Collision and Overload Protection OPS

Transcription

1 Translation of the original manual Collision and Overload Protection OPS Assembly and Operating manual Superior Clamping and Gripping

2 Imprint Imprint Copyright: This manual remains the copyrighted property of SCHUNK GmbH & Co. KG. It is solely supplied to our customers and operators of our products and forms part of the product. This documentation may not be duplicated or made accessible to third parties, in particular competitive companies, without our prior permission. Technical changes: We reserve the right to make alterations for the purpose of technical improvement. Document number: Edition: /08/2014 en SCHUNK GmbH & Co. KG All rights reserved. Dear customer, congratulations on choosing a SCHUNK product. By choosing SCHUNK, you have opted for the highest precision, top quality and best service. You are going to increase the process reliability of your production and achieve best machining results to the customer's complete satisfaction. SCHUNK products are inspiring. Our detailed assembly and operation manual will support you. Do you have further questions? You may contact us at any time even after purchase. Kindest Regards Yours SCHUNK GmbH & Co. KG Spann- und Greiftechnik Bahnhofstr D Lauffen/Neckar Tel Fax info@de.schunk.com OPS en

3 Table of contents Table of contents 1 About this manual Warnings Applicable documents Basic safety notes Intended use Not intended use Ambient conditions and operating conditions Product safety Protective equipment Constructional changes, attachments, or modifications Personnel qualification Using personal protective equipment Notes on particular risks Warranty Scope of delivery Technical Data Assembly Mechanical connection Electrical connection Sensor PNP-Version (standard) Sensor NPN-Version (special) Air connections Module OPS Module OPS Maximum operating pressure How to dertermine the operating pressure Calculation of the input air pressure (P) Troubleshooting OPS does not react? OPS does not lock? No electrical signal? Maintenance and Care Notes Disassembly of the module Renew seals and O-Ring Assembly of the module Seal kit Enclosed pack OPS en 3

4 About this manual About this manual This instruction is an integral part of the product and contains important information for a safe and proper assembly, commissioning, operation, maintenance and help for easier trouble shooting. Before using the product, read and note the instructions, especially the chapter "Basic safety notes". Warnings To make risks clear, the following signal words and symbols are used for safety notes. DANGER Danger for persons. Non-compliance will inevitably cause irreversible injury or death. WARNING Dangers for persons. Ignoring a safety note like this can lead to irreversible injury and even death. CAUTION Dangers for persons. Non-observance can cause minor injuries. NOTICE Material damage Information about avoiding material damage. WARNING Warning about dangerous electrical voltage 1.2 Applicable documents General terms of business Catalog data sheet of the purchased product The documents listed here, can be downloaded on our homepage OPS en

5 Basic safety notes Basic safety notes Intended use The Kollision- and Overload Protection OPS was designed as a device to protect robots and handling unit from damage resulting from collisions and overload conditions. The product is intended for installation in a machine/system. The requirements of the applicable guidelines must be observed and complied with. The product may be used only in the context of its defined application parameters ( 5, Page 8). The product is designed for industrial use. To use this unit as intended, it is also essential to observe the technical data and installation and operation notes in this manual and to comply with the maintenance intervals. 2.2 Not intended use Use which is not specified as an intended use is for instance when the product is for example used as a pressing tool, stamping tool, lifting tool, guide for tools, cutting tool, tensioning mean, boring tool. 2.3 Ambient conditions and operating conditions Make sure that the product has a sufficient size for the application. Make sure that the environment is free from splash water and vapors as well as from abrasion or processing dust. Exceptions are products that are designed especially for contaminated environments OPS en 5

