Hainbuch HYDROK 100 Operating Instructions Manual Download Page 1

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Operating instructions

[incl. installation manual]

HYDROK

Summary of Contents for HYDROK 100

Page 1: ...Operating instructions incl installation manual HYDROK EN...

Page 2: ...HYDROK 2 Order hotline 49 7144 907 333 Translation of the original operating instructions Order hotli ne 49 7144 907 333...

Page 3: ...equipment 16 2 5 Particular hazards 17 2 6 Other safety instructions 19 2 7 Screws 21 2 8 Functionality 22 2 9 Environmental protection 22 3 Technical data 23 3 1 General information 23 3 2 Performan...

Page 4: ...ond limit workpiece mass 37 5 2 4 Third limit clamping length 37 5 2 5 Fourth limit forces 38 5 2 6 Sample calculation 50 5 3 Aid to selection of the hydraulic unit 53 5 3 1 Nomenclature 53 5 3 2 Clam...

Page 5: ...le fluid 83 8 3 Checking the total stroke 83 8 4 Tests 84 8 5 Workpiece 85 8 6 Procedure after a collision 85 9 Activities after end of production 86 10 Removal 87 10 1 Safe removal 87 10 2 Preparing...

Page 6: ...6 Order hotline 49 7144 907 333 13 1 Procedure with faults 105 13 2 Fault table 106 13 3 Commissioning after a fault has been remedied 107 14 Annex 108 14 1 Contact 108 14 2 Manufacturer certificatio...

Page 7: ...gravity of clamping head segments to the rotational axis 45 Table 12 Maximum permitted tailstock force 47 Table 13 Maximum permitted cutting force 48 Table 14 Maximum permitted transverse force 49 Tab...

Page 8: ...of the product WARNING Serious injuries caused by individual products or by inappropriate combinations of them Read and pay attention to all operating instruc tions for individual products and combina...

Page 9: ...le and damage to ma terials warns of stored energy for example involving springs warns of hand injuries draws attention to the fact that the operating instructions of the product must be read 1 3 Defi...

Page 10: ...pplier con tract the General Terms Conditions of Business and the delivery terms of the manufacturer and all legislative stipula tions valid at the time of conclusion of this contract 1 5 Copyright Th...

Page 11: ...ol caused by an incorrect or defective spare parts Always use genuine spare parts made by the orig inal manufacturer NOTE Damage malfunctions or total failure of the prod uct or the machine tool cause...

Page 12: ...d solely responsible for any resultant personal injury and or damage to materials Excepted from this are changing parts that HAINBUCH ap proved explicitly for autonomous machining but specified limits...

Page 13: ...o identify and avoid potential haz ards Hydraulics specialist Hydraulics specialists are trained in the specific task profile for which they are employed and are familiar with the rele vant standards...

Page 14: ...in this manual see Use chapter Furthermore an ex tended form of use can be agreed contractually between manufacturer and operator Only skilled staff from the appropriate specialist fields may install...

Page 15: ...technical data indicated on the product see General information and Operat ing conditions chapters Never exceed the limits for use of the product see Limits of use chapter Maintain the product at reg...

Page 16: ...tended use of the product If workpieces are not clamped properly If people fail to observe the safety stipulations when working on the product and failing to use additional pro tective equipment for e...

Page 17: ...The following section explains these additional items of personal protec tive equipment Protective gloves To protect the hands from friction chafing stabbing or deeper injuries and from contact with...

Page 18: ...tal initiation of the clamping pro cess for example due to an installation error with the power supply or a programming error Insufficient workpiece clamping DANGER Serious injuries caused by parts be...

Page 19: ...ill rotating Never release the clamping of the workpiece while it is still rotating WARNING Serious injuries caused by media escaping under high pressure due to missing damaged seal ele ments Ensure t...

Page 20: ...cted against falling WARNING Serious injuries caused by the use of damaged products or by their components and accesso ries Check products or their components and acces sories on a regular basis for v...

Page 21: ...y installed screws being ejected centrifugally if installed in correctly poor handling Do not open the screws secured with sealing lac quer Screws and threaded pins fitted radially to the product that...

Page 22: ...ncorrect dis posal of environmentally hazardous substances If environmentally hazardous substances enter the environment accidentally take immediate re medial action If in doubt notify the relevant mu...

