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SCHUNK ROTA NCR 1000, Assembly And Operating Manual, Page: 40 / 43

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SCHUNK ROTA NCR 1000 Assembly And Operating Manual Download Page 40

Spare parts 

 

  

 

40 

02.00|ROTA NCR |en 

 

 

Item 

Designation 

Quantity 

60 

Mounting screw DIN EN ISO 4762-10.9 

different 

61 

Mounting screw (machine from behind) - DIN EN ISO 4762-10.9  different 

64 

Pan-head screw 

6 

66 

Countersunk screw connecting member 

6 

67 

Set-screw piston 

1 

70 

The plunger pin 

2 

72* 

Torque pin seat of bearing (165/200/250) 

12 

78 

Eye bolt 

1 

80 

Screw seal 

1 

81 

Adapter seal 

1 

82 

Piston seal 

1 

83 

Mounting seal 

1 

84 

Chuck body seal 

1 

85 

Pipe seal 

1 

86 

Locking screw seal 

1 

87 

Workpiece bolt seal (workshop star option) 

3 

88 

Screw seal 

1 

90 

Conical lubrication nipple 

3 

91 

Set-screw piston 

3 

92 

Set-screw lever 

6 

93 

Set-screw lever 

6 

  

Summary of Contents for ROTA NCR 1000

Page 1: ...Translation of the original manual Power Chuck ROTA NCR Assembly and operating manual Superior Clamping and Gripping ...

Page 2: ...n 03 00 18 12 2017 en SCHUNK GmbH Co KG All rights reserved Dear customer congratulations 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 assem...

Page 3: ...ort 11 2 11 Malfunctions 11 2 12 Disposal 11 2 13 Fundamental dangers 12 2 13 1 Protection during handling and assembly 12 2 13 2 Protection during commissioning and operation 12 2 13 3 Protection against dangerous movements 13 2 13 4 Notes on particular risks 13 3 Technical data 17 3 1 Chuck data 17 3 2 Clamping force speed diagrams 18 3 3 Calculations for clamping force and speed 21 3 3 1 Calcul...

Page 4: ...y means of a direct mount 31 5 4 Replacing or adding to jaws 32 5 5 Switching the compensating clamping on and off 32 5 6 Option with bearing plate 33 6 Function 34 6 1 Function and handling 34 6 2 Functional testing 34 7 Maintenance 36 7 1 Lubrication 36 7 2 Maintenance intervals 36 7 3 Disassembly and assembly of the Chuck 37 7 4 Disassembling and assembling the piston 38 8 Spare parts 39 9 Asse...

Page 5: ...ations in this manual are provided for basic understanding and may differ from the actual product design In addition to these instructions the documents listed under 1 1 2 Page 6 are applicable Presentation of Warning Labels To make risks clear the following signal words and symbols are used for safety notes DANGER Danger for persons Non observance will inevitably cause irreversible injury or deat...

Page 6: ...warranty period is 24 months after delivery date from factory or 500 000 cycles if it is used as intended under the following conditions Observe the applicable documents 1 1 2 Page 6 Observe the ambient conditions and operating conditions 2 6 Page 9 Observe the specified maintenance and lubrication intervals 7 Page 36 Parts touching the workpiece and wear parts are not included in the warranty A c...

Page 7: ...d RPM in the chapter Technical data 3 Page 17 Not intended use A not intended use of the product is for example It is used as a press a punch a toolholder a load handling device or as lifting equipment the product is used for unintended machines or workpieces the technical data is exceeded when using the product 3 Page 17 if workpieces are not clamped properly paying particular attention to the cl...

Page 8: ...d to greater surface pressure in the jaw guidance and can significantly reduce the clamping force If for constructional reasons the special chuck jaws are heavier than the top jaws assigned to the lathe chuck greater centrifugal forces must be accounted for when defining the required clamping force and the recommended speed The maximum recommended speed may only be operated in conjunction with max...

