Original Operating Manual Assembly and Operating Manual SWS Gripper-Change-System
Imprint Imprint Copyright: This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights reserved. Any reproduction, processing, distribution (making available to third parties), translation or other usage - even excerpts - of the manual is especially prohibited and requires our written approval. Technical changes: We reserve the right to make alterations for the purpose of technical improvement. Document number: 0389456 Version: 07.00 25/08/2017 en SCHUNK GmbH & Co. KG All rights reserved. Dear Customer, thank you for trusting our products and our family-owned company, the leading technology supplier of robots and production machines. Our team is always available to answer any questions on this product and other solutions. Ask us questions and challenge us. We will find a solution! Best regards, Your SCHUNK team SCHUNK GmbH & Co. KG Spann- und Greiftechnik Bahnhofstr. 106 134 D-74348 Lauffen/Neckar Tel. +49-7133-103-0 Fax +49-7133-103-2399 info@de.schunk.com schunk.com 2
Table of contents Table of contents 1 General... 6 1.1 About this manual... 6 1.1.1 Presentation of Warning Labels... 6 1.1.2 Applicable documents... 7 1.1.3 Sizes... 7 1.2 Warranty... 7 1.3 Scope of delivery... 8 1.4 Accessories... 9 1.4.1 SWD Dust Cover for SWA quick-change adapter... 9 2 Basic safety notes... 11 2.1 Intended use... 11 2.2 Not intended use... 11 2.3 Constructional changes... 11 2.4 Spare parts... 11 2.5 Environmental and operating conditions... 11 2.6 Personnel qualification... 12 2.7 Personal protective equipment... 12 2.8 Notes on safe operation... 13 2.9 Transport... 13 2.10 Malfunctions... 13 2.11 Disposal... 13 2.12 Fundamental dangers... 14 2.12.1 Protection during handling and assembly... 14 2.12.2 Protection during commissioning and operation... 14 2.12.3 Protection against dangerous movements... 14 2.13 Notes on particular risks... 15 3 Technical Data... 18 4 Product Overview... 20 4.1 Quick-change Head (SWK)... 20 4.2 Quick-change adapter (SWA)... 21 4.3 Optional Modules... 21 5 Assembly... 22 5.1 Example of mounting... 22 5.2 Interface Plate Design and Mounting... 23 5.3 Requirements of the storage magazine... 24 5.4 Mechanical connection... 27 5.4.1 Fastening of the quick-change head (SWK)... 27 5.4.2 Fastening the quick-change adapter (SWA)... 28 3
Table of contents 5.4.3 Tightening torque... 28 5.5 Pneumatic connection... 31 5.6 Valve Requirements and Connections... 31 5.7 Pneumatic plan... 32 5.8 Sensors - Piston Stroke Control... 32 5.8.1 Function Stroke Control of the piston SWS-011 and Larger... 33 5.8.2 Integrated Proximity Switch - SWS 040Q/076/110/160... 34 5.8.3 Typ Lock and Unlock Sensors... 34 5.8.4 Sensors... 34 5.9 Optional Module Installation... 35 5.9.1 Electrical Module Installation E10/E20 - SWS-005 and SWS-011... 35 5.9.2 Electrical Module Removal E10/E20 - SWS-005 and SWS-011... 35 5.9.3 SWK Electrical Module Installation A15/B15 - SWS-005 and SWS-011... 36 5.9.4 SWA Electrical Module Removal E10/E20 - SWS-005 and SWS-011... 37 5.9.5 Flat A Optional K Series Module Installation - SWS-020 and SWS-021... 38 5.9.6 Flat A Optional K Series Module Removal - SWS-020 and SWS-021... 38 5.9.7 Flat B Optional Module Installation - SWS-021... 39 5.9.8 Flat B Optional Module Removal - SWS-021... 39 6 Operation... 40 6.1 Conditions for Coupling... 40 6.2 Fail-Safe Operation... 41 6.3 Conditions for Uncoupling... 42 7 Trouble shooting... 43 7.1 The Quick-Change-Head (balls) doesn t move?... 43 7.2 The Quick Change Head does not clamp the Quick- Change-Adaptor correctly?. 43 7.3 The clamping force between SWK and SWA is reducing?... 43 8 Maintenance and Care... 44 8.1 Preventive Maintenance... 44 8.2 Lubrication... 46 8.2.1 External... 46 8.2.2 Internal... 46 8.3 Cleaning and Lubrication of the Locking Mechanism... 46 8.3.1 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins... 46 8.3.2 Cleaning the Bearing Race and Alignment Pin Bushings (SWA)... 47 8.4 Service of the sensors... 48 4
