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Schmalz FMHD Series, Operating Instructions Manual

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Schmalz FMHD Series Operating Instructions Manual Download Page 30

 

30 |   EN 

www.schmalz.com 

30.30.01.01648/03 

 

 

 

DANGER

 

 

 

General Safety Notes on Operation 

 

Danger to life and limb

 

►  The system may only be operated by trained personnel who have read and 

understood the operating instructions. 

►  The system integrator must secure the danger zone. 

► 

 

The system may only be operated at the workplace in accordance with the 
operating instructions. 

 
 

 

Acceleration/deceleration/kinetic energy 

 

 

Danger to life and limb due to workpieces slinging away or the system travers-
ing. 

►  See general safety notes on the start of operations 

► 

 

Maintain sufficient distance to the moving system/workpiece in order to avoid 
danger, even in the case of unforeseeable events (e.g. emergency stop) 

 

 

 

Danger of falling objects/gravity due to falling objects 

 

 

 

Danger to life and limb 

 

 

►  See general safety notes on the start of operations 

 

 

► 

 

Never stand under suspended loads. 

 

 

►  Do not place any body parts under the suspended load or the system. 

 

 

►  The system’s maximum permitted load must not be exceeded. 

 

 

 

Human error 

 

 

 

Danger to life and limb 

 

 

►  Adhere to the operating instructions  

 

 

 

Switching components that are not explosion-proof 

 

Risk of fire and explosion 

►  The product must not be used in explosion risk areas. 

 
Consult the manufacturer before operating it at higher or lower ambient temperatures.  
 
The system can only achieve its maximum load-bearing capacity if it is completely covered by an air-
tight workpiece. For the maximum permitted load, see the technical data. 
 

 

Summary of Contents for FMHD Series

Page 1: ...www schmalz com Innovative Vacuum for Automation EN Operating Instructions Vacuum area gripper FMHD 30 30 01 01648 03 04 2019 ...

Page 2: ...alz GmbH retains the rights established thereby Reproduction of the contents in full or in part is only permitted within the limits of the legal provisions of copyright law Any modifications to or abridgments of the document are prohibited without explicit written agreement from J Schmalz GmbH Contact J Schmalz GmbH Johannes Schmalz Str 1 72293 Glatten Germany Tel 49 0 7443 2403 0 Fax 49 0 7443 24...

Page 3: ...ly 19 Delivery 19 4 1 4 1 1 Items Included in Delivery 19 4 1 2 Checking for Completeness 19 4 1 3 Reporting Damage 19 Packaging 20 4 2 Removing the System from the Transport Box 20 4 3 Storage 20 4 4 5 Start of Operations and Setup 21 Start of Operations 21 5 1 Vacuum area gripper 24 5 2 Pneumatic Connection 24 5 3 Vacuum Connection 25 5 4 Solenoid Valves 25 5 5 Electrical Connection and LED Disp...

Page 4: ... 8 Inspecting and Cleaning the Gripper 41 8 9 Overview of the Tightening Torque of the Screws 44 8 10 Checking the System for Leaks 44 8 11 9 Spare and Wearing Parts 45 10 Accessories 48 11 Pneumatic Circuit Diagram 49 Pneumatic Circuit Diagram FMHD 49 11 1 Pneumatic Circuit Diagram FMHD Parallel Circuit 50 11 2 12 Other Applicable Documents 51 ...

Page 5: ...f it is not avoided WARNING Type and source of danger Consequence Remedial action Caution This warning informs the user of a risk that could result in injury if it is not avoided CAUTION Type and source of danger Consequence Remedial action Attention This warning informs the user of a risk that could result in damage to property if it is not avoided ATTENTION Type and source of danger Consequence ...

Page 6: ...con Description Icon Description Pollution warning Crushing injury Suspended load Hand injury warning Electrical voltage General warning symbol Hearing damage Warning of overpressure Electric shock Mandatory Symbols 1 4 Explanation of the mandatory symbols used in the operating instructions Icon Description Icon Description Observe the instructions Wear eye protection Use protective footwear Activ...