Page 9: ...er the base jaws should move evenly This method only provides a limited indication and is not a substitute for measuring the clamp ing force If the clamping force has dropped too much or if the base jaws and pistons no longer move properly the chuck must be disassembled cleaned and relubricated 7 Page 36 Personnel qualification Inadequate qualifications of the personnel If the personnel working wi...

Page 10: ...fety regulations and wear the required personal safety equipment Observe the valid safety and accident prevention regulations In case of sharp edges and corners and rough surfaces wear protection gloves In case of hot surfaces wear heat resistant protection gloves When dealing with hazardous substances wear protection gloves and goggles In case of moving parts wear tight protection clothes Notes o...

Page 11: ...and handling Stand clear of suspended loads Malfunctions Behavior in case of malfunctions Immediately remove the product from operation and report the malfunction to the responsible departments persons Order appropriately trained personnel to rectify the mal function Do not recommission the product until the malfunction has been rectified Test the product after a malfunction to establish whether i...

Page 12: ... serious injuries and considerable material damage Have all work carried out by appropriately qualified personnel For all work secure the product against accidental operation Observe the relevant accident prevention rules Use suitable assembly and transport equipment and take precautions to prevent jamming and crushing Incorrect lifting of loads Falling loads may cause serious injuries and even de...

Page 13: ...idents and or material damage human access to the movement range of the machine must be restricted Restrict unintentional access by persons to this range e g via a protective cover protective fence or photoelectric barrier The protective cover and protective fence must be rigid enough to withstand the maximum possible movement energy EMER GENCY STOP switches must be easily and quickly accessible C...

Page 14: ...orce until the machine comes to a standstill and the workpiece can be secured e g using a crane or suitable lifting equipment The machines and equipment must fulfill the minimum re quirements of the EC Machinery Directive specifically they must have effective technical measures to protect against po tential mechanical hazards DANGER Possible risk of fatal injury to operating personnel if a jaw bre...

Page 15: ...ironment where the chuck is used e g by cooling lubricants or oil Ensure that the working environment is clean before starting assembly and installation work Wear suitable safety shoes Follow the safety and accident prevention regulations when operating the chuck especially when working with machine tools and other technical equipment CAUTION Danger of limbs being crushed by opening and closing of...

Page 16: ...become damaged The T nuts for connecting the top jaws to the base jaws must not protrude beyond the base jaws in the radial direction The diameter of the workpiece may not be bigger than the chuck diameter CAUTION Hazard from vibration due to imbalanced rotating parts and noise generation Physical and mental strains due to imbalanced workpieces and noise during the machining process on the clamped...

Page 17: ...338 0 935 1 491 3 360 Max jaw eccen tricity of center of gravity in axial direction amax mm 12 24 24 24 32 32 32 32 40 Sizes 1200 to 2500 upon request The maximum RPM stated is only valid with the maximum clamp ing force and when using the hard standard chuck jaws that go with the chuck If unhardened top jaws or special chuck jaws are used ensure that the jaws weigh as little as possible For soft ...

Page 18: ... D The chuck is in perfect condition and lubricated with SCHUNK LINOMAX special grease Should one or several of the above mentioned parameters be changed the diagrams are no longer valid Chuck set up for clamping force speed diagram F 3 Clamping force per jaw S Center of gravity rs Center of gravity radius amax Max jaw eccentricity of cen ter of gravity in axial direction Fmax Max actuating force ...

Page 19: ...Technical data 02 00 ROTA NCR en 19 Clamping force RPM graph for ROTA NCR 200 Clamping force RPM graph for ROTA NCR 250 Clamping force RPM graph for ROTA NCR 315 ...

Page 20: ...Technical data 20 02 00 ROTA NCR en Clamping force RPM graph for ROTA NCR 400 Clamping force RPM graph for ROTA NCR 500 Clamping force RPM graph for ROTA NCR 630 ...

Page 21: ...d Fc Total centrifugal force N McAB Centrifugal torque of top jaws Nm Fsp Effective clamping force N McGB Centrifugal torque of base jaws Nm Fspmin Minimum required clamping force N n Speed rpm Fsp0 Initial clamping force N rs Center of gravity radius mm Fspz Cutting force N rsAB Center of gravity radius of top jaw mm mAB Mass of one top jaw kg ssp Safety factor for clamping force mB Mass of chuck...