Table of contents 8.4.1 Proximity Sensor Adjustment, Test, or Replacement - SWS-011... 48 8.4.2 Proximity Sensor Adjustment, Test, or Replacement - SWS 020/021/040/060/071/100/150... 50 8.4.3 Lock and Unlock Sensor Assembly Replacement (with Sensor Assemblies for SWS 040Q, 076, 110, 160)... 52 8.5 Rubber Bushings... 53 8.5.1 Seal Inspection and Replacement for Electrical Modules... 54 8.6 Alignment Pins... 55 8.7 Disassembly of the SWK Quick-Change Master... 56 8.7.1 Disassembly of SWK 005-011... 56 8.7.2 Disassembly of SWK 020-300... 57 9 Assembly drawings... 58 9.1 Assembly SWS-005/011... 58 9.2 Assembly SWS-020/021/041/060/071/150/300... 59 9.3 Assembly SWS-027... 60 9.4 Assembly SWS-076/110/160... 61 10 Seal kit... 62 11 Translation of original declaration of incorporation... 63 11.1 Annex to Declaration of Incorporation... 64 5
General 1 General 1.1 About this manual This manual contains important information for a safe and appropriate use of the product. This manual is an integral part of the product and must be kept accessible for the personnel at all times. Before starting work, the personnel must have read and understood this operating manual. Prerequisite for safe working is the observance of all safety instructions in this manual. Illustrations in this manual are provided for basic understanding and may differ from the actual product design. In addition to these instructions, the documents listed under Applicable documents [} 7] are applicable. 1.1.1 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. 6
General 1.1.2 Applicable documents 1.1.3 Sizes General terms of business* Catalog data sheet of the purchased product * Assembly and operating manuals of the accessories * The documents marked with an asterisk (*) can be downloaded on our homepage schunk.com This operating manual applies to the following sizes: SWS 005 SWS 011 SWS 020 SWS 021 SWS 022 SWS 027 SWS 040 SWS 040Q SWS 041 SWS 060 SWS 071 SWS 076 SWS 110 SWS 150 SWS 160 SWS 300 1.2 Warranty If the product is used as intended, the warranty is valid for 24 months from the ex-works delivery date under the following conditions: Observe the maximum service life. Technical Data [} 18] Observe the ambient conditions and operating conditions, Link Ungebungs- und Einsatzbedingungen Observe the specified maintenance and lubrication intervals, Maintenance and Care [} 44] Parts touching the workpiece and wear parts are not included in the warranty. 7
General 1.3 Scope of delivery The scope of delivery includes Quick-Change-System SWS in the version ordered, containing the following components: SWK quick-change head SWA quick-change adapter Accessory pack Cylindrical pin Mounting screw (Size 005 071) Fastening of the quickchange head (SWK) [} 27] 8
General 1.4 Accessories A wide range of accessories is available for this module. For information about which accessories can be used with the appropriate product version catalog. 1.4.1 SWD Dust Cover for SWA quick-change adapter SWD dust cover 1 electrical option 3 SWD 2 SWK 4 SWA The SWD dust cover is available in the following sizes Size Designation ID number for electrical option (1) 020 SWD-020-K00-000 0302252 K19/K26 (connection side A) 021 SWD-021-K00-000 0302253 K19/K26 (connection side A) 040 SWD-040-R00-000 0302254 R19/R26 (connection side A) 041 SWD-041-R00-000 0302255 R19/R26 (connection side A) 060 SWD-060-K00-000 0302256 K19/K26 (connection side A) 071 SWD-071-R00-000 0302257 R19/R26 (connection side A) 076 SWD-076-000-R00 0302258 R19/R26 (connection side B) 110 SWD-110-R00-000 0302260 R19/R26 (connection side A) 150 SWD-150-R00-000 0302261 R19/R26 (connection side A) In order to avoid contamination of the pneumatic feedthrough openings, as well as of the contacts of the electric options at the SWA quick- change tool, an SWD dust cover has to be used while it is located in the storage rack. 9
General The SWD is equipped with an integrated clamping device, which is actuated by locking/ unlocking the SWK quick-change head. Hereby the SWD dust cover can be removed from the SWA quickchange adapter and can be located onto a further SWA quickchange adapter. The SWD dust cover (material PA2220) is protecting the SWA quick-change adapter against the following contaminations: Dust Chips Various liquids (e.g. coolant) NOTE The SWD dust cover is only suitable for covering the SWA quickchange tool. It never should be used for transporting the SWA quick-change tool together with the attached tools. If the SWD dust cover should be used in extremely dirty conditions, an excessive filling of the interior of the SWK quickchange master mounting with dirt particles has to be avoided. Therefore, regular control and possible cleaning of the SWK will be necessary. In case of excessive contamination there will be the risk that the locking mechanism of the SWK will not completely move into its final position, and the SWD will get damaged. 10