Page 7: ...epressurized state Only qualified specialist personnel mechanics and electricians may perform the installation Qualified specialist personnel are persons who have received technical training and have the knowledge and experience including knowledge of applicable regulations necessary to enable them to recognize possible dangers and implement the appropriate safety measures while per forming tasks ...

Page 8: ...ace in a secure area where no people are allowed to enter WARNING Suspended loads Personal injuries and damage to the system Never stand under suspended loads The system is mounted on the load suspension provided by the customer using the T slots designated for this purpose The customer also provides a control device The system can only be used when hung vertically You must consult the manufacture...

Page 9: ... mm 4 Grid Grid 2R28 two rows cell distance 28 mm 2R28 5 Foam type Foam type Foam type specification depending on the application O20 6 Cylinder position Cylinder position L3 From the left side of the housing Left 155 mm 7 Plate Plate Currently only PnP PnP 8 Nozzle Nozzle Straight angled open Cover plate Angle angled Ø 60 mm Front align ment 9 Nozzle position Nozzle position L2 Variable 126 mm 10...

Page 10: ...ight workpiece with a smooth surface The automated handling system to which the system was attached by the customer is responsible for motion in the various axes Description of Functions Valve Technology SVK There are valves with sliders or balls in the valve plate see figure under Section 2 2 G If they are not covered by a workpiece in the moment that suction begins they will close the valve For ...

Page 11: ... external vacuum generation D Main body E T slot with quick release clamps F End cover without function G Valve section with adhesive front foil H Adhesive front foil I Quick change section J Sealing plate K Sealing plate L Slider spherical D C B A E F G I J Vacuum reservoir Vacuum distribution chamber L Diagram of the vacuum area gripper K D G I H ...

Page 12: ...y not be removed This will result in a malfunction Connection B currently does not have a function do not remove the plugs A End cover with function 1 1 Connection A vacuum gauge configurable example illustration 1 2 Compressed air connection configurable example illustration 1 3 Multi pole plug 1 4 Protective cap under which there are two solenoid valves 1 5 Compressed air connection for separati...

Page 13: ...base plate con nects or separates storage chambers and valve chambers to from one another The separating cylin der is single acting and is pneumatically operated This unit can be easily removed from the gripper in order to check the seals or the contamination level of the gripper To do so the four screws 2 2 must be removed B Separating cylinder assembly unit 2 1 Mounting plate 2 2 Screws for asse...

Page 14: ...t slots are used for flexible mechanical attachment of the gripper using the sliding blocks Suitable attachment kits are listed in the Accessories chapter The t slots on the side offer the option of con necting sensors and additional components The quick release clamps are fastened to the side t slots using sliding blocks Additional sensors can also be attached to the side t slots F End cover with...

Page 15: ... be reduced by using a second identical quick change plate while the first is being cleaned drying J Sealing plate The sealing plate J is adhered to the quick change section I The sealing plate is made of technical foam The standard grid is equipped with two rows of suction cells that have a distance of 28 mm from one another designation 2R28 The sealing plate can be quickly replaced thanks to a s...

Page 16: ...ce life of the foam is not reduced This flexing makes the foam more permeable to air When a high number of working cycles is reached it may be necessary to replace the foam even if there is no visible indication of wear The foam may not be cleaned with a compressed air gun This would make the foam permeable to air in the places where compressed air was applied ...

Page 17: ... generator must provide the specified suction flow rate at the vacuum connection pieces of the FMHD 3 Measured on a workpiece typical for the application boards vacuum 0 3 bar Compressed air consumption approx 30 l min when blow off is switched on Perm temperature range 5 to 40 C Customer specific gripper data is available on request Vacuum in the gripper For workpieces typical for the application...

Page 18: ...Dimensions H H1 1 H2 2 L variable L1 variable L2 variable L3 variable D 111 6 158 6 20 1050 1057 8 3 126 152 60 L4 foam B B1 B2 B3 foam Y ZA grid 1004 170 191 3 175 5 168 120 28 Gray highlighted fields are fixed dimensions for all grippers 1 Depending on the hose connection used Depending on the foam used 3 Use of an analog gauge ...

