Rotary feed-through DDF 2
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1 Translation of the original operating manual Rotary feed-through DDF 2 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: /05/2016 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 DDF 2 en
3 Table of contents Table of contents 1 About this manual Presentation of Warning Labels Applicable documents Basic safety notes Intended use Not intended use Environmental and operating conditions Product safety Protective equipment Constructional changes Personnel qualification Personal protective equipment Notes on particular risks Warranty Scope of delivery Technical data Assembly Mounting the DDF on the robot Air connections Electrical connection Connector assignment Repositioning cable outlet Trouble shooting The DDF lets out air when stopped Does the DDF let out air when in operation? Electric signals are not transmitted? Maintenance Lubricants/Lubrication points Life span of seals and slip rings Disassembling module for seal replacement Disassembling DDF 2 and DDF 2-P Disassembling DDF 2-E Servicing and assembling the module Assembly drawings Assembly drawing DDF 2 31E DDF 2 en 3
4 Table of contents 9.2 Assembly drawing DDF 2 31/40/ Assembly drawing DDF 2 40E/50E Assembly drawing DDF 2 31P/40P/50P Assembly drawing DDF /50-1/ Assembly drawing DDF 2 63E Assembly drawing DDF 2 63P Assembly drawing DDF 2 80/100/125/160/80-1/ Assembly drawing DDF 2 80E/100E/125E/160E Assembly drawing DDF 2 80P/100P/125P/160P Sealing kit Accessories kit Mechanical connection components accessory pack Electrical connections accessory pack DDF 2 en
5 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". Presentation of Warning Labels To make risks clear, the following signal words and symbols are used for safety notes. DANGER Danger for persons! Non-observance will inevitably cause irreversible injury or death. WARNING Dangers for persons! Non-observance 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. 1.2 Applicable documents General terms of business * Catalog data sheet of the purchased product * The documents marked with an asterisk (*) can be downloaded on our homepage DDF 2 en 5
6 Basic safety notes Basic safety notes Intended use The rotary feed-through was designed to transfer the energy (electrical signals and air) to the handling module in robotic applications with endless rotation. 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 12). 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 Any utilization that exceeds or differs from the appropriate use is regarded as misuse. 2.3 Environmental and operating conditions Required ambient conditions and operating conditions Incorrect ambient and operating conditions can make the product unsafe, leading to the risk of serious injuries, considerable material damage and/or a significant reduction to the product's life span. Make sure that the product is used only in the context of its defined application parameters, ( 5, Page 12). Observe maintenance and lubrication intervals, ( 8.2, Page 24). 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 DDF 2 en
7 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 is contained in the relevant chapters Protective equipment Provide protective equipment per EC Machinery Directive Constructional changes Making constructional changes Attachments and modifications, constructional changes and subsequent work, e.g. additional threads, drill holes and safety devices may impair the operation and safety or damage the product. Constructional changes may only be done with SCHUNK's permission. 2.5 Personnel qualification Inadequate qualifications of the personnel If the personnel working with the product is not sufficiently qualified, the result may be serious injuries and significant property damage. All work may only be performed by qualified personnel. Before working with the product, the personnel must have read and understood the complete assembly and operating manual. Observe the national safety regulations and rules and general safety instructions DDF 2 en 7