Page 23: ...1 0 12 174 x 174 x 130 1000 40 35 80 30 1 65 3 65 2 5 2 0 6 1 0 15 174 x 174 x 130 1000 40 45 105 30 1 80 5 80 2 5 2 0 6 1 0 17 5 186 x 186 x 130 1000 40 50 115 30 1 100 15 100 5 3 2 0 1 5 29 229 x 22...

Page 24: ...range see Clamping force diagram chapter 3 3 Balancing quality The product is balanced before leaving the factory balanc ing quality see General information chapter DANGER Serious injuries caused by p...

Page 25: ...without a workpiece in stalled When several clamping points are involved clamp a suitable workpiece to each one If necessary adjust the machining forces 3 5 Clamping force diagram The clamping force d...

Page 26: ...a supply pressure of 25 bar radial clamping force is in the range of 15 3 kN to 64 kN A lower limit value B upper limit value 3 5 2 Size 42 52 Scan sample At a supply pressure of 25 bar radial clampi...

Page 27: ...At a supply pressure of 25 bar radial clamping force is in the range of 34 kN to 76 kN A lower limit value B upper limit value 3 5 4 Size 80 Scan sample At a supply pressure of 25 bar radial clamping...

Page 28: ...ply pressure of 25 bar radial clamping force is in the range of 64 kN to 104 kN A lower limit value B upper limit value 3 5 6 Size 100 aluminum variant Scan sample At a supply pressure of 25 bar radia...

Page 29: ...ulation The following formula should be used to determine the sup ply pressure that needs to be set to achieve a defined level of actuating force INFORMATION The maximum supply pressure and the maxi m...

Page 30: ...be present for size 65 A Size 32 B Size 42 52 C Size 65 D Size 80 E Size 100 aluminum vari ant F Size 100 3 7 Operating conditions Indication Value Unit Ambient temperature range 15 65 C Workpiece tem...

Page 31: ...t clamps the work piece being machined When clamping the clamping element performs an axial movement The mobile coupling draws the clamping element into the stationary taper 4 2 Accessories required 4...

Page 32: ...ing range to be expanded 4 3 2 Magnet module The magnet module is an adaptation clamping device for ferromagnetic materials for grinding or turning 4 3 3 MANDO Adapt Through adaptation of the MANDO Ad...

Page 33: ...tuated by manual force Depending on size the changing fixture may be designed for single handed or for two handed actuation The clamping head is clamped firmly in the changing fixture and can be inst...

Page 34: ...clamping devices from the manufacturer the clamping device can rapidly be con verted to suit a different clamp setting 5 2 Limits of use Limits are set on the operation of clamping head chucks in the...

Page 35: ...ered out Clamping force to absorb the machining forces and torques during turning and or drilling operations towards the chuck axis Tailstock force Maximum tailstock force 2 Specific cutting force Tot...

Page 36: ...of gravity of clamping head segment and rotational axis of the chuck Clamping force scatter width factor Friction coefficient in axial direction Friction coefficient in radial direction Table 4 Nomenc...

Page 37: ...rkpiece mass Horizontal application Vertical application 32 12 18 42 20 30 52 28 40 65 40 60 80 50 75 100 65 100 125 80 120 140 100 150 160 120 180 Table 5 Maximum workpiece mass 5 2 4 Third limit cla...

Page 38: ...found to be sufficient 5 2 5 Fourth limit forces The following sample calculation shows how to quantify the forces that are exerted on the workpiece from an external source The aim here is to establi...

Page 39: ...amping head chuck is used for a turning operation or for an axial or radial drilling operation on the workpiece There is no funda mental reason why the clamping head chuck cannot also be used for othe...

Page 40: ...e scatter width factor apply if the system is being operated in accordance with the operating instruc tions that is with regular maintenance and lubrication Provided that the radial clamping force is...

Page 41: ...diameter of the workpiece The clamping diameter of the clamping head is less than the clamping diameter of the workpiece WS Workpiece SP Clamping element Table 7 Contact forms scenarios Contact factor...

Page 42: ...ting forces at Designation DIN ISO Cast iron For example EN GJL 250 1980 1260 900 Spherulitic graphite iron unhardened For example EN GJS 400 15 2120 1190 1060 construction steels without alloys or w...

Page 43: ...mm Table 9 Specific cutting forces Friction coefficients With workpieces made from a material other than steel mul tiply these values by the correction values listed below When the workpiece is made...