Page 19: ...ions may unload and transport the product Delivery 4 1 4 1 1Items Included in Delivery For the exact items included in delivery please refer to the order confirmation The delivery documents list the shipping weight and dimensions Note the system weight and dimen sions when choosing suitable lifting equipment Note The operating instructions are part of the system and must be kept with the system ev...

Page 20: ...ansport box Attach a suitable lifting device to the system Now lift the system so that it is freely suspended after all other packaging elements are removed Storage 4 4 The system must be stored in its original packaging as long as it is not being used and is to be stored for any period of time ATTENTION Incorrect storage of the system Material damage to the system The system may only be stored as...

Page 21: ...een the bottom of the gripper and a surface High pressure Placement release of compressed air lines The system integrator must secure the danger zone Regularly inspect the gripper and perform regular maintenance in order to detect and replace porous compressed air lines in good time Replace defec tive connectors Stored energy vacuum Body parts could be crushed cut sucked in caught or sliced if the...

Page 22: ...the task being performed Dust and fog Reduced visibility difficulty breathing Keep the environment clean wherever possible avoid kicking up large amounts of dust WARNING System set up by untrained personnel Serious personal injury The system must only be set up by trained personnel who have read and un derstood the operating instructions Non compliance with work safety instructions Personal injuri...

Page 23: ...g set up The system may only be set up at the workplace in accordance with the operat ing instructions The system must be disconnected during setup The production system must be secured to prevent activation during setup Acceleration deceleration kinetic energy Danger to life and limb See general safety notes on the start of operations Danger of falling objects gravity Danger to life and limb See ...

Page 24: ...ries Pneumatic Connection 5 3 1 Electrical connection 2 Compressed air pneumatic coupling 3 Gauge 4 Ventilation The compressed air is connected using the quick connect coupling which is located on the sealing plate and is included in delivery Requirements for the compressed air provided by the customer Dry filtered air according to ISO 8573 1 2010 7 4 4 Constant operating pressure 6 bar If you sel...

Page 25: ...he use of longer hoses could impair the functionality of the system Vacuum Once vacuum is applied in a gripper it immediately begins suction when the cylin der is open Solenoid Valves 5 5 The solenoid valves control the separating cylinder as well as blow off The customer is responsible for the control system The pin assignments for control of the solenoid valves can be found in the pin assignment...

Page 26: ...ection work may only be carried out by a qualified electrical specialist The system must incorporate safe electrical cut off of the power supply in com pliance with EN60204 Do not connect or disconnect the plug connectors when voltage is applied Only operate the system with protected extra low voltage Observe the separate operating instructions when connecting the vacuum genera tor Plug Pin Lead c...

Page 27: ...atus Valve status Cylinder extended LED illuminated Extend cylinder ON Reservoir separated from valve chamber no suction LED not illuminated Cylinder OFF suction applied Blow off LED illuminated Blow off ON depositing the workpiece LED not illuminated Blow off OFF ...

Page 28: ...ure the danger zone Regularly inspect the gripper and perform regular maintenance in order to de tect and replace porous compressed air lines in good time Replace defective connectors Stored energy vacuum Body parts could be crushed cut sucked in caught or sliced if the area gripper is abruptly attached to a workpiece or a surface Do not place any body parts between the bottom of the gripper and a...

Page 29: ...e task being performed Dust and fog Reduced visibility difficulty breathing Keep the environment clean wherever possible avoid kicking up large amounts of dust WARNING System operation by untrained personnel Serious personal injury The system may only be operated by trained personnel who have read and understood the operating instructions Non compliance with work safety instructions Personal injur...

Page 30: ...anger even in the case of unforeseeable events e g emergency stop Danger of falling objects gravity due to falling objects Danger to life and limb See general safety notes on the start of operations Never stand under suspended loads Do not place any body parts under the suspended load or the system The system s maximum permitted load must not be exceeded Human error Danger to life and limb Adhere ...

