement of the guides. Grease the intended lubrication points ( 10.3, Page 28)
regularly
rodless cylinder
Checking for leaks
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Assembly / spare parts
10.3 Lubricants/Lubrication points (basic lubrication)
Fig. 12 Lubrication points carriage
We recommend the lubricants listed. During maintenance, treat all grease areas with lubricant. Thinly apply lubricant with a lint-free cloth. Lubrication point
Lubricant
Carriage
Isoflex-Topas NCA 52
Guide rails
Fa. Klüber
10.4 Dismantling the module NOTICE For disassembly and assembly of the module for the wealth of technical knowledge is required. ( 2.5, Page 8) The single handed maintenance or removal of deficiencies to the module by the customer will void the warranty and responsibility for any resulting warranty and consequential damages. • It is recommended to repair damaged and defective modules in the factory. Contact your SCHUNK contact person.
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Assembly / spare parts
10.5 Assembling the module Assemble the module as shown in chapter "Assembly" ( 11, Page 29).
NOTICE Assembly measures • Select suitable tightening torque values for screws when assembling the module, in accordance with the generally accepted guidelines for screw connections • Observe specified lubricant and greasing areas ( 10.3, Page 28). • Secure all screws using a suitable chemical screw lock.
11 Assembly / spare parts Wearing parts and individual components are available individually according to the following sectional drawings ( 11.1, Page 30) / ( 11.2, Page 31).
Order numbers are composed as follows: • PMPS16 part no. 4: PMPS 16-04 • PMPF16 part no. 4: PMPF 16-04 • PMPS25 part no. 4: PMPS 25-04 • PMPF25 part no. 4: PMPF 25-04 Always order the cylinder (30) without piston rod as a complete component. Always state the module stroke or the Id-No. when placing orders. Please contact your SCHUNK contact if damage should occur to the heavy-duty guide (01).
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Assembly / spare parts
11.1 PMPS/F 16
Fig. 13 PMPS 16
Fig. 14 PMPF 16
* Glued to the base part, order together * stroke- dependent, always indicate the stroke or the Id.-No. to the order *
30
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Assembly / spare parts
11.2 PMPS/F 25
Fig. 15 PMPS 25
Fig. 16 PMPF 25
*
Glued to the base part, order together
**
stroke- dependent, always indicate the stroke or the Id.-No. to the order
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Translation of original declaration of incorporation
12 Translation of original declaration of incorporation In terms of the EC Machinery Directive 2006/42/EG, Annex II, Part B manufacturer/ distributor
SCHUNK GmbH & Co. KG. Precision Workholding Systems Bahnhofstr. 106 – 134 D-74348 Lauffen/Neckar
We hereby declare that the following product: Product designation:
Portal module / PMPS/F 16 - 25 / pneumatic
ID number
0314141, 0314142, 0314151, 0314152
meets the applicable basic requirements of the Directive Machinery (2006/42/EC). The incomplete machine may not be put into operation until conformity of the machine into which the incomplete machine is to be installed with the provisions of the Machinery Directive (2006/42/EC) is confirmed. Applied harmonized standards, especially: EN ISO 12100-1
Safety of machines – Basic concepts, general principles for design – Part 1: Basic terminology, methodology
EN ISO 12100-2
Safety of machines – Basic concepts, general principles for design – Part 2: Technical principles
The manufacturer agrees to forward on demand the special technical documents for the incomplete machine to state offices. The special technical documents according to Annex VII, Part B, belonging to the incomplete machine have been created. Person responsible for documentation: Mr. Robert Leuthner, Adress: see adress of the manufacturer
Lauffen/Neckar, December 2012
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Ralf Winkler; Business Unit Manager R & D Mechanical Gripping Systems
