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TOPlus mini / TOPlus premium pull-back
Faults

114

Order h49 7144.907-333

13 Faults

The following chapter describes possible causes for faults,
and the work involved in remedial action.

If multiple faults occur, shorten the maintenance intervals in
accordance with actual load levels.

Contact the manufacturer if faults occur that cannot be rem-
edied by following these instructions [see »Contact« chap-
ter].

13.1 Procedure with faults

This applies in all cases:

1. With faults that constitute an immediate danger to peo-

ple or capital 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 machine tool into set-up mode.

4. Notify the person on location of the fault immediately.

5. Depending on the type of fault, get it remedied by au-

thorized and appropriately skilled specialists.

INFORMATION

The troubleshooting table in the following section pro-
vides information about who is authorized to remedy
a given fault.

6. In the event of a fault not caused by the product, the fault

may be caused by something close to the machine tool.
For this, refer to the operating instructions of the ma-
chine tool.

13.2 Fault table

Fault

Possible cause

Remedial action

Remedied by

Defective axial
strokes in the
clamping device

Dirt in the parts in
the power flow

Remove and clean the clamping
element and, if necessary, re-
move, dismantle and clean the
clamping device

Skilled special-
ist

Defective drawtube
adapter

Discussion with the manufacturer Manufacturer

Incorrect drawtube
position

Check drawtube position and align
with the clamping device

Skilled special-
ist

Clamping element
cannot be
swapped in or out

Defective axial
strokes in the
clamping device

See fault »Defective axial strokes
in the clamping device«

Содержание TOPlus mini

Страница 1: ...Operating instructions incl installation manual TOPlus mini TOPlus premium pull back EN...

Страница 2: ...TOPlus mini TOPlus premium pull back 2 Order hotline 49 7144 907 333 Translation of the original operating instructions Order hotli ne 49 7144 907 333...

Страница 3: ...2 3 Intended use 14 2 4 Personal protective equipment 16 2 5 Particular hazards 17 2 6 CFRP products 19 2 7 Other safety instructions 19 2 8 Screws 21 2 9 Functionality 22 2 10 Environmental protectio...

Страница 4: ...ging fixture 34 4 4 3 Screwdriver bit with tip guide 34 5 Use and limits of use 35 5 1 Use 35 5 2 Limits of use 35 5 2 1 Nomenclature 35 5 2 2 First limit workpiece length 38 5 2 3 Second limit workpi...

Страница 5: ...xial screw connection 83 7 7 5 Installation of the radially clamped variant 84 7 8 Aligning the clamping device with the test specimen 86 8 Commissioning 87 8 1 Commissioning safety 87 8 2 Checking th...

Страница 6: ...1 4 Visual inspection 111 11 5 Lubricating the product 111 11 6 Use of lubricants 112 12 Disposal 113 13 Faults 114 13 1 Procedure with faults 114 13 2 Fault table 114 13 3 Commissioning after a fault...

Страница 7: ...iction coefficient for steel workpieces 45 Table 10 Clamping head mass and distance of mass center of gravity of clamping head segments to the rotational axis 46 Table 11 Maximum permitted tailstock f...

Страница 8: ...configu ration 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 produ...

Страница 9: ...injury to people 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 b...

Страница 10: ...usiness 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 protected by copyright and are only i...

Страница 11: ...the machine 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 mac...

Страница 12: ...his 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 t...

Страница 13: ...the following skills sets required for vari ous different areas of activity Skilled specialist Skilled specialists due to their professional training knowledge and experience and awareness of applicab...

Страница 14: ...ed use The product is only intended for installation in a CE compli ant machine tool with a separating set of guards The product is only intended for the type of use described in this manual see Use c...

Страница 15: ...ever exceed the 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...

Страница 16: ...xamples of unintended 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...

Страница 17: ...of this manual 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 fro...

Страница 18: ...Prevent accidental 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 cau...