2 Basic safety notes Basic safety notes 2.1 Intended use The product (SWS quick-change systems, consisting of SWK quickchange head and SWA quick-change adapter) was designed for a quick changing of parts and automation components at a robot in the context of its technical data. The product may only be used within the scope of its technical data, Technical Data [} 18]. When implementing and operating components in safety-related parts of the control systems, the basic safety principles in accordance with DIN EN ISO 13849-2 apply. The proven safety principals in accordance with DIN EN ISO 13849-2 also apply to categories 1, 2, 3 and 4. The product is intended for installation in a machine. The applicable guidelines must be observed and complied with. The product is intended for industrial and industry-oriented use. 2.2 Not intended use It is not intended use if the product is used, for example, as a pressing tool, stamping tool, lifting gear, guide for tools, cutting tool, clamping device or a drilling tool. Any utilization that exceeds or differs from the appropriate use is regarded as misuse. 2.3 Constructional changes Implementation of structural changes By conversions, changes, and reworking, e.g. additional threads, holes, or safety devices can impair the functioning or safety of the product or damage it. Structural changes should only be made with the written approval of SCHUNK. 2.4 Spare parts Use of unauthorized spare parts Using unauthorized spare parts can endanger personnel and damage the product or cause it to malfunction. Use only original spare parts or spares authorized by SCHUNK. 2.5 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. See also Link Ungebungs- und Einsatzbedingungen. 11
Basic safety notes Trained electrician Qualified personnel Instructed person Service personnel of the manufacturer 2.6 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. 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. 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. 2.7 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, observe 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. 12
Basic safety notes 2.8 Notes on safe operation Incorrect handling of the personnel Incorrect handling and assembly may impair the product's safety and cause serious injuries and considerable material damage. Avoid any manner of working that may interfere with the function and operational safety of the product. Use the product as intended. Observe the safety notes and assembly instructions. Do not expose the product to any corrosive media. This does not apply to products that are designed for special environments. Eliminate any malfunction immediately. Observe the care and maintenance instructions. Observe the current safety, accident prevention and environmental protection regulations regarding the product's application field. 2.9 Transport Handling during transport Incorrect handling during transport may impair the product's safety and cause serious injuries and considerable material damage. When handling heavy weights, use lifting equipment to lift the product and transport it by appropriate means. Secure the product against falling during transportation and handling. Stand clear of suspended loads. 2.10 Malfunctions Behavior in case of malfunctions Immediately remove the product from operation and report the malfunction to the responsible departments/persons. Order appropriately trained personnel to rectify the malfunction. Do not recommission the product until the malfunction has been rectified. Test the product after a malfunction to establish whether it still functions properly and no increased risks have arisen. 2.11 Disposal Handling of disposal The incorrect handling of disposal may impair the product's safety and cause serious injuries as well as considerable material and environmental harm. Follow local regulations on dispatching product components for recycling or proper disposal. 13