6 Basic safety notes 2.4 Product safety Dangers arise from the product, if: the product is not used in accordance with its intended purpose. the product is not installed or maintained properly. the safety and installation notes are not observed. Avoid any manner of working that may interfere with the function and operational safety of the product. Wear protective equipment. NOTE More information are contained in the relevant chapters Protective equipment Provide protective equipment per EC Machinery Directive Constructional changes, attachments, or modifications Additional drill holes, threads, or attachments that are not offered as accessories by SCHUNK may be attached only with permission of SCHUNK. 2.5 Personnel qualification The assembly, initial commissioning, maintenance, and repair of the product may be performed only by trained specialist personnel. Every person called upon by the operator to work on the product must have read and understood the complete assembly and operating manual, especially the chapter "Basic safety notes" ( 2, Page 5). This applies particularly to personnel only used occasionally, such as maintenance personnel. 2.6 Using personal protective equipment When using this product, observe the relevant industrial safety regulations and use the personal protective equipment (PPE) required! Use protective gloves, safety shoes and safety goggles. Observe safe distances. Minimal safety requirements for the use of equipment OPS en

7 Basic safety notes 2.7 Notes on particular risks Generally valid: Remove the energy supplies before installation, modification, maintenance, or adjustment work. Make sure that no residual energy remains in the system. Do not move parts by hand when the energy supply is connected. Do not reach into the open mechanism or the movement area of the unit. Perform maintenance, modifications, and additions outside the danger zone. Secure the product during all operations against uncontrolled activation. Take a precautionary approach by maintenance and disassembly. Only specially trained staff should disassemble the product. WARNING Risk of injury when the machine/system moves unexpectedly. WARNING While disassembling uncontrollable moves of parts of the gripper possible! WARNING possibility of uncontrolled movements of individual parts of the module during dissassembly! OPS en 7

8 Technical Data 3 Warranty If the product is used as intended, the warranty is valid for 24 months from the date of delivery from the production facility under the following conditions: Observe the applicable documents ( 1.2, Page 4) Observance of the ambient conditions and operating conditions ( 2.3, Page 5) Parts touching the workpiece and wearing parts are not part of the warranty. 4 Scope of delivery The scope of delivery includes: Collision and Overload Protection OPS in the ordered model. Accessory pack 5 Technical Data Size Operating pressure [bar] Axial deflection [mm] Angular deflection [ ] ca. ± 1 * Rotational deflection [ ] With rotational limitations * The sizeops 300 (special) is equipped with flexible stop elements. Therefore higher payloads at larger angles of deflection are involved. Further technical data can be found in the catalog data sheet. The most recent version applies OPS en

9 Assembly Assembly Mechanical connection Fig. 1 OPS 80 Item Designation Item Designation 1 Sensor connection 3 Air connection 2 Notch A Tool side 4 Cylinder head screw 4 x M6 5 Cylindrical pin 2x Ø 6mm B Robot side 6 Cylinder head screw 3 x M4 7 Cylindrical pin 2x Ø 4mm Fig. 2 OPS 100 Item Designation Item Designation 1 Sensor connection 3 Air connection 2 Notch A Tool side 4 Cylinder head screw 6 x M8 5 Cylindrical pin 2x Ø 8mm B Robot side 6 Cylinder head screw 6 x M5 7 Cylindrical pin 2x Ø 5mm OPS en 9

10 Assembly Fig. 3 OPS 160 Item Designation Item Designation 1 Sensor connection 3 Air connection 2 Notch A Tool side 4 Cylinder head screw 6 x M10 B Robot side 5 Cylindrical pin 2x Ø 10mm 6 Cylinder head screw 6 x M8 7 Cylindrical pin 2x Ø 8mm Fig. 4 OPS 200 Item Designation Item Designation 1 Air connection 3 Notch 2 Sensor connection A Tool side 4 Cylinder head screw 6 x M10 B Robot side 5 Cylindrical pin 2x Ø 10mm 6 Cylinder head screw 6 x M8 7 Cylindrical pin 2x Ø 8mm OPS en

11 Assembly Fig. 5 OPS 300 (special) Item Designation Item Designation 1 Air connection 3 Notch 2 Sensor connection A Tool side 4 Cylinder head screw 6 x M10 B Robot side 5 Cylindrical pin 2x Ø 10mm 6 Cylinder head screw 6 x M8 7 Cylindrical pin 2x Ø 8mm NOTE The basic position of the OPS is clearly defined, since it only snaps in a certain position. The OPS snaps, when the notch of the flange is aligned with the notch on the housing OPS en 11