Страница 19: ...CFK Pay attention to the following with carbon components on the CFRP product WARNING Serious injuries caused by loss of endurance strength of the product Check product for visible signs of damage or...

Страница 20: ...hat the machine spindle is unable to start up WARNING Serious injuries caused by reaching into slots and bores Never reach into slots or bores WARNING Serious injuries caused by workpieces dropping or...

Страница 21: ...uer 2 8 Screws WARNING Serious injuries caused by radially installed screws being ejected centrifugally if installed in correctly poor handling Do not open the screws secured with sealing lac quer Scr...

Страница 22: ...nt handling or incorrect dis posal of environmentally hazardous substances If environmentally hazardous substances enter the environment accidentally take immediate re medial action If in doubt notify...

Страница 23: ...2 23 2 4 0 18 0 5 2 149 0 204 0 x 105 0 230 0 7000 40 108 4 1 65 4 65 2 5 2 0 0 6 1 0 10 6 42 1 4 5 36 0 6 1 165 0 230 0 x 111 0 250 0 6000 45 120 4 1 80 5 80 2 5 2 0 0 6 1 0 13 2 43 9 4 6 34 7 7 4 1...

Страница 24: ...g force measurements must be performed The clamping force measured must be in the approved range see Clamping force diagram chapter 3 3 Balancing quality The product is balanced before leaving the fac...

Страница 25: ...er a loss of clamping power Never rotate the product without a workpiece in stalled When several clamping points are involved clamp a suitable workpiece to each one If necessary adjust the machining f...

Страница 26: ...n axial actuation force of 12 5 kN the radial clamping force is in a range of between 13 kN and 31 kN A lower limit value B upper limit value 3 5 2 Size 40 Scan sample At an axial actuation force of 2...

Страница 27: ...an axial actuation force of 25 kN the radial clamping force is in a range of between 31 kN and 67 7 kN A lower limit value B upper limit value 3 5 4 Size 65 Sample scan At an axial actuation force of...

Страница 28: ...an axial actuation force of 25 kN the radial clamping force is in a range of between 33 kN and 65 7 kN A lower limit value B upper limit value 3 5 6 Size 100 Sample scan At an axial actuation force of...

Страница 29: ...nt temperature range 15 65 C Workpiece temperature 80 C Humidity 80 Table 2 Operating conditions 3 7 Type designation The type designation is on the product and it includes the following indications M...

Страница 30: ...e drawtube adapter and is screwed to the spindle flange The clamping element was installed in the clamping device with an appropriate changing fixture and it clamps the work piece being machined The w...

Страница 31: ...2 3 Clamping head The clamping head is there to support the workpiece being machined It consists of hard steel and rubber segments con nected by vulcanization Depending on workpiece requirements vario...

Страница 32: ...s for grinding or turning 4 3 3 MANDO Adapt Through adaptation of the MANDO Adapt internal clamp ing of the workpiece can be achieved 4 3 4 Morse taper adaptation Through Morse taper adaptation adapta...

Страница 33: ...nd stop can be replaced with a swarf baffle ring 4 3 8 vario flex end stop system The vario flex end stop system enables the workpiece to be ejected automatically from the clamping device 4 3 9 vario...

Страница 34: ...mping device with the help of the changing fixture 4 4 2 Pneumatic changing fixture The pins on the changing fixture are installed in the chang ing bores in the clamping head The changing fixture is a...

Страница 35: ...end stop or a workpiece end stop can be mounted For this different connection points are provided on the clamping device The clamping device can be used as a through chuck for machining bar stock For...

Страница 36: ...workpiece Feed rotational movement of drilling op eration Transverse force Maximum permitted transverse force Radial clamping force Required radial clamping force Clamping force to prevent the workpie...

Страница 37: ...clamping head Drilling operation torque Torque due to lateral force on the chuck axis Maximum torque due to lateral force on the chuck axis Workpiece mass Maximum workpiece mass 1 Speed Key indicator...