Basic safety notes 2.12 Fundamental dangers General Observe safety distances. Never deactivate safety devices. Before commissioning the product, take appropriate protective measures to secure the danger zone. Disconnect power sources before installation, modification, maintenance, or calibration. Ensure that no residual energy remains in the system. If the energy supply is connected, do not move any parts by hand. Do not reach into the open mechanism or movement area of the product during operation. 2.12.1 Protection during handling and assembly Incorrect handling and assembly Incorrect handling and assembly may impair the product's safety and cause serious injuries and considerable material damage. Have all work carried out by appropriately qualified personnel. For all work, secure the product against accidental operation. Observe the relevant accident prevention rules. Use suitable assembly and transport equipment and take precautions to prevent jamming and crushing. Incorrect lifting of loads Falling loads may cause serious injuries and even death. Stand clear of suspended loads and do not step into their swiveling range. Never move loads without supervision. Do not leave suspended loads unattended. 2.12.2 Protection during commissioning and operation Falling or violently ejected components Falling and violently ejected components can cause serious injuries and even death. Take appropriate protective measures to secure the danger zone. Never step into the danger zone during operation. 2.12.3 Protection against dangerous movements Unexpected movements Residual energy in the system may cause serious injuries while working with the product. Switch off the energy supply, ensure that no residual energy remains and secure against inadvertent reactivation. 14
Basic safety notes Never rely solely on the response of the monitoring function to avert danger. Until the installed monitors become effective, it must be assumed that the drive movement is faulty, with its action being dependent on the control unit and the current operating condition of the drive. Perform maintenance work, modifications, and attachments outside the danger zone defined by the movement range. To avoid accidents and/or material damage, human access to the movement range of the machine must be restricted. Restrict unintentional access by persons to this range e.g. via a protective cover, protective fence or photoelectric barrier. The protective cover and protective fence must be rigid enough to withstand the maximum possible movement energy. EMER- GENCY STOP switches must be easily and quickly accessible. Check the function of the EMREGENCY STOP before starting up the machine or system. If this protective equipment is not working properly, prevent the operation of the machine. 2.13 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. 15
Basic safety notes 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. WARNING Risk of injury from objects falling and being ejected! Falling and ejected objects during operation can lead to serious injury or death. Take appropriate protective measures to secure the danger zone. WARNING Risk of injury due to unexpected movement of the machine/system! Switch off the energy supply. WARNING Remove all temporary protective materials (caps, plugs, tape, etc.) on locking face of Tool Changer and modules prior to operation. Failure to do so will result in damage to Tool Changers, modules, and end-of-arm tooling and could cause injury to personnel. WARNING Injury or equipment damage can occur with power or air on. Do not perform maintenance or repair on Tool Changer or modules with power or air on. Turn off power and air before performing maintenance or repair on Tool Changer or modules. 16
Basic safety notes WARNING During operation, the area between the Quick-Chance-Head SWK and Quick Change Adapter SWA must be kept clear. Failure to keep area clear will result in damage to Tool Changer, modules, or end-of-arm tooling and could cause injury to personnel. WARNING Using the Tool Changer in applications other than intended will result in damage to Tool Changer, modules, or end-of-arm tooling and could cause injury to personnel. The Tool Changer is only to be used for intended applications and applications approved by the manufacturer. CAUTION The SWK locking mechanism must not be actuated without being mounted to the robot interface plate. Damage to the Cover Plate and O-ring may result. Always attach the SWK to the Robot interface plate prior to attempting any operations. 17
