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HYDROK – Safety

reliably execute their work are considered as person-
nel. Persons whose capability to react is impaired, for
instance through drugs, alcohol, or medication, are
not approved.



Comply with age-specific and job-specific regula-
tions that are applicable at the installation site when
selecting personnel.

2.3 Intended use

The clamping device is designed for installation in a ma-
chine tool according to CE compliant. Within the machine
tool   the   clamping   device   is   designed   exclusively   as   a
through-bore chuck for bar work and / or as an end-stop
chuck for chuck work.
The clamping device should only be mounted, operated,
maintained,   and  cleaned  by instructed,   specialized   per-
sonnel.
Intended   use   also   includes   compliance   with   all   the   in-
structions in this manual.
The clamping device is to be used for the case of applica-
tion contractually agreed between the producer/deliverer
and the user, as well as such cases of application de-
scribed in the product description which are also in accor-
dance with the technical values.
The safe function of the clamping device is, as far as it
can be foreseen, guaranteed when it is used for the in-
tended purpose in accordance with the appropriate safety
regulations.
Any use that extends beyond  the intended  use, or any
other use of the clamping device is considered to be mis-
use and can cause dangerous situations.

WARNING!
Danger due to misuse!

Misuse of the clamping device can cause danger-
ous situations.
Particularly refrain from the following uses of the
clamping device:



Use in machines other than machine tools.



Use in machine tools with technical data other
than that specified on the clamping device.

Claims of any type due to damage arising from non-in-
tended use are excluded.

Order h49 7144.907-333

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Содержание HYDROK

Страница 1: ...Installation manual HYDROK HYDROK 40 SE HYDROK 32 RD Hydraulic stationary chuck SPANNTOP force operated...

Страница 2: ...gate 37 2 11 1Clamping and release flow at HYDROK 37 2 11 2Clamping and release times at 2 liter hydraulic aggregate 37 2 11 3Clamping and release times at 4 liter hydraulic aggregate 37 2 11 4Clampin...

Страница 3: ...dem cylinder 58 4 7 7 Hydraulic base plate 58 4 7 8 Multiple clamping pallet 59 5 Transporting packaging and storing 60 5 1 Safety instructions for transporting 60 5 2 Symbols on the packaging 60 5 3...

Страница 4: ...d HYDROK 40 SE 84 8 3 Preservation 85 8 4 Use of lubricant 85 8 5 Maintenance schedule 86 8 6 Bolt torque 87 9 Trouble shooting 88 9 1 Safety 88 9 2 Trouble shooting table 89 9 3 Start up after correc...

Страница 5: ...mping device It is assumed that the reader is familiar with standard procedures such as cleaning the mounting surfaces 1 2 Explanation of symbols Safety instructions Safety instructions are indicated...

Страница 6: ...approved spare parts The actual scope of delivery can vary from the expla nations and graphic representations provided in this manual in the case of special versions if supplemental order options are...

Страница 7: ...s dupli cation in any form including excerpts as well as ex ploitation and or communication of the content are not permitted except for internal use without written ap proval from the manufacturer Act...

Страница 8: ...lfunction or total failure they can also impair safety Only use manufacturer s original spare parts Only purchase spare parts from authorized dealers or direct from the manufacturer Addresses are in t...

Страница 9: ...plementation of the device Note in particular that the status scans of the machine must be adjusted to the respective product DANGER Risk of injury due to thrown out parts Incorrect machine settings m...

Страница 10: ...as well as knowledge of the applicable regulations are capable of executing the tasks assigned to them and of recognizing and avoiding possible hazards on their own Hydraulic specialist The hydraulic...

Страница 11: ...evice is to be used for the case of applica tion contractually agreed between the producer deliverer and the user as well as such cases of application de scribed in the product description which are a...

Страница 12: ...Follow the instructions that have been posted in the work area Always wear For all tasks always wear Protective work clothing is tight fitting work clothing with low resistance to tear ing with tight...

Страница 13: ...e in a machine tool In each case the residual risks that have been determined based on a risk analysis of the machine must be specified by the customer Follow the safety instructions listed here and t...

Страница 14: ...in projecting compo nents Only use approved hoists and sling gear with sufficient bearing capacity Do not use rope and belts that are torn or frayed Moving parts WARNING Danger of injury due to movin...

Страница 15: ...imensional accuracy Missing changing parts WARNING Danger of injury due to missing changing parts When operating the clamping device without changing parts segmented clamping bushing clamping heads wo...