Страница 38: ...ith 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 4 T...

Страница 39: ...apply which may be even higher Consult the manufacturer for these details 7 when using clamping heads with Z ser rations 5 when using clamping heads with F serrations If HAINBUCH uses a different and...

Страница 40: ...the resultant torques are not directed at the cen ter due account of this can be taken by a quasi cutting force outside the center AND 5 Principle Relevant to a radial drilling operation directed at...

Страница 41: ...highest forces that is the least favorable machining moment If in doubt several blade en gagement situations need to be checked to record the least favorable one If radial drilling operations are bein...

Страница 42: ...e scatter width factor can be reduced by factor 0 85 example Size 52 1 7 0 85 1 45 Table 5 Scatter widths of clamping force Contact factor Consult the following tables for the contact factor depending...

Страница 43: ...deviations from 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 bei...

Страница 44: ...4CrNiMo6 1 6582 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 s...

Страница 45: ...nly permitted 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...

Страница 46: ...osition Clamping 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 10 Clamping head mass and distance of mass center of gravity of cla...

Страница 47: ...rinciple defined 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...

Страница 48: ...a tailstock due to 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 clamp...

Страница 49: ...12000 Table 12 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 26 with 150 120 150 1600 1...

Страница 50: ...nciple 5 With drilling operations that are radial to the workpiece axis the transverse force examined under Principle 4 exerts an additional torque on the clamping head and or on the chuck This moment...

Страница 51: ...ed 800 1 Feed 0 25 Chip cutting depth 1 5 Use of cooling lubricant Total clamping length 20 Clamping head chuck Pull back TOPlus size 65 Clamping head used Smooth Clamping diameter of clamping head 60...

Страница 52: ...Table 7 from Table 8 interpolated for 0 25 from Table 9 from Table 10 I 1 6 from Table 5 1 6 from Table 7 1 3 1 6 1 3 1 6 II 1 3 2 2 2 from Table 9 0 14 0 16 Turning 1 3 1 3 1 5 0 25 2515 2 1226 Dril...

Страница 53: ...1 3 1 6 14703 14727 301 98569 99 Since the 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...

Страница 54: ...values established must lie within an appropriate range for the rotational speed see Clamping force diagram chapter 5 2 7 Permitted maximum speed WARNING Serious injuries caused by breakage of the pr...

Страница 55: ...ing lifting gear 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...

Страница 56: ...y Keep packaging 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...

Страница 57: ...prevent it from 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 packagin...

Страница 58: ...basis check the 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 pro...

Страница 59: ...d from the working 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...

Страница 60: ...weight of the product or of its components if not trans ported properly From a weight of 10 kg use appropriate transport equipment lifting gear and lifting tackle CAUTION Serious cut injuries caused...

Страница 61: ...l mating surfaces Pay attention to notes about lubricants see Use of lub ricants chapter Avoid too much lubricant on the locating face because this can cause face run out errors Apply grease to the se...

Страница 62: ...12 Thread designa tion Tightening torque at screw quality Nm 10 9 12 9 M4 4 5 M5 7 9 M6 12 15 M8 25 38 M10 50 70 M12 100 130 M16 220 300 M20 400 550 M24 600 800 Table 15 Screw tightening torques metr...

Страница 63: ...e machine or cover them 7 5 Installation of the product A Drawtube adapter B Spindle flange B1 Fixing screws spindle flange B2 Transport thread spindle flange C Functional unit C1 Fixing screws functi...

Страница 64: ...ition The following preparatory steps are needed to install the product WARNING Serious injuries caused by imbalance during in correct installation During preparation of the product for installation o...

Страница 65: ...product can or cannot be aligned Check the order confirmation If the clamping device can be aligned the order confirmation will have a note to this effect And or check if there is clearance at the int...

