Hainbuch HYDROK Operating Instructions Manual Download

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HYDROK
Installation

Order h49 7144.907-333

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 device.

2. Install the expanders.

Summary of Contents for HYDROK

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: ...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 Performance values 23 3...

Page 4: ...t forces 37 5 2 6 Sample calculation 49 5 3 Aid to selection of the hydraulic unit 52 5 3 1 Nomenclature 52 5 3 2 Clamping and release volume 53 5 3 3 Clamping release times 53 6 Transport packaging s...

Page 5: ...8 6 Procedure after a collision 84 9 Activities after end of production 85 10 Removal 86 10 1 Safe removal 86 10 2 Preparing the machine for removal 88 10 3 Removal of the changing parts 88 10 3 1 Rem...

Page 6: ...HYDROK 6 Order hotline 49 7144 907 333 13 3 Commissioning after a fault has been remedied 107 14 Annex 108 14 1 Contact 108 14 2 Manufacturer certification 108...

Page 7: ...gravity of clamping head segments to the rotational axis 44 Table 12 Maximum permitted tailstock force 46 Table 13 Maximum permitted cutting force 47 Table 14 Maximum permitted transverse force 48 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: ...000 40 60 5 164 30 1 Aluminum variant Table 1 Technical data 3 2 Performance values NOTE Material damage to the products use and or to the machine tool caused by exceeding the maximum performance valu...

Page 24: ...ts at tached to the product NOTE Material damage caused by machining with incor rectly balanced products Do not clamp rotationally symmetrical work pieces or do so only after contacting the manu factu...

Page 25: ...ange in which the radial clamping force is permitted to move in re sponse to axial actuating force The clamping force diagram indicates the influences of fric tion and of the clamping diameter WARNING...

Page 26: ...supply pressure of 25 bar the radial clamp ing force is in a range between 19 kN and 58 kN A lower limit value B upper limit value 3 5 2 Size 65 Scan sample At a supply pressure of 25 bar radial clam...

Page 27: ...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 4 Size 100 aluminum variant Scan sample At a supply pressure of 25 bar radia...

Page 28: ...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 29: ...bar must occur for size 65 A Size 52 B Size 65B C Size 100 Aluminum vari ant D Size 100 3 7 Operating conditions Indication Value Unit Ambient temperature range 15 65 C Workpiece temperature 80 C Hum...

Page 30: ...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 31: ...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 32: ...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 33: ...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 34: ...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 35: ...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 36: ...k Maximum workpiece mass Horizontal application Vertical application 26 8 12 40 18 22 52 28 40 65 40 60 80 50 75 100 65 100 125 80 120 Table 5 Maximum workpiece mass 5 2 4 Third limit clamping length...

Page 37: ...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 38: ...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 39: ...The values for the 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...

Page 40: ...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 41: ...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 42: ...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 43: ...ad with Z serra tions Clamping head with F serra tions Finished ground 0 06 0 08 0 07 0 09 0 15 0 20 0 17 0 22 Finished to roughed 0 10 0 13 0 11 0 15 0 18 0 25 0 23 0 28 Blank or unma chined 0 14 0 1...

Page 44: ...head mass 26 0 013 0 23 40 0 018 0 70 52 0 022 1 00 65 0 026 1 65 80 0 032 2 10 100 0 040 4 30 125 0 062 8 00 Table 11 Clamping head mass and distance of mass center of gravity of clamping head segme...

Page 45: ...d at the start this means that the radial clamping force of the clamping head chuck equates to at least the computed level of radial clamp ing force required to resolve this use of the clamping head c...

Page 46: ...ce is limited to the following values in ac cordance with the size of the clamping head chuck Size of the clamping head chuck 26 2 40 4 52 6 65 8 80 8 100 8 125 8 Table 12 Maximum permitted tailstock...