Страница 16: ...ping device while the spindle is rotating Before starting to work on the mandrel make sure the machine spindle cannot be put in motion WARNING Risk of injury Falling down of the clamping device or its...

Страница 17: ...or pneumatic connections are available and undamaged WARNING Damage of clamping device The clamping device may be released exclu sively in the standing condition 2 7 Clamping force The achieved clampi...

Страница 18: ...the product itself near the screw or threaded pin and or given in chapter Bolt torque All screws or stud screws that are not marked with a tightening torque specification are tightened with the prescr...

Страница 19: ...rning operation Feed cutting edge drilling operation FB N Feed force drilling operation Fc N Cutting force turning operation Fc max N Max cutting force turning operation Ffz N Clamping force contingen...

Страница 20: ...g head mw kg Workpiece mass MB Nmm Torque drilling operation Mq Nm Moment due transverse force relative to the chuck axis Mqmax Nm Max moment due to transverse force relative to the chuck axis n 1 min...

Страница 21: ...irst limit workpiece length The max unclamping length that can be machined without the aid of steady rest or tailstock is specified at max 6x the clamping diameter 2 10 3 Second limit workpiece mass T...

Страница 22: ...etely unconsidered General Lsp 0 08 dsp Moreover the following also applies Fig 2 Lsp 2 8 mm Use of clamping heads with smooth clamping bore Lsp 13 mm Use of clamping heads with longitudinal and radia...

Страница 23: ...s Principles for the forces acting on the workpiece from the outside NOTE For safe machining2 the following must apply at all times 1st principle Frad Fraderf AND 2nd principle Ft Ftmax AND 3rd princi...

Страница 24: ...ng procedures must be added However axial drilling and turning jobs are rarely over laid because as a rule they cannot run simultaneous ly due to opposite directions of rotation For the calculation th...

Страница 25: ...ter of the clamping head is greater than the clamping diameter on the workpiece Edge seat The clamping diameter of the clamping head is less than the clamping diameter on the workpiece 3 These values...

Страница 26: ...ces kc N mm Corresponding to the relatively imprecise classifica tion of the materials these are guide values Thus in some cases greater deviations relative to the real val ues can be present For devi...

Страница 27: ...ol steels unhardened C105W1 1 1545 3100 2100 1690 Machining steels 35S20 1 0726 60S20 1 0728 1700 1480 1400 Stainless steels 3600 2450 2100 Hardened steels 4800 Aluminum wrought alloy 16 Si 1340 900 7...

Страница 28: ...d lose their capacity of achieving higher co efficients of friction with soft materials Workpiece surface Jaw clamping surface Smooth clamping head Clamping head with longitu dinal and trans verse ser...

Страница 29: ...mass m kg and distance rs from the center of mass of clamping head segments to the axis of rotation m S c kc a t rs m From table 2 From table 3 From table 4 From table 5 From table 6 I F raderf S c 1...

Страница 30: ...rce Fraderf in order to execute this machin ing task using the chuck If this condition is not satisfied then the chuck is not suitable The machining task must not be executed in this manner For clampi...

Страница 31: ...2 10 5 2For principle 2 Ft Ftmax 14 Tailstock force Due to the additional spreading force on the chuck the max permissible tailstock force is limited to the following values in accordance with the ch...

Страница 32: ...0 100 8 000 125 12 000 140 12 500 160 14 000 Table 8 Maximum permissible cutting force 2 10 5 4For principle 4 Fq Fqmax For drilling tasks radial to the workpiece axis due to the feed force of the too...

Страница 33: ...n the clamping head or on the chuck This moment as well must not limitlessly increase without the chuck being damaged although perhaps the clamping set up would nonetheless still securely clamp the wo...

Страница 34: ...ping length Lsp 20mm Chuck SPANNTOP pull back size 65 Clamping head used D 60 mm smooth extension length 3 mm Detailed consideration The first condition namely that the workpiece length may equal up t...

Страница 35: ...ing F C 1 3 1 5mm 0 25mm 2515 N mm2 F C 1226N Drilling Here not relevant because drilling is not intended Consequently M B 0Nmm F B 0N F sk 0 27 Lz dsp 0 63 F c Lz F G Lg 2 F c p 2 0 5 0 67 1 9 Lsp 4...

Страница 36: ...tting force of Fc 1226 N is far below the limit of 4500 N In this example principles 4 and 5 are again irrele vant because both principles must only be considered for radial drilling work Result of th...

Страница 37: ...size 65 size 80 size 100 Clamping volume 1 Clamping device 0 013 0 01 0 022 0 022 0 028 0 031 0 080 Release volume 1 Clamping device 0 013 0 01 0 022 0 022 0 028 0 031 0 080 2 11 2 Clamping and relea...

