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Operating instructions

[incl. installation manual]

MANOK plus

EN

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Содержание MANOK Plus

Страница 1: ...Operating instructions incl installation manual MANOK plus EN...

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

Страница 3: ...ular hazards 16 2 6 Other safety instructions 17 2 7 Screws 19 2 8 Functionality 19 2 9 Environmental protection 20 3 Technical data 21 3 1 General information 21 3 2 Performance values 21 3 3 Balanci...

Страница 4: ...Sample calculation 46 6 Transport packaging storage 50 6 1 Safety transport packaging storage 50 6 2 Symbols on the packaging 51 6 3 Transport inspection 51 6 4 Unpacking and internal transportation...

Страница 5: ...moval of the changing parts 81 10 3 1 Removal of the variant with direct screw connection 82 10 3 2 Removal of the variant x times with axial screw connection 82 10 3 3 Removal of the variant x times...

Страница 6: ...utting forces 39 Table 10 Friction coefficient for steel workpieces 40 Table 11 Clamping head mass and distance of mass center of gravity of clamping head segments to the rotational axis 41 Table 12 M...

Страница 7: ...n 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 combi...

Страница 8: ...ople 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 De...

Страница 9: ...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 This manual is prot...

Страница 10: ...tool 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 cau...

Страница 11: ...erator 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 b...

Страница 12: ...to 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 standard...

Страница 13: ...ed 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 insta...

Страница 14: ...se of the product Only in a CE compliant machine tool with a sepa rating set of guards Only use for the type of use indicated see Use chapter Only skilled staff from the appropriate specialist fields...

Страница 15: ...rts It serves pri marily to protect the wearer from coming into contact with moving machine parts Do not wear rings chains or other jewelry Safety footwear To protect the wearer from any heavy items t...

Страница 16: ...juries caused by touching rotating and or moving parts Do not open guards while the system is operating During operation do not reach for rotating and or moving parts Pay attention to the gap dimensio...

Страница 17: ...t field Also wear the following items of personal protec tive equipment in addition to the basic equip ment 2 6 Other safety instructions DANGER Serious injuries caused by workpieces being ejected cen...

Страница 18: ...tected 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...

Страница 19: ...s and threaded pins fitted radially to the product that were bonded with adhesive need to be secured again using a standard medium strength screw adhesive and tightened to the specified tightening tor...

Страница 20: ...rdous substances enter the environment accidentally take immediate re medial action If in doubt notify the relevant municipal authori ties about the incident The following environmentally hazardous su...

Страница 21: ...not exceed the lowest of the maximum performance values Only use product in machine tools with the same performance values INFORMATION Details of maximum performance values can be found on each produc...

Страница 22: ...g force diagram indicates the permitted range 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...

Страница 23: ...B upper limit value 3 6 Conversion of actuating torque to actuating force To find the right settings you need to convert from actuating torque to actuating force or vice versa 3 6 1 Nomenclature Brie...

Страница 24: ...and the maxi mum actuating force can be taken from the General information chapter The following formula should be used to determine the actu ating force present at a given actuating torque setting I...

Страница 25: ...an ac tuating torque of 45 Nm must be applied for size 65 A Size 65 3 7 Operating conditions Indication Value Unit Ambient temperature range 15 65 C Workpiece temperature 80 C Humidity 80 Table 3 Ope...

Страница 26: ...amping element was installed in the clamping device with an appropriate changing fixture and it clamps the work piece being machined The workpiece end stop can be screwed to the base end stop screwed...

Страница 27: ...o with different profiles and bores 4 2 2 Workpiece end stop The workpiece end stop is produced with an end stop di mension that reflects customer wishes 4 3 Optional accessories The following optiona...

Страница 28: ...gh Morse taper adaptation adaptation options are rendered possible with a Morse taper connection 4 3 5 Face driver adaptation Adaptation of the face driver makes it possible to machine the entire leng...

Страница 29: ...the clamping head The changing fixture is ac 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 f...

Страница 30: ...plicit approval of the manufacturer The clamping device can be used as an end stop chuck It can be attached directly to the base end stop or a workpiece end stop can be mounted For this different conn...

