ZeroClamp NP90 Assembly And Maintenance Instruction Download Page 48

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Residual Risks

ZeroClamp zero point clamping system

– manual

Cleaning

Appropriate cleaning and care agents:

•

WD 40

•

Ballistol

•

Hebro Multiplus

Inappropriate cleaning and care agents:

•

Acids

•

Leaches

•

Aggressive media

•

not approved cleaning and care agents

9. Residual Risks

Risk description

Reducing risks

Non-observance of safety
instructions

Training of personal in terms of
raising awareness for potential
dangers

Summary of Contents for NP90

Page 1: ...O r i g i n a l A s s e m b l y a n d M a i n t e n a n c e I n s t r u c t i o n Zero Point Clamping Systems NP90 NP120 NP138 and NP190 Please keep this manual for future use and reference...

Page 2: ...e manual This manual is the property of Messrs ZeroClamp GmbH with headquarters in 83052 Bruckm hl Germany This document must not be copied or otherwise reproduced either in part or in its entirety wi...

Page 3: ...Mechanical data 12 3 1 1 Dimensions 12 3 1 2 Weights 12 3 1 3 Materials in contact with Cooling Lubricant CL 12 3 2 Pneumatic data 12 3 3 Clamping forces 13 3 4 Operation temperature 13 3 5 Operating...

Page 4: ...40 7 2 3 Correlation table torque withdrawal force 41 7 2 4 Example determining the holding force 41 7 2 5 Calibrating the withdrawl force tester 41 7 2 6 Additional recommended safety measures 42 7 2...

Page 5: ...ing this high quality and extremely precise zero point clamping system We reserve the right to make modifications regarding the design dimensions and material if this positively affects the productivi...

Page 6: ...General Information ZeroClamp zero point clamping system manual 6 Scope of delivery Delivery includes Chuck Fastening screws O rings Air connection fitting...

Page 7: ...n ISO 16156 Machine tools Safety Safety requirements for the design and construction of work holding chucks ISO 19719 Machine tools Work holding chucks Vocabulary Commissioning of the incomplete machi...

Page 8: ...n clamped condition if the zero point clamping system is not in use for a longer period of time As a result the clamping force cannot be exerted or the zero point clamping system does not fully open w...

Page 9: ...chuck thoroughly every time before you clamp a new part Ensure an exact concentric alignment of clamp bolt and chuck Check the clamping force of the zero point clamping system on a regular basis using...

Page 10: ...ils the adherence to the assembly operation operation environment and maintenance specificati The manufacturer cannot be held liable if the system is used for any other purpose as those specified Prio...

Page 11: ...nance and cleaning Everyone responsible for assembly operation and maintenance must have read and be familiar with the entire manual especially chapter one Safety and preferably provide a written conf...

Page 12: ...Air hose 07 13 Viton FKM 70 1156 Air hose NBR 70 Perbunan O Ring HPP9441 05 Vulvanisation taper ring 10 17 Viton FKM60 1279 Vulvanisation taper ring Eladur 33 Polyurethan Elastomer Spacer 10 17 Viton...

Page 13: ...with ingredients of the cooling lubricant CL used ZeroClamp has made comprehensive laboratory studies with regard to eventual incompatibilities Due to the high variety of CL s available on the market...

Page 14: ...point clamping system Design layout Pos Description Pos Description 1 Hardened steel cone 6 Locking unit 2 Radial spring 7 Spacer Elastomer Viton Eladur 3 NBR Viton rubber 8 Air hose NBR Viton 4 Chuck...

Page 15: ...d on the opened ZeroClamp chuck The spring elements keep the locking unit clamping wedges open with the help oft he air pressure inside the air hose Venting the air hose results in the positioning and...

Page 16: ...elease coupling connecting block centering set alignment set pallets Modifying the chuck additional bores threads subsequent grinding etc or additional parts that are not included in the range of acce...

Page 17: ...terference fit of the clamp bolt when using the clamp bolt in in house assemblies Please consult ZeroClamp when in doubt ZeroClamp cannot be held liable for any damage resulting from improper use Cove...

Page 18: ...plate Specifically the clamping pots with media transfer require special protection when not in use Article no 24513 Sealing plate 2 point 120 mm pitch 200 mm Warning Only use sealing plates approved...

Page 19: ...umstances pitting may occur on the aluminum plates particularly if the anodic coating has been damaged scratches Console Consoles serve to adapt the height and inside micrometer Exemplary illustration...

Page 20: ...0003 or 10241 A safe unlocking of the central locking unit in the plug nipple can only be ensured when these couplings are used Connection block You can choose between different connection blocks Stan...

Page 21: ...n exact concentric alignment of clamp bolt and chuck Caution When operating the zero point clamping systems the skin of your fingers can get caught between the clamping elements Do not reach inside th...

Page 22: ...ry part connecting block using the functions clamping unclamping and blow out or via docking a quick release coupling to release Using alignment sets and centering sets only serves for pre centering t...

Page 23: ...have been cleaned The O ring now insert carefully and lubricate with conventional machine grease Fitting and o ring The carefully lubricate fitting can be inserted in the airconnectionhole by lightly...

Page 24: ...Note For the calculation formula and table values from the current technical literature were used which represent the state of the art at the date of this document The base units are made of the foll...

Page 25: ...on the actually occurring forces and surface pressures at the base plates Please ensure in their own interest to comply with the conditions for fitting the screw head and thread not greased counterbo...