8 Basic safety notes Trained electrician Pneumatics specialist Hydraulic specialist Qualified personnel Instructed person Service personnel of the manufacturer 2.6 The following personal qualifications are necessary for the various activities related to the product: Due to their technical training, knowledge and experience, trained electricians are able to work on electrical systems, recognize and avoid possible dangers and know the relevant standards and regulations. Pneumatics specialists have been trained for this particular area of responsibility and know the relevant standards and regulations. Hydraulic specialists have been trained for this particular area of responsibility and knows the relevant standards and regulations. Due to its technical training, knowledge and experience, qualified personnel is able to perform the delegated tasks, recognize and avoid possible dangers and knows the relevant standards and regulations. Instructed persons were instructed by the operator about the delegated tasks and possible dangers due to improper behaviour. Due to its technical training, knowledge and experience, service personnel of the manufacturer is able to perform the delegated tasks and to recognize and avoid possible dangers. Personal protective equipment Using personal protective equipment Not wearing personal protective equipment while working with the product, may result in dangers that impact the personnel's safety and health. While working with the product, obeserve the health and safety regulations and wear the required personal safety equipment. Observe the valid safety and accident prevention regulations. In case of sharp edges and corners and rough surfaces, wear protection gloves. In case of hot surfaces, wear heat-resistant protection gloves. When dealing with hazardous substances, wear protection gloves and goggles. In case of moving parts, wear tight protection clothes DDF 2 en
9 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 module. Perform maintenance, modifications, and additions outside of the danger zone. For all work, secure the unit against accidental operation. Take a precautionary approach by maintenance and disassembly. Only specially trained staff should disassemble the module. CAUTION Possible risk of injury due to electrostatic energy! Components or assembly groups may become electrostatically charged. When touched, the electrostatic discharge can trigger a startle response, which can result in injuries. The operator must ensure that all components and assembly groups are included in the local equipotential bonding in line with the applicable regulations. NOTE The equipotential bonding must be installed by a specialist electrician in line with the applicable regulations, paying particular attention to the actual conditions in the working environment. The effectiveness of the equipotential bonding must be verified by a specialist electrician through regular safety measurements DDF 2 en 9
10 Basic safety notes WARNING Risk of injury from objects falling and being ejected! Falling and ejected objects during operation can lead to serious injury or death. The danger zone must be cordoned off by a protective barrier. WARNING Risk of injury due to unexpected movement of the machine/system! Switch off the energy supply DDF 2 en
11 Scope of delivery 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: Intended use in 1-shift operation Observe the mandatory maintenance and lubrication intervals Observe the environmental and operating conditions Parts touching the work piece and wear parts are not part of the warranty. 4 Scope of delivery The scope of delivery includes Rotary feed-through DDF 2 in der bestellten Variante. Accessory pack (mechanical connection) Accessory pack with cable connector (electrical connection) DDF 2 en 11
12 Technical data Technical data DDF Weight [kg] Max. rotation speed [min-1] Max. rotation speed [ /s] Constant torque [Nm]: pneumatic and electric pneumatic electric Starting torque [Nm] (after shutdown): pneumatic and electric pneumatic elektric Rotary movement Pressure range for sealed air 0,5-1 Energy transmission Air (compressed air up to 10 ba) 2x 2x 2x 4x 4x 4x 4x 4x Electrical energy electric signals,, with max. 60V; 1A x 4x 4x 6x 6x 6x 10x 10x Noise emission [db(a)] DDF Weight [kg] Max. rotation speed [min-1] Max. rotation speed [ /s] Constant torque [Nm] Starting torque [Nm] (after shutdown): Rotary movement Pressure range for sealed air 0,5-1 Energy transmission 5 Air (compressed air up to 10 ba) 4x 4x 4x 4x Electrical energy electric signals,, with max. 60V; 1A 6x 6x 10x 10x Noise emission [db(a)] DDF 2 en
13 Technical data Maximum lateral force P 31-E P 40-E DDF P 50-E P 63-E Max. lateral force F Q [N] Max. permitted mounted weight [kg] Max. dynamic bending moment [Nm] M x M y M z P 80-E P 100-E DDF P 125-E P 160-E Max. lateral force F Q [N] Max. permitted mounted weight [kg] Max. dynamic bending moment [Nm] M x M y M z This is the max. total of all loads (acceleration forces and torques, process forces etc.), which can affect a rotary feed-through. More technical data are included in the catalog data sheet. Whichever is the latest version DDF 2 en 13
