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HYDROK
Safety

12

Order h49 7144.907-333

2 Safety

This section provides an overview of all the important safety
aspects for optimum protection of personnel, and for safe
and problem-free operation.

2.1 Responsibility of the operator

The product is used in the industrial sector. The operator of
the product is therefore governed by the provisions of Health
& Safety at Work legislation.

As well as the safety notices in this manual, the area of use
of the product must also comply with locally applicable
safety, accident prevention and environmental protection
specifications as well as those in the manual for the machine
tool.

No modifications must be made to the product. The operator
is wholly and 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 must never be exceeded.

DANGER

Serious injuries caused by parts being ejected
centrifugally due to a drop in actuating force / sup-
ply pressure!



On the machine, ensure that the actuating force /
the supply pressure do not drop while the product
is in use.



If no precautions have been taken on the machine
to maintain the actuating force / the supply pres-
sure, it is prohibited to use this product on the ma-
chine.



Pay attention to the operating instructions for the
machine tool.

2.2 Personnel requirements

WARNING

Serious injuries caused by incorrect handling of
the product by insufficiently skilled or trained per-
sonnel!



All activities must be performed by skilled staff
from the relevant specialist field.

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Содержание HYDROK

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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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