Page 26: ...res 6H7 10 deep 0 90 270 8H7 12 deep 0 120 240 10H7 16 deep 0 120 240 10H7 16 deep 0 90 270 H Standard depth chuck section 181 241 19 28 I J Installation depth 5 22 5 28 5 33 5 38 Surface finish Rz 6...

Page 27: ...torque Nm 10004 18M16 18 k6 M16 18H7 18 0 02 0 03 6 mm 24 mm 35 10005 16M8 16 k6 M8 16H7 16 0 02 0 03 6 mm 24 mm 17 10006 16M10 16 k6 M10 16H7 16 0 02 0 03 6 mm 24 mm 35 10098 18M12 18 k6 M12 18H7 18...

Page 28: ...ondition if the zero point clamping system is not in use for a longer period of time As a result the clamping force cannot be exerted or the zero point clamping system does not fully opened when used...

Page 29: ...Operation ZeroClamp zero point clamping system manual 29...

Page 30: ...r of the fixture if a controlled chip transport cannot be ensured Otherwise the clamping pot can be covered partly Inaccuracy of the surfaces caused by wear will also prevent that the correct clamping...

Page 31: ...ex and dynamic process The static examination of the system shall rather serve to estimate the level of the potential dangers The level of potential danger rises with increasing processing height z ro...

Page 32: ...ng workpiece on a baseunit with four clamping pots with a pitch of 200 mm By not lying on the rotational axis center of gravity m creates these an imbalance Fzentri Parameter n rotational speed U min...

Page 33: ...Sicherheit S MAuszug MSchnitt Unwucht As this is a static examination the safety factor for this estimate should be S 3 7 1 2 Sample calculation 1 This sample calculation is about a base unit with fo...

Page 34: ...25000 N 0 26 m 6500 Nm M 0 2 1500 Nm 2 6500 Nm 1200 Nm 164 Nm Sicherheit S 16000 Nm 1364 Nm 11 73 The security is over 3 The system is to be regarded as safe 7 1 3 Sample calculation 2 The second app...

Page 35: ...uszug pull out force clamping pot N MSchnitt FSchnitt hs MKipp MSchnitt FRes MKipp d FRes FAuszug Sicherheit S FAuszug FRes As this is a static examination the safety factor for this estimate should b...

Page 36: ...Kipp d 690 Nm 0 06 m 11500 N FRes FAuszug Sicherheit S FAuszug FRes 2 25000 N 11500 N 4 34 The security is over 3 The system is to be regarded as safe These sample is only conditional suitable for man...

Page 37: ...clamping pots 120 mm Even in this situation it is necessary to ensure that the torques are in equilibrium Parameter hs height cutting force m hg height emphasis m a lever arm pull out force 1 m b lev...

Page 38: ...he safety factor for this estimate should be S 3 Drilled with a cutting force of 6 1 kN at a height of 0 5 m Depending on material tool and cutting parameters Also acts a weight force of the workpiece...

Page 39: ...amp zero point clamping system manual 39 M 0 1500 Nm 6400Nm 12650Nm 3050Nm 1600Nm MAutzug Gewicht 22150Nm MAuszug 3050 Nm Sicherheit S 22150 Nm 3050 Nm 7 26 The security is over 3 The system is to be...

Page 40: ...clamp bolt counter clock wise view from below on the clamp bolt out of the withdrawal force tester up to the stop 7 2 2 Applying torque 1 Supply compressed air to the chuck open it up 2 Mount the wit...

Page 41: ...amp bolt is yanked out which results in wear at the clamp bolt If this occurs repeatedly it can lead to the wear at the clamp bolt preventing the generation of the required holding force even if the c...

Page 42: ...ot initiate any clamping force the safety function is passive and self locking Preparing of chuck and clamp bolt Caution The zero point clamping system only operates reliably when the clamp bolt lies...

Page 43: ...ng manual when using connecting blocks Using of locking bolts If clamp bolts are not used they have to be sealed with locking bolts This prevents the chuck from filling up with lubricoolant as well as...

Page 44: ...efore putting it into storage After having cleaned the mechanical parts in the chuck spray it with fine oil approved agents see 8 4 Cleaning and while operating the clamping mechanism Caution If clamp...

Page 45: ...ly basis Caution The clamping sheets in the zero point clamping system may adhere in clamped and non clamped condition if the zero point clamping system is not in use for a longer period of time As a...

Page 46: ...ires special tools If the chuck is in need of repair please contact ZeroClamp The zero point clamping system is designed for low maintenance operation and opening or disassembling of the unit is norma...

Page 47: ...o remove any dirt Caution Carry out the cleaning without a component clamping device only when the machine door closed Flowing chips may cause injury 8 3 3 Spraying the mechanical parts Spray fine oil...

Page 48: ...nts WD 40 Ballistol Hebro Multiplus Inappropriate cleaning and care agents Acids Leaches Aggressive media not approved cleaning and care agents 9 Residual Risks Risk description Reducing risks Non obs...

Page 49: ...10 Cover sheet 21 D Declaration of incorporation 7 Description of the system 18 Dimensions 12 Disassembly 48 F Formulas and modelled presentation35 L LC Influence 17 Locking bolt 21 Locking bolts usag...

Page 50: ...Attachments ZeroClamp zero point clamping system manual 50 11 Attachments...

Page 51: ...Attachments ZeroClamp zero point clamping system manual 51...

Page 52: ...Attachments ZeroClamp zero point clamping system manual 52...

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