Page 44: ...18 0 25 0 23 0 28 Blank or unma chined 0 14 0 16 0 16 0 18 0 20 0 28 0 25 0 30 Material correction values Aluminum alloys 0 97 Brass 0 92 Cast iron 0 80 WS Workpiece SP Clamping element Table 10 Fric...

Page 45: ...is Determining the required clamping force INFORMATION from Table 6 from Table 8 from Table 9 from Table 10 from Table 11 I 1 6 INFORMATION Factor 1 6 takes account of possible fluctuations that may o...

Page 46: ...ssible to per form this machining task When clamping and machining workpieces with bigger er rors in axial and face run out please note that the cutting cross section fluctuates greatly Particular att...

Page 47: ...ed forces The total of set tailstock force and axial clamping force during the clamping process must be ex ceeded by the release force When operating with a tailstock using an end stop in the clamping...

Page 48: ...al to the workpiece axis the feed force of the tool generates transverse forces that ultimately act on the clamping head chuck The application of this load during drilling operations should be viewed...

Page 49: ...adial to the workpiece axis the transverse force examined under Principle 4 exerts an additional torque on the clamping head and or on the chuck This moment must not rise in an unlimited way to pre ve...

Page 50: ...25 Chip cutting depth 1 5 Use of cooling lubricant Total clamping length 20 Clamping head chuck Pull back SPANNTOP size 65 Clamping head used Smooth Clamping diameter of clamping head 60 Front end len...

Page 51: ...ble 9 interpolated for 0 25 from Table 10 from Table 11 I 1 6 from Table 6 1 6 from Table 8 1 3 1 6 1 3 1 6 II 1 3 2 2 2 from Table 10 0 14 0 16 Turning 1 3 1 3 1 5 0 25 2515 2 1226 Drilling Not relev...

Page 52: ...he size 65 clamping head chuck can exert a maximum radial clamping force of 105 this satisfies Prin ciple 1 In this example Principle 2 does not apply because work is performed without a tailstock in...

Page 53: ...tion in terms of the level of contamination It is advisable to conduct a check on radial clamping force using an appropriate clamping force meter before the ma chining operation The values established...

Page 54: ...volumes Here is a sample calculation to explain the values Example HYDROK size 65 Stroke release stroke 2 5 Maximum axial actuating force 45 Maximum supply pressure 40 Volumetric flow rate of the hyd...

Page 55: ...1 875 3 750 100 2 438 4 875 9 750 100 2 269 4 538 9 075 Aluminum variant Table 18 Clamping release times on a 2 hydraulic assembly Size of the clamping de vice Clamping release time 1 Clamping de vice...

Page 56: ...ice 2 Clamping de vice 4 Clamping de vice 32 0 141 0 281 0 563 42 0 164 0 328 0 656 52 0 164 0 328 0 656 65 0 211 0 422 0 844 80 0 234 0 469 0 938 100 0 609 1 219 2 438 100 0 567 1 134 2 269 Aluminum...

Page 57: ...r use appropriate load bearing equipment and lifting tackle WARNING Serious injuries caused by transporting off center equipment Pay attention to marks on the packaging items Attach the crane hook dir...

Page 58: ...n coat of grease if necessary 6 2 Symbols on the packaging Fragile Designates packaging items with fragile or breakable con tents Handle the packaging item with care Do not drop it and protect it agai...

Page 59: ...ged prod ucts 3 Attach load bearing equipment to the lifting tackle 4 Subject to weight use lifting gear to lift the product out of its packaging safely and place it down on a stable flat surface 5 Se...

Page 60: ...id mechanical vibration Storage temperature 15 to 35 C Relative humidity Maximum 60 In the event of storage for more than 3 months On a regular basis check the general condition of all parts and packa...

Page 61: ...ing area of the machine WARNING Serious injuries caused by the escape of media under high pressure Shut down media delivery during installation and removal Relieve any pressure trapped in the system S...

Page 62: ...d lifting tackle CAUTION Serious cut injuries caused by sharp edged changing parts and or clamping elements All installation removal of changing parts and clamping elements must be performed by skille...

Page 63: ...t greases see Use of lubricants chapter Do not damage the functional surfaces flat mating ta pered and sealing surfaces 7 3 Screw tightening torques The tables show the specified values Knowledge of t...

Page 64: ...owing table contains the reduced screw tightening torques for securing aluminum components Thread designa tion Tightening torque Nm Minimum screw depth mm M6 10 12 M8 23 16 M10 46 20 Table 22 Screw ti...