Страница 66: ...tion of the drawtube adapter INFORMATION Depending on the geometry of the drawtube adapter it must be installed either on the machine drawtube or in the functional unit 1 Screw the drawtube adapter in...

Страница 67: ...tically sus pended spindle INFORMATION The positioning block on the machine spindle and the positioning bore in the spindle flange can be used for positioning 3 Fit the spindle flange on the machine s...

Страница 68: ...run out on the test surface of the spindle flange ideally 0 005 mm Whenever the face run out and or the axial run out is greater than the maximum permitted value 9 Remove the spindle flange 10 Clean t...

Страница 69: ...cessary fit the mounting aid onto a vertically sus pended spindle INFORMATION The positioning block on the machine spindle and the positioning bore in the spindle flange can be used for positioning 3...

Страница 70: ...he spindle flange and tighten to the specified tightening torque see Screw tightening torques chapter 9 Check face run out on the test surface of the spindle flange ideally 0 005 mm Whenever the face...

Страница 71: ...ny lifting gear that may be required 2 If necessary fit the mounting aid onto a vertically sus pended spindle 3 Move the machine drawtube to the front limit stop INFORMATION If lifting gear needs to b...

Страница 72: ...ocated be tween the bores for the fixing screws in the spin dle flange 5 Turn back the functional unit until the balancing marks on the spindle flange are aligned with those on the func tional unit WA...

Страница 73: ...the mounting aid on a vertically suspended spindle if one was used 10 Check the face run out on the test surface of the func tional unit ideally 0 01 mm and if necessary correct carefully with a plas...

Страница 74: ...e product is aligned on the axial run out test sur face of the functional unit the axial run out values may change when the workpiece is clamped due to distor tion of the product If the product needs...

Страница 75: ...clamping screws must always be located be tween the bores for the fixing screws in the spin dle flange 5 Turn back the functional unit until the balancing marks on the spindle flange are aligned with...

Страница 76: ...k face run out on the test surface of the functional unit ideally 0 01 mm 11 Check axial run out on the test surface of the functional unit ideally 0 01 mm Whenever the face run out and or the axial r...

Страница 77: ...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 fixture 1 As described i...

Страница 78: ...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 fixture 3 Install the clamping head in the product with a...

Страница 79: ...ction E Changing part variant radially clamped E1 Clamping screw changing part variant radially clamped The changing parts such as the workpiece end stop can be installed in different ways If necessar...

Страница 80: ...ine 49 7144 907 333 7 7 1 Installation of the variant screwed directly 1 Screw the changing part into the product using its thread and tighten it down 7 7 2 Installation of the variant x times with ax...

Страница 81: ...times with bayonet 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...

Страница 82: ...pull back Installation 82 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...

Страница 83: ...e 49 7144 907 333 83 7 7 4 Installation of the central variant with axial screw connection 1 Place the changing part into the product 2 Screw in the changing part fixing screw and tighten it to the sp...

Страница 84: ...t may be necessary to use a grab handle or an appropriate auxiliary tool INFORMATION When installing the changing part ensure that it gets installed in the right direction to enable the clamping screw...

Страница 85: ...ck Installation Order hotline 49 7144 907 333 85 2 Screw in the clamping screws on the changing part and tighten to the specified tightening torque see Nomen clature 3 Unfasten and remove the grab han...

Страница 86: ...ing device using the test specimen the functional unit fixing screws must be readily accessible 1 As described in the Preparation of the machine for in stallation chapter prepare for the following ste...

Страница 87: ...force at regular 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 mac...

Страница 88: ...flushing with 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...

Страница 89: ...p ing reserve and axial release stroke must be added together see General information chapter 8 3 Tests NOTE Serious damage to or destruction of the machine tool and the workpiece caused by damaged in...

Страница 90: ...measurement 8 4 Workpiece DANGER Serious injuries caused by parts being ejected centrifugally if level of workpiece clamping is in sufficient Never utilize the full clamping reserve Do not exceed the...