Страница 38: ...ubstances particularly improper dis posal can cause significant environmental damage Always comply with the instructions cited be low If environmentally harmful substances should inadvertently get int...

Страница 39: ...94 46 65 16 4 174 x 174 x 130 105 40 80 17 5 186 x 186 x 130 115 40 100 30 9 229 x 229 x 140 150 40 RD Alu 100 13 5 229 x 229 x 130 143 40 SE 40 2 7 79 8 x 79 8 x 95 75 63 110 52 11 8 154 x 154 x 120...

Страница 40: ...8 150 40 Stationary chuck SPANNTOP SE 32 12 3 134 x 134 x 118 148 x 8 70 40 42 12 3 154 x 154 x 120 170 x 8 80 40 65 16 4 174 x 174 x 140 196 x 8 105 40 80 17 5 186 x 186 x 140 210 x 8 115 40 100 30...

Страница 41: ...g forces are outside the allowed range the maintenance is mandatory to perform After servicing the clamping forces have to be re examined If the clamping force even after the mainte nance is not in th...

Страница 42: ...kN Given values pmax HYDROK 40 bar Fax max HYDROK 35 kN Fax adaptation clamping device 20 kN Example Requested value p HYDROK if Fax adaptation clamping device 20kN Calculation p HYDROK pmax HYDROK F...

Страница 43: ...HYDROK Technical data 3 3 1 Clamping force diagram HYDROK size 32 RD Fig 4 Order hotline 49 7144 907 333 43 nom inal...

Страница 44: ...HYDROK Technical data 3 3 2 Clamping force diagram hydraulic stationary chuck size 32 RD Fig 5 44 Order hotline 49 7144 907 333 n o m i n a l...

Страница 45: ...HYDROK Technical data 3 3 3 Clamping force diagram HYDROK size 40 SE Fig 6 Order hotline 49 7144 907 333 45 nom inal...

Страница 46: ...HYDROK Technical data 3 3 4 Clamping force diagram HYDROK and hydraulic stationary chuck size 42 52 RD SE Fig 7 46 Order hotline 49 7144 907 333 n o m i n a l...

Страница 47: ...HYDROK Technical data 3 3 5 Clamping force diagram HYDROK and hydraulic stationary chuck size 65 RD SE Fig 8 Order hotline 49 7144 907 333 47 n o m i n a l...

Страница 48: ...HYDROK Technical data 3 3 6 Clamping force diagram HYDROK and hydraulic stationary chuck size 80 RD Fig 9 48 Order hotline 49 7144 907 333 n o m i n a l...

Страница 49: ...HYDROK Technical data 3 3 7 Clamping force diagram HYDROK and hydraulic stationary chuck size 100 RD SE Fig 10 Order hotline 49 7144 907 333 49 n o m i n a l...

Страница 50: ...ifications of clamping device machine adapter and machine do not agree severe damage extending to total damage can occur Only operate clamping devices and adapters in machines with the same power spec...

Страница 51: ...nction 4 Structure and function 4 1 Overview HYDROK 3 x Fig 12 1 Clamping head optional 2 Housing 3 Piston coupling 4 Locking ring 5 Cylinder cover 6 Fitting 7 Mounting screws Order hotline 49 7144 90...

Страница 52: ...Clamping head optional 2 Mounting screws 4x 3 HYDROK 32 4 Tandem cylinder optional 5 Cylindrical screws 4x 6 Hydraulic base plate optional 7 Hydraulic connection 8 Hydraulic connection optional for th...

Страница 53: ...hydraulically actuated sta tionary chuck that provides even more implementa tion possibilities It can be used with all clamping de vice adaptations such as the MANDO Adapt man drel in the clamping de...

Страница 54: ...nnection to base plate or table 5 Media supply from side or through the base plate 6 Positioning for front end stop 7 Radial positioning 8 Mounting screws 9 Safety ring 10 Mounting thread for frond co...

Страница 55: ...hining or rational multiple clamping wit h the HYDROK we offer a hydraulically actuated sta tionary chuck that provides even more implementa tion possibilities It can be used with all clamping de vice...

Страница 56: ...e not included in the scope of delivery Specially developed segmented clamping bushings match to the respective maximum RPM are available for each clamping device Trouble free and precise function of...

Страница 57: ...nging fixture and can be inserted into the mounted clamping device with the aid of the changing fixture 4 7 2 Clamping head Fig 19 The clamping heads are used to accommodate the workpiece that will be...