Page 65: ...are used for direct connection to the machine where necessary via a base plate Or the product is connected to the hydraulic supply via the ports on its side 1 As described in the Preparation of the m...

Page 66: ...g seals during installation removal of the cap plugs During installation removal of the cap plugs the cap plug seals must remain in the product 1 Remove the cap plug from the product 7 5 3 Preparation...

Page 67: ...line 49 7144 907 333 67 1 Remove the cap plugs and the cap plug seals from the product INFORMATION After being installed in its intended bore the expander must always be sealed using an appropriate de...

Page 68: ...l of the screw plugs During installation removal of the screw plugs the screw plug seals must remain in the product 3 Unfasten and remove the screw plugs Ensure while do ing so that the screw plug sea...

Page 69: ...ine and baseplate must be connected together The same applies to the Release ports WARNING Serious injuries can be caused by escaping media when seals and damaged missing Replace missing or damaged se...

Page 70: ...on machine baseplate and product must be connected to gether The same applies to the Release ports WARNING Serious injuries can be caused by escaping media when seals and damaged missing Replace missi...

Page 71: ...nded spindle if one was used 9 Check the position of the product relative to the position of the test surface ideally 0 01 mm and if necessary correct carefully with a plastic hammer 10 Tighten the pr...

Page 72: ...jected by incorrectly connected hydraulic ports The hydraulic connections on the machine and the baseplate must be connected up correctly The Clamping hydraulic ports on machine and baseplate must be...

Page 73: ...it the product to the machine table the base plate 6 Screw in the product fixing screws and tighten them gen tly 7 Unfasten and remove any lifting gear that may have been required 8 Remove the mountin...

Page 74: ...sing or damaged sealing elements Ensure that the sealing elements do not fall out or get damaged during installation removal and apply a thin coat of grease if necessary 9 Connect up the hydraulics Fo...

Page 75: ...l stone 4 Reinstall the product 5 Repeat the alignment process 6 Repeat the face run out test 7 6 Installation of the clamping element A Clamping head clamping element INFORMATION Before installing th...

Page 76: ...anging fixture During actuation never reach into the coupling slot area in the clamping head or into the chang ing fixture 3 Install the clamping head in the product with an appro priate changing fixt...

Page 77: ...top can be installed in different ways If necessary in addition to these operating instruc tions you should also read and follow the operating instructions for the relevant changing parts INFORMATION...

Page 78: ...1 Installation of the variant x times with axial screw connection 1 Place the changing part onto the product 2 Screw in the changing part fixing screws on the chang ing part and tighten to the specifi...

Page 79: ...s in accordance with the variant with an x times axial screw connection see Installation of x times variant with axial screw connection After initial installation the changing part fixing screws remai...

Page 80: ...HYDROK Installation 80 Order hotline 49 7144 907 333 3 Screw in the changing part fixing screws and tighten to the specified tightening torque see Screw tightening torques chapter...

Page 81: ...ar intervals and correct if necessary WARNING Serious injuries can be caused if the machine tool starts up accidentally Prior to commissioning close all safety doors or hoods on the machine tool WARNI...

Page 82: ...cooling lubricants and or when using tools with internal flushing ensure that the cooling lubricant is cleaned processed and that it contains no particles measuring 100 microns filtered with a mesh wi...

Page 83: ...luid that attacks and damages the installed sealing elements Those installed seal ing elements can be made of NBR Viton and PUR materials Always use ester free and non polar fluids 8 3 Checking the to...

Page 84: ...the clamping elements and attachments are torn or exhibit porous areas Serrations and grooved profiles must not be excessively rounded because this would prevent the friction coeffi cient from being a...

Page 85: ...hands fingers is workpiece is installed incorrectly Do not place hands fingers between workpiece and clamping device Never reach into the clamping area CAUTION Burns caused by high workpiece temperatu...

Page 86: ...ack on 3 Open the safety door hood WARNING Eye injuries and cuts caused by failure to wear protective clothing during cleaning operation Never use compressed air to clean the product Also wear the fol...

Page 87: ...up accidentally Set the machine tool into set up mode Remove all tools auxiliary equipment and items of test equipment immediately from the working area of the machine Remove all lifting gear from the...

Page 88: ...n the working area of the machine with the potential to drop down Depending on weight use an appropriate mount ing aid for installation or installing on a vertically suspended machine spindle WARNING...