Page 31: ...at ed The cylinder s piston rod extends and separates the suction chamber from the storage chamber Vacuum is generated in the storage chamber when the vacuum generator is switched on Applying suction Once the sealing mat has been placed on the workpiece and is compressed the system can start picking it up Resetting the solenoid valve I separating cylinder upper LED not illumi nated The cylinder s ...

Page 32: ...chmalz com 30 30 01 01648 03 Functional diagram 24 V EMV Cylinder Voltage 0 V Pretensioning Applying suction Depositing Time 24 V EMV Blow off Voltage 0 V Pretensioning Applying suction Depositing Idle state Tim e ...

Page 33: ... the danger zone Regularly inspect the gripper and perform regular maintenance in order to de tect and replace porous compressed air lines in good time Replace defective connectors Stored energy vacuum Body parts could be crushed cut sucked in caught or sliced if the area gripper is abruptly attached to a workpiece or a surface Do not place any body parts between the bottom of the gripper and a su...

Page 34: ...e task being performed Dust and fog Reduced visibility difficulty breathing Keep the environment clean wherever possible avoid kicking up large amounts of dust WARNING System operation by untrained personnel Serious personal injury The system may only be operated by trained personnel who have read and understood the operating instructions Non compliance with work safety instructions Personal injur...

Page 35: ...motion Avoid acceleration peaks especially when lifting the work pieces The workpieces to be lifted are not suitable for the area grippers e g non rigid Use a different gripping system Sealing plate wears out very quickly The area gripper is angled or makes a grinding noise when ap plied to the workpiece to be lifted Set it down vertically on the workpiece External vacuum gen erator works but work...

Page 36: ...y to 6 bar check the supply lines is the hose bent or disconnected Inspect the solenoid valve Dirt defective control Solenoid valve is not working Electrical control is not working Check the connections and replace valve if necessary Solenoid valve is defective Repair or replace the solenoid valve Recommendation We recommend always performing tests with original sample workpieces We would be happy...

Page 37: ...e when operating the gripper and its assemblies when there is a risk of injury e g fingers being crushed by the cylinder sealing plate Short circuit Electric shock The system must be disconnected during maintenance work Moisture Very wet workpieces can permanently impair the function of the gripper Regularly clean and if necessary dry the gripper Careless use of personal protective equipment Dange...

Page 38: ...move any dirt on the exterior with a soft cloth and soap suds max 60 C Operation of the area gripper can draw in dust from the environment This dust can collect inside the gripper The gripper must be cleaned regularly depending on the amount of dust sucked in Maintenance Schedule 8 2 Interval Daily Weekly Month ly Every six months Annual inspec tion Does the vacuum generator make strange noises wh...

Page 39: ... the first month after start of operations External Vacuum Generator 8 3 See the relevant operating instructions Dust Filter 8 4 When using a dust filter see the relevant operating instructions Cleaning Agents 8 5 Use cleaning solvents to clean the device not petroleum ether or corrosive liquids Petroleum ether or corrosive liquids destroy the vacuum hoses Quick change Plate 8 6 To make maintenanc...

Page 40: ...m vacuum must be adjusted ac cordingly when the sealing plates are replaced The foam may not be cleaned with a compressed air gun This would make the foam permeable to air in the places where compressed air was applied If the sealing plate shows mechanical damage it can be repaired up to a certain point using standard vulcanizing adhesive e g adhesive for repairing the inner tubes of bicycles Repl...

Page 41: ... no screws are miss ing etc 2 Check that the attachment parts such as the housing cover cylinder mounting plate and quick release clamp are secured correctly Check that the quick release clamps are securely attached intact and easy to oper ate 3 Open the quick release clamp and remove the quick change plate The suspension device must be clean For information on inspecting and re placing the sealin...