Страница 58: ...m cylinder Fig 23 By adapting the tandem cylinder to the HYDROK 32 RD you can reach a clamping pressure of 70 kN by only 50 bar By adapting the tandem cylinder to the HYDROK 40 SE you can reach a clam...

Страница 59: ...sult in serious injury Connect the rapid action coupling only with extreme vigilance 4 7 8 Multiple clamping pallet Fig 25 For size 65 a special multiple clamping pallet has been developed Connecting...

Страница 60: ...in such a manner that it is located above the center of gravity Carefully lift and see if the load tilts If neces sary change the attachment Transport For transport always use a suitable clamping mean...

Страница 61: ...packed vertically and has threaded bores in the end face From about weight 15 kg there are also thread ed holes in the circumference of the clamping device Lifting eye bolts can be screwed into these...

Страница 62: ...just before installation The packed goods are sealed in foil airtight and packed in cartons See the Technical Data section for the specific weight of the re spective sizes Handling packaging material...

Страница 63: ...midity max 60 For storage periods longer than 3 months Check the general condition of all parts and the packaging at regular intervals Touch up or re apply anti corrosion agents as needed Subsequent s...

Страница 64: ...ces see Mainte nance The ex works wetting of the plate surfaces and the clamping element is only corrosion protection It s not functionally lubricated The insertion of lubricant is provided only on th...

Страница 65: ...injury and material damage Two people are always required for this task Use a crane WARNING Risk of injury due to stored energy The clamping device can be designed with disc springs These disc spring...

Страница 66: ...de Always remove immediately all the tools and wrenches from the clamping device after use WARNING Risk of injury By operating the clamping device without changing parts clamping head segmented clampi...

Страница 67: ...e may be thrown out If the clamping pressure is too high severe damages of the components of the clamping device may occur the throwing out of the work piece Before operation set the operation pressur...

Страница 68: ...main in the stationary chuck 1 Remove the plug from the rear side of the clamp ing device Property danger due to not fitting hydraulic connections With not fitting of the hydraulic connections of bas...

Страница 69: ...tationary chuck is carried out via the base plate The stationary chuck can be centered either on an outer diameter or on an inner diameter Fig 27 Caution Property damage due to missing seal rings By r...

Страница 70: ...the rear side on the HYDROK 32 RD HYDROK 40 SE till end stop Use the Index holes for positioning 6 Turn back the tandem cylinder till the Index holes fit 7 Put the ring in the base plate 8 Put the ta...

Страница 71: ...ition Make sure that the clamping device is empty and leakage of hydraulic fluid is avoided 6 3 3 Installation of the clamping head 12 x The changing of the clamping head is only possible in release p...

Страница 72: ...mensional requirements in this regard pay attention to the maximum utilization of the clamping reserve reserve stroke see chapter 2 5 Faulty workpiece clamping Only clamp workpieces with a minimum cl...

Страница 73: ...ents must be intact this means that they are neither torn nor are they porous at any point All edges and bearing surfaces are intact this means that they are neither broken nor do they show any signs...

Страница 74: ...nto moving parts or handle moving parts during operation Note the gap dimensions of moving parts Wearing of gloves PSA is required 6 7 Activities after production is concluded 5 x 1 Move the clamping...

Страница 75: ...afeguarding against restart DANGER Life threatening danger if restarted without authorization When disassembling there is danger of the en ergy supply being switched on inadvertently This poses a life...

Страница 76: ...ding screws they have to be operated continuously alternately to reduce the clamping pressure to a mini mum Particularly cautious approach is required For cleaning and maintenance disassemble the clam...

Страница 77: ...ead is squeezed at the coupling area 2 Remove the clamping head out of the clamping el ement reception and or the housing 3 Loosen the changing fixture by light pressure in ax ial direction and pull i...

Страница 78: ...each disassembly 4 Remove the ring from the base plate and clean it 5 Move the tandem cylinder into front end position 6 Move the coupling of the H HYDROK 32 RD HY DROK 40 SE into reserve stroke down...

Страница 79: ...Loosen and remove the mounting screws 2 Disconnect the hydraulic connection at the station ary chuck 3 Remove the stationary chuck from the machine ta ble Clean the mounting surfaces of the stationar...

Страница 80: ...f screw and drain re maining liquid Discard the liquid NOTE Improper disposal causes environmental damage Lubricants and other auxiliary materials are subject to treatment as special waste and should...

Страница 81: ...ity and perpendicularity tolerances Clean these surfaces with an appropriate cleaner CAUTION Danger of injury due to improper handling of cleaners Improper handling of cleaners can cause health impair...