12 Assembly 6.2 Electrical connection DANGER Danger from electric voltage! Touching live parts can result in death. Switch off the power supply before any assembly, adjustment or maintenance work and secure against being switched back on again. Only qualified electricians should perform electrical installations. Cover up live parts. Check if de-energized, ground it and hot wire. WARNING For connection of inductive loads switch a recovery diode parallely to the load! Please make sure that power supply will be correctly polarized. The electronic has a reverse battery protection OPS en

13 Assembly Sensor PNP-Version (standard) When the OPS is in basic position (not released), the circuit is closed. As soon as the collision sensor got deflected (no longer in basic position), the circuit is open. Fig. 6 Sensor connector Fig. 7 Circuit diagram sensor PNP-Version Item Designation Color 1 +24V Brown 2 Signal Black 3 GND Blue 4 Load Designation Value Power supply [VDC] (Remaining ripple max. 10%) Power demand [ma] Max. 7.5 (wihtout load at 24 V) Voltage drop [V] Max. 3,6 Output PNP switching Max. power output [ma] 180 (resistive load); short circuit proof Output signal OPS locked transistor leading OPS unlocked transistor not leading OPS en 13

14 Assembly Sensor NPN-Version (special) The basic sensor position is closed, the sensor is energized. Fig. 8 Sensor connector Fig. 9: Circuit diagram sensor NPN-Version Item Designation Color 1 +24V Brown 2 Signal Black 3 GND Blue 4 Load Designation Value Power supply [VDC] (Remaining ripple max. 10%) Power demand [ma] Voltage drop [V] Max. 3,5 Output Max. power output [ma] Output signal Max. 2 (without load) NPN switching, Open Collector 40 (resistive load); short circuit proof OPS locked transistor not leading OPS unlocked transistor leading OPS en

15 Assembly 6.3 Air connections NOTICE Observe the requirements for the air supply ( 5, Page 8). The compressed air must be filtered (10 μm), dry, oiled or unoiled. Standard for quality of the compressed air according to ISO : Module OPS Compressed air connection at the throttle check valve ensue with a hose Ø4 x Module OPS Compressed air connection at the throttle check valve ensue with a hose Ø6 / Ø Maximum operating pressure OPS 80: 3 OPS 100: 5 OPS 160: 5 OPS 200: 6 OPS 300: 6 bar bar bar bar bar OPS en 15

16 Assembly 6.4 How to dertermine the operating pressure NOTICE The OPS deflects during deaeration! During deflection air will exhaust permanently from the OPS. If this should have to be avioded, the compressed air should be switched off via an external valve during this time. If the facility should be switched off, please make sure that the air supply of theops is assured. If this shouldn t be possible, the OPS has to be positioned in a way that no more deflection may occur (possibly via devices or hanging position). During a longer stillstand, for example over night or weekend put the OPS always in a hanging position NOTE Because of an attached throttle check valve the pressure in the OPS can be short term maintain. This is especially important during assembly work. Before adjusting the operating pressure open the throttle check valve by turning the adjusting screw to the left Calculation of the input air pressure (P) For the rough calculation of the input air pressure use the following formulas and charts: Fy und Fz: force (F) out of mass (m) and acceleration (a) calculated in N, F=m a My und Mz: Moment (M) out of force (F) and lever arm (L) calculated in Nm, M=F L P: input air pressure in bar S: center of gravity D: Distance of the mounting surfaceops to the center of gravity (S) in mm The determined input air pressure (P) must be within the operat OPS en

17 Assembly ing pressure range of theops, ( 5, Page 8). Module OPS 80 Fig. 10 Calculation input air pressure OPS 80 Module OPS 100 Fig. 11 Calculation input air pressure OPS OPS en 17

18 Assembly Module OPS 160 Fig. 12 Calculation input air pressure OPS 160 Module OPS 200 Fig. 13 Calculation input air pressure OPS OPS en