Technical Data Designation 3 Technical Data More technical data is included in the catalog data sheet. Whichever is the latest version. 005 011 020 021 022 027 040 040Q 041 Weight [kg] 0.36 0.22 0.99 0.8 0.8 1.39 1.85 1.85 2.1 Recommended handling weight [kg] 8 16 25 38 50 50 Locking force 690 1100 2300 2300 3500 4500 5600 4500 (at 5.5 bar) [N] Maximum distance on locking [mm] min. 1.5 0 0 0 0 max. 3.0 3.0 2.0 3.0 3.0 Repeatability [at 2 Mio. cycles] 0.015 0.01 0.015 0.015 Noise emission [db(a)] 70 Pressure medium Compressed air, compressed air quality according to ISO 8573-1:7 4 4 Designation SWS SWS 060 071 076 110 150 160 300 Weight [kg] 2.0 3.1 3.65 6.2 7.5 9.3 19.1 Recommended handling weight [kg] 75 79 100 150 200 300 450 Locking force 7400 8100 12000 16000 31000 35000 (at 5.5 bar) [N] Maximum distance on locking [mm] min. 0 0 0 0 0 0 max. 3.0 2.0 3.0 2.0 2.0 2.5 Repeatability [at 2 Mio. cycles] 0.015 Pressure medium Compressed air, compressed air quality according to ISO 8573-1:7 4 4 18
Technical Data Designation SWS Ambient temperature [ C] min. +5 max. +60 IP protection class (in lockled 40 state) * Noise emission [db(a)] 70 * For use in dirty ambient conditions (e.g. sprayed water, vapors, abrasion or processing dust) SCHUNK offers corresponding product options as standard. SCHUNK also offers customized solutions for special applications in dirty ambient conditions. 19
Product Overview 4 Product Overview 4.1 Quick-change Head (SWK) The Quick-change Head (SWK) includes an anodized aluminum body, a hardened stainless-steel locking mechanism, and hardened steel alignment pins. The SWK has sides for mounting of optional modules. The locking mechanism consists of a cam, a male coupling, and chrome-steel ball bearings. Tapered pins located on the SWK are inserted in the bushings in the SWA to ensure repeatable alignment during the coupling process. An extreme pressure grease is applied to the cam, male coupling, ball bearings, and pins to enhance performance and maximize the life of the SWK Two port connections are available to supply air pressure for coupling and uncoupling the tool changer, Pneumatic connection [} 31] Port connections are available for pass through air for supplying air to tools. A mounting pattern is machined into the SWK for mounting to a robot arm or a robot interface plate. Cam Alignment pins (2x) Male coupling Ball bearing Proximity sensor assembly location (RTL signal) SWK Lock and unlock ports Ports for air feed through Proximity sensor assembly location (Lock/Unlock signal) For safe monitoring of the end position of the SWK s locking mechanism we are recommending the use of a piston stroke control. Stroke control of the piston available for Models SWS-011 and Larger. 20
Product Overview 4.2 Quick-change adapter (SWA) A mounting pattern is machined into the quick-change head (SWA) for mounting to a customer tooling or a tooling interface plate. Ports for air feed through Bearing race Proximity sensor target (RTL) Alignment pin bushing (2x) SWA 4.3 Optional Modules There are flats available for mounting of the optional modules for support of various utility pass-through, such as signal, fluid/air, and electric. SCHUNK website gives assistance in choosing the right modules. For information about which optional modules can be used with the appropriate product version, see catalog. 21
Assembly 5 Assembly 5.1 Example of mounting 1 Robot arm 2 Interface plate (optional or supplied by user) 3 Piston cover plate (not necessary if sealing is provided by interface plate (2)) 4 Fastening screws (provided) 5 SWK 6 SWA 7 Interface plate for end-effector (supplied by user) An optional custom interface plate with a mounting hole pattern on one side for the robot and the other for the SWK provides adaptation between the two (consult the catalog for fastener and locating pin specifics). The end-effector is attached to the tool typically by using an interface plate designed and provided by the user (The required information is provided in the catalog for each model). Pneumatic lines and electrical cables attached, bundled, and strain relieved in such a manner to allow for freedom of movement during operation. 22