Page 22: ...e effective clamping force Fsp for gripping from the outside inwards for gripping from the inside outwards DANGER Risk to life and limb of the operating personnel and significant property damage when the RPM limit is exceeded With grip ping from the outside inwards and with increasing RPM the effective clamping force is reduced by the magnitude of the increasing centrifugal force the forces are op...

Page 23: ... Fsp and the total centrifugal force Fc is multiplied by the safety factor for the clamping force Ssp According to VDI 3106 the following also applies here Ssp 1 5 The total centrifugal force Fc is dependent on both the sum of the masses of all jaws and on the center of gravity radius and the rpm NOTICE For safety reasons in accordance with DIN EN 1550 the centrifugal force may be a maximum of 67 ...

Page 24: ...cation specific Mass of one top jaw mAB 5 33 kg applicationspecific Center of gravity radius of top jaw rsAB 0 107 m application specific Safety factor Sz 1 5 according to VDI 3106 Safety factor Ssp 1 5 according to VDI 3106 Note Masses of the jaw mounting screws and T nuts are not taken into account First the required effective clamping force Fsp is calculated using the machining force stated Ini...

Page 25: ...k for safety reasons Example of calculation Permissible RPM for a given effective clamping force The following data is known from previous calculations Initial clamping force during shutdown Fsp0 17723 N Machining force for machining job Fspz 3000 N application specific Total centrifugal torque of all jaws Mc 2 668 kgm Safety factor Sz 1 5 according to VDI 3106 Safety factor Ssp 1 5 according to V...

Page 26: ...N ISO 1940 1 Torques per screw Tightening torques for mounting screws used to clamp the chuck on lathes or other suitable technical equipment screw quality 10 9 Screw size M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 Admissible torque MA Nm 13 28 50 88 120 160 200 290 400 500 1050 1500 Tightening torques for mounting screws used to attach top jaws onto the chuck screw quality 12 9 Screw size M6 M...

Page 27: ...Page 27 2 Mounting of the chuck 5 3 Page 28 3 Check the function 6 2 Page 34 Checking the chuck mounting Checking the spindle nose for mounting the chuck flange The machine side has to be aligned prior to the flange being installed in order to achieve high true running accuracy for the chuck To do this check the contact surfaces on the spindle for axial and concentric run out using a dial indicato...

Page 28: ... screw the chuck into the drawbar Fasten the chuck with the mounting screws supplied item 60 to the spindle nose Tighten the chuck mounting screws item 60 alternately Check radial and axial run out at the checking edge Check the jaw stroke of the base jaws and that these can move easily Attach top jaws according to the marking to the base jaws Chuck from size 250 Remove screws item 39 and take off...

Page 29: ...item 33 together with pins item 31 into the piston item 3 as far as it will go pendulum locking is active Assemble the three stop pins item 40 Place cover on item 34 and tighten with screws item 39 Attach top jaws according to the marking to the base jaws The spindle is disassembled in the same way but in the reverse order The following must be taken into account during chuck assembly The attachme...

Page 30: ...ced before the chuck is mounted After mounting it must be ensured that the flange is fitted tightly on the entire surface Then check the run out accuracy and true running as described in Measures before starting assembly see Fig Assembly of the chuck B The chuck is mounted after the flange has been aligned During this it must be ensured that any contaminations on the flange and on the chuck contac...

Page 31: ...lange The flange must be slightly tightened on the chuck by means of the supplied screws and aligned towards the chuck body The radial and axial run out must be checked Next the screws must be tightened with the specified torque 4 Page 26 After mounting it must be ensured that the flange is fitted tightly on the entire surface Check radial and axial run out After mounting the flange on the chuck t...