Страница 31: ...ed force of drilling operation Cutting force of drilling operation Maximum cutting force of drilling opera tion Clamping force supplement for rotational compensation Density of workpiece Feed rotation...

Страница 32: ...t end length Distance between Machining point clamping point when turning Mass of the clamping head Drilling operation torque Torque due to lateral force on the chuck axis Maximum torque due to latera...

Страница 33: ...out the aid of a back rest or a tailstock is 6 times the clamping diameter 5 2 3 Second limit workpiece mass The maximum workpiece mass depends on the size of the clamping head chuck see Table 5 These...

Страница 34: ...8 when using clamping heads with a smooth clamping bore 13 when using clamping heads with longitu dinal and transverse grooves When using clamping heads with a closed first tunnel different details a...

Страница 35: ...sure a safe machining process Pay attention to the following principles 1 Principle AND 2 Principle AND 3 Principle Relevant to turning and or to axial drilling operations AND 4 Principle Relevant to...

Страница 36: ...erations need to be added together However it is rare for axial drilling and turning operations to be superimposed because their opposing directions of rota tion usually preclude them from running sim...

Страница 37: ...ing head chuck is used up the clamping force scatter width factor can be reduced by factor 0 85 example Size 52 2 0 0 85 1 7 Table 6 Scatter widths of clamping force Contact factor Consult the followi...

Страница 38: ...rom real values can be present For deviating workpiece materials and or for machining tasks in the boundary area of the clamping device the respective values of the workpiece material being machine ne...

Страница 39: ...82 2850 1960 1660 tool steels without alloys or with only a low alloy content unhardened C105W1 1 1545 3100 2100 1690 Machining steels 35S20 1 0726 60S20 1 0728 1700 1480 1400 Stainless steels 3600 24...

Страница 40: ...clamping heads are smooth with longi tudinal and transverse serrations Other versions of clamping head may get dam aged and lose their ability to achieve higher fric tion coefficients on soft materia...

Страница 41: ...0 015 0 55 42 0 021 0 70 52 0 022 1 00 65 0 027 2 20 80 0 032 2 70 100 0 045 3 60 125 0 061 9 10 140 0 062 9 10 160 0 075 12 20 Table 11 Clamping head mass and distance of mass center of gravity of c...

Страница 42: ...ned 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...

Страница 43: ...the additional expanding force exerted on the clamping head chuck the permitted maxi mum tailstock force is limited to the following values in ac cordance with the size of the clamping head chuck Size...

Страница 44: ...14000 Table 13 Maximum permitted cutting force On extended chuck versions the ratio of maximum permitted cutting force to chuck lengths needs to be reduced For ex ample size 32 with 150 120 150 1900...

Страница 45: ...120 150 2200 1760 5 2 5 5 Further to Principle 5 With drilling operations that are radial to the workpiece axis the transverse force examined under Principle 4 exerts an additional torque on the clam...

Страница 46: ...150 120 96 5 2 6 Sample calculation Applied to a specific example Longitudinal turning of an offset shaft made of 16MnCr5 blank clamping diameter unsupported in a horizontal posi tion Workpiece data C...

Страница 47: ...not exceed 40 of size 65 of clamping head chuck This more than satisfies the third condition which is that the workpiece must at least be clamped with 0 08 0 08 60 4 8 with a clamping length of 20 3...

Страница 48: ...e the shaft should be surface turned at the front end of the shaft 75 since the center of gravity is located centrally on the longitudinal axis of the work piece 17 corresponds to the total clamping l...

Страница 49: ...ation can therefore be used to deter mine this on the basis of the values for and as indicated on the clamping head chuck or you can consult the clamping force diagram see Clamping force diagram chapt...

Страница 50: ...ear 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 d...

Страница 51: ...ing items dry and protect them from the in gress of water Position designation Points to the correct upright position of the packaging item 6 3 Transport inspection Check the delivery on receipt immed...

Страница 52: ...om rolling away 6 When transporting on a trolley or car ensure that the product is securely mounted on a non slip surface be fore starting to move it 6 5 Packaging The individual packaging items are p...