Page 47: ...e size 26 with 150 120 150 1600 1280 5 2 5 4 Further to Principle 4 With drilling operations radial to the workpiece axis the feed force of the tool generates transverse forces that ultimately act on...

Page 48: ...r 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 vent damage to the clamping head chuck even if the clamp ing of...

Page 49: ...20 Clamping head chuck Pull back TOPlus size 65 Clamping head used Smooth Clamping diameter of clamping head 60 Front end length 3 Detailed observation This satisfies the first condition which is tha...

Page 50: ...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 51: ...he size 65 clamping head chuck can exert a maximum radial clamping force of 120 this satisfies Prin ciple 1 In this example Principle 2 does not apply because work is performed without a tailstock in...

Page 52: ...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 53: ...le 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 hydraulic assembly 4 Volum...

Page 54: ...ing release time 1 Clamping de vice 2 Clamping de vice 4 Clamping de vice 52 0 328 0 656 1 313 65 0 422 0 844 1 688 100 1 219 2 438 4 875 100 1 134 2 269 4 538 Aluminum variant Table 19 Clamping relea...

Page 55: ...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 56: ...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 57: ...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 58: ...ollowing conditions Safe for storage Do not store outdoors Store in a dry dust free place Avoid exposure to aggressive media Protect against direct sunlight Avoid mechanical vibration Storage temperat...

Page 59: ...under the following conditions 1 Preserve the product see Preservation chapter 2 The product must be stored in a safe condition Use an appropriate container for the product on a non slip sur face or...

Page 60: ...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 61: ...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 62: ...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 63: ...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 64: ...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 65: ...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 66: ...hotline 49 7144 907 333 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 67: ...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 68: ...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 69: ...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 70: ...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 71: ...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 72: ...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 73: ...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 74: ...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 75: ...r into the changing 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...

Page 76: ...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 77: ...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 78: ...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 79: ...HYDROK Installation Order hotline 49 7144 907 333 79 3 Screw in the changing part fixing screws and tighten to the specified tightening torque see Screw tightening torques chapter...

Page 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 85: ...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 86: ...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 87: ...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 88: ...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 89: ...7144 907 333 89 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 90: ...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 91: ...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 92: ...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 93: ...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 94: ...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 95: ...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 96: ...HYDROK Removal 96 Order hotline 49 7144 907 333 5 Unfasten and remove the fixing screws on the product 6 Remove the product from the machine table the baseplate...

Page 97: ...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 98: ...age chapter depending upon which stipulation is achieved first Table 23 Maintenance table 11 3 Scheduled maintenance A Housing A1 Housing fixing screws A2 Housing gasket gasket kit B Cap plug B1 Cap p...

Page 99: ...rials 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 sealing...

Page 100: ...ews Tighten all fixing screws to the specified tightening torque see nomenclature and or Screw tightening torques chapter When tightening the screws do so evenly to prevent any distortion under load O...

Page 101: ...ean the 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...

Page 102: ...s comply with the maintenance intervals see Maintenance schedule chapter Lubrication takes place every time the system is cleaned maintained or assembled and also when required The product is equipped...

Page 103: ...bil ity in coolants Furthermore there must be no particles of dirt in the grease because these cause an operational malfunc tion if they come between two interference fit surfaces For this the followi...

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: ...pecial ist Supply pressure too low Check machine setting and cor rect if necessary Seals worn Check fluid pressure at the ports and replace the seals if necessary Hydraulic pneu matic specialist Incor...

Page 107: ...ndentations on the clamping sur face Clamping force is too high Reduce clamping force to the size applicable to the clamping device and the workpiece Skilled special ist Wrong type of clamping element...

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 65 Preparation of the hydraulic port variant on the side of the product 65 Preparation of the machine 63 Product 64...

Page 111: ...ope of delivery 10 Screw tightening torques Aluminum components 63 Metric control threads 62 Spare parts 11 Speed 24 Storage 58 Suitable fluid 82 Symbols on the packaging 56 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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