Page 42: ...earings e g using a magnet 6 1 Soak the contaminated bearings in a soap detergent solution Blow out the valve section G valves without sliders with compressed air or if necessary clean them with solvents soak if necessary Dry all of the parts Insert the sliders spheres back into the valves Insert one slider into each valve to ensure that the valves work properly Reattach the masking film Ensure th...

Page 43: ...ning screws of the cylinder mounting plate Remove the mounting plate from the system together with the cylinder Inspect the hoses quick exhaust valve and T section and blow them out with compressed air if necessary See also chapter 2 2 1 Check the sealing Remove any defective sealing adhesive residue or other contamination The adhesive surfaces must be kept clean and dry before the new seal can be...

Page 44: ...acuum gen erator used Example The vacuum generator reaches a maximum of 0 5 bar A vacuum of at least 0 45 bar must be displayed on the gauge If the vacuum is not achieved the system must be checked for leakage as follows 1 Check the hose hose connections tubing and the cable screw union on the multi pole plug for damage and leaks and replace them as necessary 2 Check that all the sections and all ...

Page 45: ...nvironmental damage Disposal according to national guidelines Item Quantity Description Part no Legend 1 1 Housing cover assembled 10 01 40 00021 S 2 1 Form seal suitable for item 1 10 01 40 00013 W 3 1 Form seal for the protective cap 10 01 40 00080 W 4 1 Housing cover assembled 10 01 40 00024 S 5 1 Form seal suitable for item 4 10 01 40 00014 W 6 1 Separating cylinder assembled 10 01 40 00161 S ...

Page 46: ... steel bearing 10 01 40 00102 S 13 1 Masking film length 3 000 mm cut to size 10 01 40 00108 W 14 Sealing ring M6 10 07 08 00017 W 15 Separating cylinder connection hose On request S 16 Spacing sleeve with thread locking compound 10 01 40 00151 W Quantity depends on the length of the area gripper Items not shown S Spare part W Wearing part ...

Page 47: ...n Part no Legend 17 1 Valve section attached comprised of items 18 20 including mounting materials On request S 18 1 Masking film On request W 19 Stainless steel bearing 10 01 40 00102 S 20 1 Gripper section FMHD M On request S 21 1 Area gripper suction plate comprised of items 22 24 On request S 22 1 Sealing plate O04 On request S 23 1 Gripper section FMHD U On request S 24 1 Sealing plate On req...

Page 48: ... 10 01 03 00175 2 FLK G1 2 IG G1 2 AG V Flexolink reinforced design 10 01 03 00207 3 FLAN PL 10 01 10 08805 We recommend connecting the gripper to a combination of FST STARR and FST FLEX fixed and floating bearings Rigid suspension FST C Item Description Part no 1 FST C 100 HD1 100 mm stroke 10 01 20 01260 2 MOD FLAN 157x120x64 1 10 01 11 03187 Similar to the figure Vacuum distributor Item Descrip...

Page 49: ...kpiece must be able to freely detach from the gripper Maximum overpressure The maximum overpressure in the gripper vacuum reservoir or valve chamber must be limited to a maximum of 0 2 bar For example no continuous blow off pulse as long as the gripper is placed on a workpiece in the waiting position or similar 2 1 Blow off ON OFF control valve Cylinder ON OFF control valve Function integrated in ...

Page 50: ...tic Circuit Diagram FMHD Parallel Circuit 11 2 Compressed air source Optimum flowing compressed air pressure 6 0 bar Vacuum distributor Vacuum filter Hose clamps connector Vacuum Items Included in Delivery Vacuum area gripper FMHD Vacuum generator ...

Page 51: ...30 30 01 01648 03 www schmalz com EN 51 12 Other Applicable Documents EC declaration of incorporation FMHD 30 30 01 01665 ...

Page 52: ...rating instructions and CAD data and get com prehensive information about our products and services www schmalz com dokumentationen How to videos In short easy to understand videos we explain the extensive features of our prod ucts Take a look it s worth it www schmalz com gewusst wie Further services ranging from consultation to training can be found at www schmalz com services J Schmalz GmbH Joh...

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