14 Assembly 6 Assembly WARNING Risk of injury during assembly! Switch off the energy supply The torque support (shaft) must be mounted on the nonmoving housing of the robot. 2 Shaft with shaft-ø ( 6.1, Page 15) 3 Bracket on the DDF (included in the DDF scope of delivery) 4 The shaft for the torque support (torque pin) should run precisely parallel to the»middle axis«of the DDF and at a»right angle«(90 ) to the bracket DDF 2 en
15 Assembly 6.1 Levelness of the mounting surface Mounting the DDF on the robot The values apply to the whole mounting surface to which the product is mounted. Requirements for levelness of the mounting surface (Dimensions in mm) Diameter < 100 < 0.02 > 100 < 0.05 Permissible unevenness The following figure is an example image. It serves for illustration and assignment of the spare parts. Variations are possible depending on size and variant. Assembly of the DDF * deduction thread DDF 2 en 15
16 Assembly 1 Shaft for torque support 2 DDF bracket 3 Tool, e.g. PGN gripper type from SCHUNK 4 Robot with interface according to DIN ISO Rotary feed-through from SCHUNK 6 Cylindrical pin (in accessory pack) 7 Base with interface according to DIN ISO 9409 for connecting to robot 8 Seals for sealing air ducts between shaft and flange (in accessory pack) 9 Screws for mounting the base on the robot flange (in accessory pack)(number varies depending on the size) 10 Cylindrical pin for positioning the base with shaft 11 Shaft completely pre-assembled 12 Cylindrical pins for positioning the shaft and flange (only in connection with flange (14)) 13 Screws for fastening the shaft onto the base (number varies depending on the size) 14 Flange with interface DIN ISO 9409 for tool-mounting (e.g. gripper) (only optional - on special order) 15 Screws for assembly of shaft and flange (only in connection with flange (14)) Shaft-Ø of the torque support Type DDF 2 31 DDF 2 40 and 50 DDF and 50-1 DDF 2 63 DDF 2 80 and 100 DDF and DDF and 160 Shaft-Ø of the torque support Ø 9 mm Ø 11 mm Ø 11 mm Ø 11 mm Ø 17 mm Ø 23 mm Ø 23 mm 1 Fasten the base (7) on the robot interface with the screws (9) from the accessory pack.the cylindrical pin (6) from the accessory pack can be used for centering the base (7). 2 Insert the cylindrical pin (10) into the base DDF 2 en
17 Assembly Screw tightening torques 3 Place the completely assembled shaft (11) onto the base. NOTICE! This pre-assembled unit must not be separated 4 Screw together the shaft (11) and the base (7) with the screws (13). 5 Insert the seals (8 for sealing the air ducts) and insert the cylindrical pins (12) into the shaft. 6 Fasten the flange (optional, on special order) with the screws (15) onto the shaft (11). Screw M5 M6 M8 M10 M12 Tightening torque [Nm] 10 Nm 17 Nm 40 Nm 80 Nm 140 Nm 6.2 Air connections WARNING Risk of injury during connection! Switch off the energy supply. NOTICE Observe the requirements for the air supply ( 5, Page 12) DDF 2 en 17
18 Assembly The precise positions and options for the air connections are shown in the SCHUNK catalog. air connections 1 Air connections, robot side 2 Air connections, tool-side 3 Air purge connection Open only the air connections that are needed. Close unused main air connections using the screw plugs from the enclosed pack. For a hose-free direction connection, use the O-rings from the enclosed pack DDF 2 en
19 Assembly 6.3 Electrical connection WARNING Risk of injury from uncontrolled movements! If the energy supply is switched on or residual energy remains in the system, parts may move unexpectedly and cause serious injuries. Switch off energy supply. Make sure there is no residual energy in the system NOTE Electrical energy: max. 60 volts, 1 amp Connector assignment 1 Tool-side: Flange receptacle 2 Robot-side: Flanged panel plug DDF 2 en 19
20 Assembly Connector assignment Size DDF 2 31 / 40 / 50 Flange receptacle Flanged panel plug Notes DDF / 50-1 / 63 / 80 / 100 PIN 7 not connected DDF / / / 125 / 160 PIN L and M not connected DDF 2 en
21 Assembly Repositioning cable outlet Turning the flange receptacle In delivery status the cable outlet is tangentially attached to the tool-side. This position is suitable for SCHUNK cables. If another cable position is required, the cable outlet can be repositioned by turning the flange receptacle. 1 If necessary, loosen plugged in cables. 2 Loosen hexagon nut (1) and screws (6). 3 Carefully remove the bracket (2) with ring (3). 4 Pull the flange receptacle (4) carefully out of the rotary feedthrough. ATTENTION! Do not tension the cables. 5 Turn ring (3) in the bracket (2) in the desired twisting angle of the flange receptacle (4) (max. possible are 90 steps) 6 Turn the flange receptacle (4) by 90 or 180 and insert it in the bracket (2) with ring (3). ATTENTION! Do not turn the cable by more than 360. For the sizes of rotary feed-through 40-1/50-1/63/80/100, the nose of the ring (3) must be in the groove of the flange receptacle (4). For the sizes of rotary feed-through 80-1/100-1/125/160, the flattened sides of the flange receptacle must be on the corresponding sides of the ring (3). 7 Slightly tighten the hexagon nut (1) in order to attach the flange receptacle (4) with intermediate ring (3) to the bracket (2) DDF 2 en 21