19 Assembly Module OPS 300 (special) Fig. 14 Calculation input air pressure OPS 300 (special) OPS en 19

20 Troubleshooting Troubleshooting OPS does not react? Possible cause Corrective action Operating pressure is too high Check the operating pressure, ( 6.3.3, Page 15) 7.2 OPS does not lock? Possible cause Basic orientation is wrong Dirt in the piston area Corrective action Turn the module into basic orientation, ( 6.1, Page 9) Remove the cover, Clean the module and relubricate it. ( 8, Page 21) operating pressure is too low Check the operating pressure, ( 6.3.3, Page 15) Piston seal is dammaged Renew the sealings, ( 8, Page 21) 7.3 No electrical signal? Possible cause Cable is not connected correctly The electrical outputs are misaligned The installed electrical signal transmitter are dammaged Break of cable Corrective action Check if the circular connectors and the miniature flat connectors are plugged in correctly.. Check, if strands are swapped. Observe Pinassignment.. Send the module to SCHUNK with a repair order.. Replace the cable OPS en

21 Maintenance and Care Maintenance and Care Notes Collision and Overload protection OPS is maintenance-free. Carefully clean the OPS from dirt with a soft cloth. Don t use any solvents. Pay attention that no dirt penetrates into piston area when OPS is depressurized. If an exchange of seals or O-Ring is necessary the OPS must be disassembled. ( 8.2, Page 22). The seals are in the enclosed sealing kit ( 9, Page 25). The sealing kit can only be ordered complete. NOTICE Proximity switches are poured in and can not be removed. If the proximity switches should be damaged, return theops for repair to SCHUNK OPS en 21

22 Maintenance and Care 8.2 Disassembly of the module NOTICE Do not disassemble parts without position number, bolts and set screw, otherwise the OPS must be newly adjusted. Fig. 15 Assembly drawing, example OPS Screw 7 Spring 2 Flange 8 Piston 3 Screw 9 Sealring 4 Sensor cap 10 O-ring 5 Screw 11 Cover 6 Housing 12 Sealring * Included in the seal kit OPS en

23 Maintenance and Care 1 Loosing the screws (1) at the flange (2) and disassemble the flange (2). 2 Loosing the Screws (3) of the sensor cap (4) and loosen the sensor cap (4). NOTE Sensor cap (4) must stay connected with the Cable. Do not disassemble the cable. 3 Loosing the screws (5) at the housing (6) and separate housing (6) and cover (11). WARNING! Spring (7) is installed under spring tension. 4 Take springs (7) and piston (8) out of the housing (6). 8.3 Renew seals and O-Ring Stick in the seal (9) at the flange (8) with Pattex, or any equivalent glue. Treat the O-Ring (10) on the cover (11) with Renolit HLT 2, or any equivalent grease. Stick in the seal (12) at the cover (11) with Loctite 480, or any equivalent glue OPS en 23

24 Maintenance and Care 8.4 Assembly of the module NOTICE Damage of the proximity switch cable Between housing and cover is only very little space. When cables lie to loose on the cover, they can be jammed during the assembly of the housing and the cover. Cable need to fit tightly on the side of the cover. When housing and cover get stuck together work carefully and do not jam any cables. 1 Insert spring (7) and piston (8) into the cover (11). 2 WARNING! The spring (7) is installed under spring tention. Plug the housing (6) on the cover (11) and screw it on with screws (5). 3 Screw in the sensor cap (4) with screws (3). 4 Plug the flange (2) on the alignment pin. 5 Mount flange (2) with screws (1) NOTICE! Glue the screws (1) at the flange (2) with Weicom AN , or any equivalent glue. Tightening torque OPS Screws between housing and cover [Nm] Screws flange [Nm] OPS en

25 Seal kit 9 Seal kit Content of the sealing kit: 2 x Seal ring 1 x O-ring ID.-No. of the seal kit Seal kit for ID number OPS OPS OPS OPS OPS OPS en 25

26 Enclosed pack 10 Enclosed pack Content of the accessories pack: 1 x Swiveling connection 1 x cable for sensors, ID number: Cylinder pin for mounting Screws for mounting ID.-No. of the accessory pack Accessory pack for ID number OPS OPS OPS OPS OPS OPS en

27 01.00 OPS en 27

28 OPS en