Page 32: ...e see Screw torques chapter 4 Page 26 Tighten the mounting screws of the top jaws with a torque wrench Never tighten the Allen key with an extension pipe or by hitting it with a hammer WARNING If the workpiece is clamped at the end of the base jaw stroke this poses the risk that the entire clamping force is not transferred onto the workpiece Risk of injury due to loss of workpiece Always clamp the...

Page 33: ...until the stop on the stop pins item 40 Observe the maximum permissible torque The stop pin item 40 may be damaged Screw in the screw item 35 Option with bearing plate Using the conversion kit a workpiece rest can be produced on the chuck face In addition an air control can be created The bearing plate Item 44 has not been pre drilled for the work piece bolts Item 45 Instead the radial position of...

Page 34: ...n be centered without distortion of the workpiece For special applications the pendulum compensation can be disabled and all jaws simultaneously clamp concentrically 5 5 Page 32 Functional testing Functional test After installation of the chuck its function must be checked prior to start up Two important points are Clamping Force The clamping force of the chuck must be achieved at max operating fo...

Page 35: ...rsonnel if the chuck s top speed is exceeded and a workpiece is released or parts fly off If the machine tool or technical equipment can reach a higher speed than the chuck s top speed a reliable speed limiter must be installed and proof must be provided that the speed limiter is effective ...

Page 36: ...er Maintenance intervals 7 2 Page 36 Measure the clamping force only by using a calibrated Grip Force Tester SCHUNK SGT 270 Technical Condition The base jaws must move evenly at the smallest possible operating pressure cylinder This method is only to some extend expressive and cannot replace clamping force measurement If clamping force has dropped too low or if base jaws and piston cannot be moved...

Page 37: ...with the suitable screws screws not included in the scope of delivery Remove the six levers item 6 together with the bearing seat item 8 from the chuck body To do this there is a bore hole on the side of the bearing seat in which a removal tool can be in serted At chuck size 165 200 250 Push the six base jaws item 2 radially outwards to the stop and push the piston item 3 out of the chuck body ite...

Page 38: ...ctly to the piston item 3 and secured using the pin item 67 Items 9 70 and 80 are no longer required Unscrew the stop pin item 40 from the piston Unscrew and remove the screw item 33 and take off the safety ring item 38 then remove the thrust washer item 32 Remove the screws item 64 take off the plate item 12 and pull the compensation piece item 5 out of the piston item 3 The screw item 66 is glue...

Page 39: ...n 1 5 Compensation piece 3 6 Lever 6 7 Mount 1 8 Seat of bearing 12 9 Nut 1 10 Screw 1 11 Connecting member 6 12 Plate 3 15 Scraper strips 630 800 1000 12 29 Jaw safety lock screw 6 31 Bolt 3 32 Thrust washer 1 33 Screw 1 34 Cover 1 35 Locking screw 1 38 Safety ring 1 39 Pan head screw 6 40 Stop pin 3 42 Pipe workshop star option 1 44 Cover workshop star option 1 45 Workpiece bolt workshop star op...

Page 40: ...crew connecting member 6 67 Set screw piston 1 70 The plunger pin 2 72 Torque pin seat of bearing 165 200 250 12 78 Eye bolt 1 80 Screw seal 1 81 Adapter seal 1 82 Piston seal 1 83 Mounting seal 1 84 Chuck body seal 1 85 Pipe seal 1 86 Locking screw seal 1 87 Workpiece bolt seal workshop star option 3 88 Screw seal 1 90 Conical lubrication nipple 3 91 Set screw piston 3 92 Set screw lever 6 93 Set...

Page 41: ...Assembly drawings 02 00 ROTA NCR en 41 Assembly drawings 9 ...

Page 42: ...Assembly drawings 42 02 00 ROTA NCR en ...

Page 43: ... be installed with the provisions of the Machinery Directive 2006 42 EC is confirmed Applied harmonized standards especially DIN EN ISO 12100 2011 03 Safety of machinery General principles for design Risk assessment and risk reduction EN 1550 1997 A1 2008 Machine tools safety Safety requirements for the design and con struction of work holding chucks Other related technical standards and specifica...

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