22 Assembly Turning the flange connector 8 Put the cable carefully into the interior of the rotary feedthrough. ATTENTION! Do not bend or clamp the cable. 9 Position the sealing (5) flushly with the bottom side of the rotary feed-through and press the bracket (2) against the rotary feed-through. 10 Glue the screws (6) with screw locking "middle-tight" and tighten them firmly. 11 Firmly tighten the hexagon nut (1). In order to reposition the cable outlet on the robot-side, the flange connector must be repositioned according to the previously described steps DDF 2 en
23 Trouble shooting Trouble shooting The DDF lets out air when stopped Possible cause Corrective action Air connection not installed correctly. Tighten air connection.,( 6.2, Page 17) Unused air connections open. Close unused air connections. 7.2 Does the DDF let out air when in operation? Possible cause Components have come loose e.g. due to overloading. Corrective action Sent the product to SCHUNK with a repair order.or disassemble the product. 7.3 Electric signals are not transmitted? Possible cause Cable connected incorrectly. Strands swapped. Bus signals should be transmitted. Slip ring defective. Corrective action Check circular connections and both miniature flat connections on the right seat. Check pin allocation. Bus signals can not be transmitted. Send the product to SCHUNK with a repair order DDF 2 en 23
24 Maintenance Maintenance Lubricants/Lubrication points SCHUNK recommends the lubricants listed. During maintenance, treat all greased areas with lubricant. Thinly apply lubricant with a lint-free cloth. Lubricant point Lubricant All seals Renolit HLT Life span of seals and slip rings NOTICE Damage caused by insufficient lubricant! Lubricants harden more quickly at temperatures above 60 C, leading to possible product damage. Reduce the lubricant intervals accordingly. Life span: Seals / slip rings Type Seals Slip rings Revolutions in millions Revolutions in millions DDF DDF 231P 10 DDF 231E 6 DDF DDF 240P 10 DDF 240E 6 DDF DDF DDF 250P 10 DDF 250E 6 DDF DDF DDF 263P DDF 2 en
25 Maintenance Type Seals Slip rings Revolutions in millions Revolutions in millions DDF 263E 6 DDF DDF 280P 8 DDF 280E 5 DDF DDF DDF 2100P 8 DDF 2100E 5 DDF DDF DDF 2125P 6 DDF 2125E 4 DDF DDF 2160P 6 DDF 2160E DDF 2 en 25
26 Maintenance 8.3 Disassembling module for seal replacement pneumatic feedthrough Disassembling DDF 2 and DDF 2-P Position of the position numbers ( 9, Page 29) NOTICE Do not damage any seals during assembly. 1 Remove compressed air lines. 2 Detach cable connections. 3 Completely unscrew screws (30 and 34). 4 NOTICE! Robot flange (3) and shaft (1) are bolted (21) together Pull shaft (2) down from base (3). 5 Unscrew screws (22). 6 Unscrew screws (44). 7 NOTICE! Tool flange (1) and shaft (2) are bolted together (20) Pull tool flange (1) carefully from the shaft (2). 8 Push shaft (2) carefully out of the ring (4). 9 Unscrew screws (17). 10 Push the sleeves (10 and 14) with the seals carefully out of the ring (4). 11 Remove all seals according to sealing kit list.( 10, Page 39) electrical feedthrough Position of the position numbers ( 9, Page 29) NOTICE Treat the slip ring contacts of the electrical feed-through with the greatest possible care and do not touch them. 1 Remove compressed air lines. 2 Detach cable connections DDF 2 en
27 3 Completely unscrew screws (30 or 34). Maintenance 4 NOTICE! Robot flange (3) and shaft (1) are bolted (21) together Pull shaft (2) from robot flange (3). 5 Unscrew screws (22). 6 Unscrew screws (44). 7 NOTICE! Tool flange (1) and shaft (2) are bolted together (20) Pull tool flange (1) carefully from the shaft (2). 8 Unscrew screws (47) carefully. 9 Remove washer (8). 10 NOTICE! The contacts of the slip ring unit must not come into contact with other parts or be touched. Pull the protective housing (6) carefully from the tool flange (1). 11 Remove all seals according to sealing kit list.( 10, Page 39) DDF 2 en 27