Страница 53: ...he general condition of all parts and packaging If necessary refresh the preservation or replace it 6 7 Preservation 1 Clean and lubricate the product see Cleaning and Lubricating the product chapters...

Страница 54: ...rking 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...

Страница 55: ...and 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 skil...

Страница 56: ...out 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...

Страница 57: ...minum components The following 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 M1...

Страница 58: ...re for the following steps 7 5 1 Compatibility check Check the compatibility of the product and the connection point of the machine For this check that the connection point and the product share the s...

Страница 59: ...vertically sus pended spindle 4 Place the product on the machine table 5 Screw in the product fixing screws and tighten them gen tly 6 Unfasten and remove any lifting gear that may have been required...

Страница 60: ...uct and the machine table 11 Check face run out on the test surface of the product ideally 0 01 mm Whenever the face run out is greater than the maximum per mitted value 1 Remove the product 2 Clean t...

Страница 61: ...t A Clamping head clamping element INFORMATION Before installing the clamping element install the changing part if necessary otherwise it can no longer be installed Special aids needed Changing fixtur...

Страница 62: ...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 changing fi...

Страница 63: ...D1 Fixing screw changing part variant central axial screw connection E Changing part variant radially clamped E1 Clamping screw changing part variant radially clamped The changing parts such as the w...

Страница 64: ...can for example be performed by marks or a cy lindrical pin and a bore or a groove 7 7 1 Installation of the variant screwed directly 1 Screw the changing part into the product using its thread and ti...

Страница 65: ...ayonet axial screw connection INFORMATION Initial installation of the changing part with bayonet is in accordance with the variant with an x times axial screw connection see Installation of x times va...

Страница 66: ...tallation 66 Order hotline 49 7144 907 333 2 Twist the changing part until firmly home 3 Screw in the changing part fixing screws and tighten to the specified tightening torque see Screw tightening to...

Страница 67: ...g part into the product 2 Screw in the changing part fixing screw and tighten it to the specified tightening torque see Screw tightening torques chapter 7 7 5 Installation of the radially clamped vari...

Страница 68: ...n the radially clamped changing part variant to engage in the groove in the changing part When installing the base end stop the ground side must face forwards 1 Place the changing part into the produc...

Страница 69: ...ccessible 1 As described in the Preparation of the machine for in stallation chapter prepare for the following steps 2 Install the appropriate clamping element for the test specimen and changing part...

Страница 70: ...ular 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 WAR...

Страница 71: ...filtered with a mesh width of 100 mi crons NOTE Damage to seals caused by using the wrong cool ant lubricants To clean the product never use a cooling lubri cant that attacks and damages the sealing e...

Страница 72: ...ts used are undamaged All fixing screws are present on the products and are tightened to the correct tightening torque None of the rubber segments on the clamping elements and attachments are torn or...

Страница 73: ...kpiece clamping is in sufficient Never utilize the full clamping reserve Do not exceed the permitted maximum clamping reserve stroke The remaining clamping reserve must always be adapted to suit the w...

Страница 74: ...unction of the actuating wrench does not work or is impaired it must not be used until after a new spring has been installed INFORMATION The actuating wrench is equipped with a spring that presses the...

Страница 75: ...uating key in the actuating screw and hold it firmly INFORMATION To assure uniform tension on the workpiece to tighten the drive use the torque wrench kit 4 Turn the actuating screw clockwise with the...

Страница 76: ...e actuating screw and remove it from the working area of the machine 6 Remove the workpiece mounting if one was used 8 4 2 Releasing tension on the workpiece 1 If necessary secure the workpiece to pre...

Страница 77: ...working area of the machine 5 Remove the workpiece from the product To do this re move the workpiece mounting if one was used 8 5 Procedure after a collision In the event of a collision the product a...

Страница 78: ...back 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 f...

Страница 79: ...s 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 t...

Страница 80: ...in 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 WARNIN...

Страница 81: ...variant x times axial screw connec tion C Changing part variant x times axial screw connection bayonet C1 Fixing screws changing part variant x times axial screw connec tion bayonet D Changing part va...