Страница 91: ...ocedure after a collision In the event of a collision the product and its components must be checked for cracks and damage before being used again For this remove the product from the machine see Re m...

Страница 92: ...eing switched 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 Al...

Страница 93: ...ne tool starts 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 liftin...

Страница 94: ...s under parts 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 s...

Страница 95: ...of the changing parts A Changing part variant direct screw connection B Changing part variant x times axial screw connection B1 Fixing screws changing part variant x times axial screw connec tion C Ch...

Страница 96: ...As described in the Preparing the machine for re moval chapter prepare for the following steps 2 Move the clamping device into release position 10 3 1Removal of the variant with direct screw connectio...

Страница 97: ...emoval Order hotline 49 7144 907 333 97 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 b...

Страница 98: ...us premium pull back Removal 98 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...

Страница 99: ...ium pull back Removal Order hotline 49 7144 907 333 99 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...

Страница 100: ...ially clamped 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...

Страница 101: ...907 333 101 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...

Страница 102: ...ing injuries 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...

Страница 103: ...face run out functional unit Special aids needed Screwdriver bit with tip guide 1 As described in the Preparing the machine for re moval chapter prepare for the following steps 10 5 1Removal of the f...

Страница 104: ...de 5 Using the least possible force and speed move the drawtube on the machine to its front limit stop see Pre paring the machine for removal chapter INFORMATION If lifting gear needs to be used rotat...

Страница 105: ...05 10 5 2Removal of the spindle flange 1 Attach any lifting gear that may be required 2 If necessary fit the mounting aid onto a vertically sus pended spindle 3 Unfasten and remove the fixing screws o...

Страница 106: ...mium pull back Removal 106 Order hotline 49 7144 907 333 10 5 3Removal of the drawtube adapter 1 If the drawtube adapter was mounted on the machine drawtube use its thread to unscrew and remove it fro...

Страница 107: ...dule The following 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 inter...

Страница 108: ...see Lubricating the product chapter with storage See Storage chapter depending upon which stipulation is achieved first Table 17 Maintenance table 11 3 Cleaning A Base end stop A1 Actuating pin clamp...

Страница 109: ...ster 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 materials caused b...

Страница 110: ...base end stop 4 Clean all oil and grease residues off all components with an ester free non polar soft lint free cloth and check for visible signs of damage 5 Assemble the product as shown on the expl...

Страница 111: ...y due to insufficient lubrication of the product Never drop below the lower limit value for clamp ing force see Clamping force diagram chap ter Always comply with the maintenance intervals see Mainten...

Страница 112: ...lubricants are 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 D...

Страница 113: ...r dis posal NOTE Substantial damage to the environment can result from incorrect disposal of environmentally haz ardous substances Lubricants auxiliary materials and operating flu ids are governed by...

Страница 114: ...ending on the type of fault get it remedied by au thorized and appropriately skilled specialists INFORMATION The troubleshooting table in the following section pro vides information about who is autho...

Страница 115: ...the clamp ing device and correct if neces sary Skilled special ist Face run out error of the clamping de vice Check face run out of the clamp ing device and clean the mating surfaces if necessary Dirt...

Страница 116: ...iffer ence between workpiece diame ter and clamping bore is too big Use clamping element with a suit able clamping diameter Table 19 Fault table 13 3 Commissioning after a fault has been remedied Afte...

Страница 117: ...7144 907 333 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...

Страница 118: ...equired 31 B Balancing quality 24 Brief description 30 C Checking the total stroke 89 Cleaning 108 Copyright 10 D Definition of terms 9 E End of production 92 Environmental protection 22 F Fault table...

Страница 119: ...afety Commissioning 87 General 12 Maintenance 107 Removal 93 Transport packaging storage 55 Scope of delivery 10 Screw tightening torques Aluminum components 62 Metric control threads 62 Spare parts 1...

Страница 120: ...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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