28 Maintenance Disassembling DDF 2-E Position of the position numbers ( 9, Page 29) 1 Detach cable connections. 2 Completely unscrew screws (30). 3 NOTICE! Tool flange (1) and robot flange (13) are bolted together Pull tool flange (1) carefully down from robot flange (13). 4 for DDF 2-31-E: Completely unscrew screws (22). 5 Unscrew screws (47) carefully. 6 Unscrew washer (8 or 37). 7 NOTICE! The contacts of the slip rings must not come into contact with other parts or be touched. Pull protective housing (6 or 35) carefully down from the tool flange. 8 Remove all seals according to sealing kit list.( 10, Page 39) 8.4 Maintenance Servicing and assembling the module Clean all parts thoroughly and check for damage and wear. Replace all wear parts and seals. The seals are in the enclosed sealing kit. ( 10, Page 39) Treat all greased areas with lubricant. ( 8.1, Page 24) Oil or grease bare external steel parts. Assembly Assembly takes place in the opposite order to disassembly. Observe the following: Unless otherwise specified, secure all screws and nuts with Loctite no and tighten with the appropriate tightening torque. Screw tightening torques Screw M5 M6 M8 M10 M12 Tightening torque [Nm] 10 Nm 17 Nm 40 Nm 80 Nm 140 Nm DDF 2 en
29 Assembly drawings Assembly drawings Assembly drawing DDF 2 31E Assembly drawing DDF 2 31E * Wearing part, replace during maintenance. Included in the seal kit. Seal kit can only be ordered completely. ** Contained in accessory pack. *** Optional - only in connection with item DDF 2 en 29
30 Assembly drawings 9.2 Assembly drawing DDF 2 31/40/50 Assembly drawing DDF 2 31/40/50 * Wearing part, replace during maintenance. Included in the seal kit. Seal kit can only be ordered completely. ** Contained in accessory pack. *** Optional - only in connection with item DDF 2 en
31 Assembly drawings 9.3 Assembly drawing DDF 2 40E/50E Assembly drawing DDF 2 40E/50E * Wearing part, replace during maintenance. Included in the seal kit. Seal kit can only be ordered completely. ** Contained in accessory pack. *** Optional - only in connection with item DDF 2 en 31
32 Assembly drawings 9.4 Assembly drawing DDF 2 31P/40P/50P Assembly drawing DDF 2 31P/40P/50P * Wearing part, replace during maintenance. Included in the seal kit. Seal kit can only be ordered completely. ** Contained in accessory pack. *** Optional - only in connection with item DDF 2 en
33 Assembly drawings 9.5 Assembly drawing DDF /50-1/63 Assembly drawing DDF /50-1/63 * Wearing part, replace during maintenance. Included in the seal kit. Seal kit can only be ordered completely. ** Contained in accessory pack. *** Optional - only in connection with item DDF 2 en 33
34 Assembly drawings 9.6 Assembly drawing DDF 2 63E Assembly drawing DDF 2 63E * Wearing part, replace during maintenance. Included in the seal kit. Seal kit can only be ordered completely. ** Contained in accessory pack. *** Optional - only in connection with item DDF 2 en
35 Assembly drawings 9.7 Assembly drawing DDF 2 63P Assembly drawing DDF 2 63P * Wearing part, replace during maintenance. Included in the seal kit. Seal kit can only be ordered completely. ** Contained in accessory pack. *** Optional - only in connection with item DDF 2 en 35
36 Assembly drawings 9.8 Assembly drawing DDF 2 80/100/125/160/80-1/100-1 Assembly drawing DDF 2 80/100/125/160/80-1/100-1 * Wearing part, replace during maintenance. Included in the seal kit. Seal kit can only be ordered completely. ** Contained in accessory pack. *** Optional - only in connection with item DDF 2 en
37 Assembly drawings 9.9 Assembly drawing DDF 2 80E/100E/125E/160E Assembly drawing DDF 2 80E/100E/125E/160E * Wearing part, replace during maintenance. Included in the seal kit. Seal kit can only be ordered completely. ** Contained in accessory pack. *** Optional - only in connection with item DDF 2 en 37
38 Assembly drawings 9.10 Assembly drawing DDF 2 80P/100P/125P/160P Assembly drawing DDF 2 80P/100P/125P/160P * Wearing part, replace during maintenance. Included in the seal kit. Seal kit can only be ordered completely. ** Contained in accessory pack. *** Optional - only in connection with item DDF 2 en
39 Sealing kit 10 Sealing kit ID.-No. of the seal kit Seal kit for ID number DDF DDF2 31P DDF2 31E DDF2 40 / DDF2 40P / 50P DDF2 40E / 50E DDF2 63 / 40-1 / DDF2 63P DDF2 63E DDF2 80 / DDF2 80P / 100P DDF / / 125 / DDF2 80E/ 100E DDF2 125P / 160P DDF2 125E / 160E Contents of the sealing kit, ( 9, Page 29) DDF 2 en 39
40 Accessories kit Accessories kit Mechanical connection components accessory pack ID.-No. of the accessory pack Accessory pack for ID number DDF2 31 / 31P / 31E DDF2 40 / 40P / 40E DDF2 50 / 50P / 50E DDF2 63 / 63P / 50-1 / DDF2 63E DDF2 80 / 80P DDF2 80E / 100E DDF / DDF2 100 / 100P DDF2 125 / 125P DDF Content of the accessories pack: ( 9, Page 29) Electrical connections accessory pack Contents: Plug and socket ID.-No. of the accessory pack Accessory pack for ID number DDF2 31 / 31E DDF2 40 / 40E DDF2 50 / 50E DDF2 63 / 63E / 50-1 / DDF2 80 / 80E / 100E DDF / DDF DDF2 125 / 125E / 160E DDF DDF 2 en
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