Страница 82: ...re for the following steps 2 Move the clamping device into release position 10 3 1Removal of the variant with direct screw connection 1 Unscrew the changing part from the product using its thread 10 3...

Страница 83: ...hotline 49 7144 907 333 83 2 Take the changing part off the product 10 3 3Removal of the variant x times with axial screw connection bayonet 1 Unfasten the fixing screws on the changing body a few tur...

Страница 84: ...OK plus Removal 84 Order hotline 49 7144 907 333 2 Turn the changing part until the screw head on the changing part fixing screw fits through the bayonet opening 3 Take the changing part off the produ...

Страница 85: ...Removal Order hotline 49 7144 907 333 85 10 3 4Removal of the central variant with axial screw connection 1 Unfasten and remove the fixing screw on the changing part 2 Take the changing part out of t...

Страница 86: ...variant INFORMATION To install remove the changing part in from the prod uct it may be necessary to use a grab handle or an appropriate auxiliary tool 1 Unscrew the clamping screws from the changing p...

Страница 87: ...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 for the following st...

Страница 88: ...caused 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 fix...

Страница 89: ...the product A Product A1 Fixing screws on the product A2 Transport thread on product B Clamping bracket a Test surface product face run out b Test surface position product 1 As described in the Prepar...

Страница 90: ...e 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 spindle 4 Where required remove the clamping bracket...

Страница 91: ...MANOK plus Removal Order hotline 49 7144 907 333 91 6 Remove the product from the machine table...

Страница 92: ...wing 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 reflec...

Страница 93: ...apter with storage See Storage chapter depending upon which stipulation is achieved first Table 18 Maintenance table 11 3 Cleaning A Base end stop A1 Clamping screws base end stop B Cover B1 Cover fix...

Страница 94: ...t contains ester nor a polar solvent NOTE Damage to clamping elements caused by the wrong solvent To clean the product never use a solvent that contains ester nor a polar solvent NOTE Damage to materi...

Страница 95: ...he thread of the housing When turning the actuating screw guide the rocker in a parallel manner 4 Clean all oil and grease residues off all components with an ester free non polar soft lint free cloth...

Страница 96: ...el manner 6 Lubricate the product see Lubricating the product chapter 7 Check the total stroke of the clamping device see the Checking the total stroke chapter 11 4 Visual inspection Perform a daily v...

Страница 97: ...or assembled and also when required The product is equipped with grease nipples WARNING Collision impact and cut injuries can be caused by slipping when applying grease with a piston actu ated grease...

Страница 98: ...e recommended GP 355 universal grease see the HAINBUCH product catalogue Alternatively Lubricants Manufacturer Product designa tion Grease MicroGleit GP 355 Kl ber QNB 50 Zeller Gmelin DIVINOL SD24440...

Страница 99: ...substances Lubricants auxiliary materials and operating flu ids are governed by legislation for the processing of special category waste All disposal to be per formed by authorized waste disposal spec...

Страница 100: ...ital 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 mach...

Страница 101: ...s too great idling moment 5 Nm Lubricate the clamping device Incorrect lubrica tion condition Check lubrication of the clamping device and correct if necessary Axial actuating force is too weak Check...

Страница 102: ...ace Clamping force is too high Reduce the clamping force to the level applicable for the clamping device and the workpiece Skilled special ist Incorrect type of clamping element Use a suitable clampin...

Страница 103: ...Tracking 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 aroun...

Страница 104: ...MANOK plus Annex 104 Order hotline 49 7144 907 333...

Страница 105: ...MANOK plus Annex Order hotline 49 7144 907 333 105...

Страница 106: ...Faults 100 H Hazards 16 I Installation Changing part 63 Clamping element 61 Preparation of the machine 57 Preparation of the product 58 Product 58 Installation safety 54 Intended use 13 K Key to symb...

Страница 107: ...w tightening torques Aluminum components 57 Metric control threads 56 Spare parts 10 Speed 22 Storage 53 Symbols on the packaging 51 T Technical data 21 Tests 72 Transport inspection 51 Transportation...

Страница 108: ...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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