Страница 82: ...By loosening the corresponding screws they have to be operated continuously alternately to reduce the clamping pressure to a mini mum Particularly cautious approach is required For cleaning and mainte...

Страница 83: ...partly disassembling of the stationary chuck for cleaning service the seal rings will be damaged Keep a new set of seal rings ready for re assembling Fig 32 1 Disassembled the clamping device see cha...

Страница 84: ...RD HYDROK 40 SE from the machine table see chapter Disassem bly of the HYDROK 32 RD HYDROK 40 SE CAUTION Risk of injury by not allowed partly disas sembly of the HYDROK 32 RD HYDROK 40 SE When partly...

Страница 85: ...ge location and safeguard it from falling 8 4 Use of lubricant With the usage of lubricant you may only use grease that corresponds to the requirements concerning bond pressure stability and solubilit...

Страница 86: ...ack if you have questions concerning mainte nance tasks and intervals Interval Maintenance task Daily Visual inspection and complete cleaning in case of heavy contamination see section Cleaning Weekly...

Страница 87: ...d in Nm in the table Total friction coefficient tot 0 12 Diameter mm mm Torque for screw quality 10 9 Nm M 4 7 3 4 M 5 8 4 7 M 6 10 5 12 M 8 13 6 25 M 10 17 8 50 M 12 19 10 100 M 16 24 14 220 M 20 30...

Страница 88: ...vice address on the back of this operating instruction 9 1 Safety Trouble shooting The following always applies 5 xx 1 Determine the cause of the fault 2 Depending on the type of fault either have aut...

Страница 89: ...ection Cleaning Specialist Contaminated clamping taper Remove the clamping head and clean the clamping taper see section Cleaning Specialist Formal defect on the work piece Elastic deformation of feed...

Страница 90: ...correcting the fault execute the following steps to start up again 4 xxx 1 Reset the emergency stop device 2 Acknowledge the fault on the machine tool con troller 3 Ensure that no one is in the dange...

Страница 91: ...f hainbuch at Internet www hainbuch at Belgium BIS Technics bvba sprl Zevenputtenstraat 20 3690 Zutendaal Phone 32 89518890 Fax 32 89518899 E mail info bistechnics com Internet www bistechnics com Bul...

Страница 92: ...e 30 210 2753725 Fax 30 210 2753725 E mail info cncmechanics gr Internet www cncmechanics gr Hungary GIMEX Hydraulik GmbH Selyem utca 1 9025 Gy r Phone 36 96525588 Fax 36 96427239 E mail info gimex hu...

Страница 93: ...tns tnssro sk Internet www tnssro eu Slovakia TMC CR s r o Masn 27 9 60200 Brno Phone 420 533433722 Fax 420 548217219 E mail info tmccr cz Internet www tmccr cz Slovenia Elmetool d o o Prvomajska uli...

Страница 94: ...hone 1 4143589550 Fax 1 4143589560 E mail sales hainbuchamerica com Internet www hainbuchamerica com Brasil Sanposs Tecnologia Suprimentos e Consultoria Internacional Ltda Rua C ndia n 65 Jardim do Ma...

Страница 95: ...om Taiwan GSTC Technology Co Ltd No 418 Youn Chun East 1st Rd Taichung City 40877 Taiwan Phone 88 6423805678 Fax 88 6423805511 E mail gstc seed net tw Internet www gstctech com tw Thailand HAINBUCH Th...

Страница 96: ...ementation limits 19 Inspections 73 Installation Clamping head 71 Hydraulic stationary chuck SPANNTOP 68 HYDROK 68 HYDROK 32 RD HYDROK 40 SE 69 Preparations 65 Intended use 11 M Maintenance schedule 8...

Страница 97: ...Symbols on the packaging 60 T Tandem cylinder 58 Transport inspection 61 Transport inner company 61 Trouble shooting 88 Trouble shooting table 89 Type designation 50 U Unpacking 61 Order hotline 49 7...

Страница 98: ...HYDROK Appendix 98 Order hotline 49 7144 907 333...

Страница 99: ...rried out subse quently by the final user The declaration is no more valid if the product is modified without agreement Hiermit erkl ren wir dass die nachstehend beschriebene Maschine Herewith we decl...

Страница 100: ...1262 71667 Marbach Erdmannhauser Strasse 57 71672 Marbach Germany Phone 49 7144 907 0 Fax 49 7144 18826 sales hainbuch de www hainbuch com 24h Emergency call 49 7144 907 444 06 2016 Part no 80001 008...

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