Page 89: ...imes axial screw connection A1 Fixing screws changing part variant x times axial screw connec tion B Changing part variant x times axial screw connection bayonet B1 Fixing screws changing part variant...

Page 90: ...49 7144 907 333 2 Move the clamping device into release position 10 3 1Removal of the variant x times with axial screw connection 1 Unfasten and remove the fixing screws on the changing part 2 Take th...

Page 91: ...al of the variant x times with axial screw connection bayonet 1 Unfasten the fixing screws on the changing body a few turns without removing them 2 Turn the changing part until the screw head on the c...

Page 92: ...t off the product 10 4 Removal of the clamping element A Clamping head clamping element Special aids needed Changing fixture 1 As described in the Preparing the machine for re moval chapter prepare fo...

Page 93: ...used by reaching into the coupling slot area in the clamping head or into the changing fixture During actuation never reach into the coupling slot area in the clamping head or into the chang ing fixtu...

Page 94: ...ifferent ways Either to the machine using the hydraulic ports on the under side of the product if necessary with a base plate Or the product can be connected to the hydraulic supply using its side por...

Page 95: ...ous injuries can be caused by escaping media when seals and damaged missing Replace missing or damaged sealing elements Ensure that the sealing elements do not fall out or get damaged during installat...

Page 96: ...rt variant of the product to the side of the product 1 Depressurize the hydraulic unit 2 Attach any lifting gear that may be required 3 If necessary fit the mounting aid onto a vertically sus pended s...

Page 97: ...HYDROK Removal Order hotline 49 7144 907 333 97 5 Unfasten and remove the fixing screws on the product 6 Remove the product from the machine table the baseplate...

Page 98: ...ng sections describe the maintenance work needed to ensure optimum and fault free operation If increased levels of wear are detected during regular checks shorten the maintenance intervals to reflect...

Page 99: ...e Lubricating the product chapter with storage See Storage chapter depending upon which stipulation is achieved first Table 23 Maintenance table 11 3 Scheduled maintenance A Housing A1 Housing fixing...

Page 100: ...erials To clean the product never use a solvent that contains ester nor a polar solvent NOTE Damage to materials caused by incorrect installa tion of sealing elements Replace missing or damaged sealin...

Page 101: ...o the following dur ing assembly Replace worn or damaged fixing screws Tighten all fixing screws to the specified tightening torque see nomenclature and or Screw tightening torques chapter When tighte...

Page 102: ...product never use a solvent that contains ester nor a polar solvent 1 Remove the changing parts and the clamping element from the product see Removal of changing parts and Removal of clamping element...

Page 103: ...ed maintenance chapter for details of the level of disassembly required 2 At all lubrication points remove escaping consumed or surplus grease and dispose of it in accordance with lo cally enforceable...

Page 104: ...ronment can result from incorrect disposal of environmentally haz ardous substances Lubricants auxiliary materials and operating flu ids are governed by legislation for the processing of special categ...

Page 105: ...al equipment press the Emergency Stop but ton on the machine tool immediately 2 Establish the cause of the fault 3 If troubleshooting requires work to be conducted in the danger area switch the machin...

Page 106: ...and cor rect if necessary Seals worn Check fluid pressure at the ports and replace the seals if necessary Hydraulic pneu matic specialist Clamping force is too high Supply pressure is too high Check...

Page 107: ...orce to the level applicable for the clamping device and the workpiece Skilled special ist Incorrect type of clamping element Use a suitable clamping element Dirty clamping ele ment Clean the clamping...

Page 108: ...racking hotline Current status of your order Just call 49 7144 907 222 24 hour emergency phone line Has a system crash occurred or some other technical emer gency Our experts are there for you around...

Page 109: ...HYDROK Annex Order hotline 49 7144 907 333 109...

Page 110: ...aration of the hydraulic port variant of the product on the underside of the product 66 Preparation of the hydraulic port variant on the side of the product 66 Preparation of the machine 64 Product 65...

Page 111: ...ope of delivery 10 Screw tightening torques Aluminum components 64 Metric control threads 63 Spare parts 11 Speed 24 Storage 60 Suitable fluid 83 Symbols on the packaging 58 T Technical data 23 Tests...

Page 112: ...ations reserved HAINBUCH GMBH SPANNENDE TECHNIK Postfach 1262 71667 Marbach Erdmannh user Strasse 57 71672 Marbach Germany Tel 49 7144 907 0 Fax 49 7144 18826 verkauf hainbuch de www hainbuch com 24 h...

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