Assembly 5.2 Interface Plate Design and Mounting All interface plates should be designed using two locating features per interface. The SWA/end-effector interface should utilize the diameter of the SWA and a dowel pin for location. A piston cover plate is provided with the sizes SWS 005/011/020/021/040/041/060/071/150/300 at the SWK quickchange head. If the robot interface plate provides sealing for the piston cylinder, then the cover plate is not necessary. Be careful when installing the O-ring, if the O-ring is not properly seated in the groove, it can be cut or damaged, resulting in a bad seal and air leakage. This can cause improper and/or unsafe operation. The robot interface plate must be properly designed to provide rigid mounting on the boss surfaces. The recommended dimensions for the interface plate bore, with and without the cover plate, are given on the respective catalog drawing for each model. The mating diameters must provide sufficient clearance so that mating corner radius do not interfere. NOTICE Failure to follow this advice when designing the robot interface plate may result in cover plate O-ring damage or loosening of the interface during operation. NOTICE Removable thread locker should be used for all mounting bolts. Failure to do so may cause vibration to loosen bolts over time. NOTICE Be careful when installing the O-ring. If the O-ring is not properly seated in the groove it can be cut or damaged, resulting in a bad seal. 23
Assembly 5.3 Requirements of the storage magazine CAUTION Tool Stand design is critical to proper operation of the quick changer. Improperly designed Tool Stands can cause misalignments that will cause jamming and/or excessive wear of SWS components. The SWAs may be stored in a Tool Stand when not being used by the robot. SCHUNK provides compatible Tool Stands designed for durability, longevity, and maximum adaptability to fit most customers applications. The SCHUNK Tool Stand system is compatible with SCHUNK quick-change sizes SWS-005 to SWS-300. The Tool Stand systems can be equipped with horizontal modules and different types of tool sensing. Visit the SCHUNK Web Site for products available for your specific application or contact SCHUNK for recommendations and assistance. If the customer is supplying the tool stand, it should be designed to provide a fixed, repeatable, level, and stable positions for tool pick-up and drop-off. The tool stand must support the weight of the SWA, Tool Interface Plate, optional modules, cables, hoses, and customer tooling without allowing deflection in excess of the offsets specified in Operation [} 40]. Ideally, the SWA should be hanging vertically in the Tool Stand so that gravity assists to uncouple the SWA from the SWK during unlocking. It is possible to design Tool Stands that hold tools in the horizontal position, but care must be taken that the necessary compliance is provided during coupling and uncoupling. In general, horizontal-position Tool Stands cause more wear on the locking mechanism and locating features of the SWA and Tool Stand. A variety of methods may be used to position the SWA in the Tool Stand. A common method is to use tapered alignment pins and bushings. Robot programming and positional repeatability are vital in tool pickup and drop-off Operation [} 40] It is highly recommended that the customer provide a sensor that detects the presence of a properly seated SWA in the Tool Stand. The sensor may be used prior to coupling to ensure there is a SWA properly seated in the stand. Sensors may also be used as the robot starts to move away after uncoupling. This provides a safety measure in the event that a SWA should become jammed in the stand or if the SWA should fail to release properly from the robot. 24
Assembly Proximity sensors should be positioned so that the sensing face is vertical to prevent metal shavings, weld spatter, or other debris from falling on the sensor and creating false readings. Tool Stands may also need to incorporate means for covering SWAs and modules to protect them in dirty environments, such as grinding or welding. Alternatively, positioning Tool Stands in areas shielded from weld spatter, fluids, adhesives, or other debris would eliminate the need for tool covers. In order to avoid contamination of the pneumatic feedthrough openings, as well as of the contacts of the electric options at the SWA quick-change tool, an SWD dust cover has to be used while it is located in the storage rack. SWD Dust Cover for SWA quickchange adapter [} 9] 25
Assembly SWK SWA Z Y Cocking Offset (About X and Y) Twisting Offset (About Z) Offset Definitions X X, Y and Z Offset Maximum Recommended Offsets Prior to Coupling Size No-Touch Z Offset (Max)* [mm] X and Y Offset (Max)** [mm] Cocking Offset (Max) [degrees] SWS 005 +3 ± 1 ± 1.1 ± 2 SWS 011 +3 ± 1 ± 0.8 ± 2 SWS 020 SWS 021 SWS 022 SWS 027 +2 ± 1 ± 0.8 ± 2 SWS 040 +3 ± 2 ± 1 ± 2 SWS 040Q +3 ± 2 ± 1 ± 2 SWS 041 +3 ± 2 ± 1 ± 2 SWS 060 +3 ± 2 ± 0.6 ± 1 SWS 071 SWS 076 +2 ± 1 ± 0.7 ± 1 SWS 110 +3 ± 1 ± 0.7 ± 1 SWS 150 +2 ± 2 ± 0.7 ± 1 SWS 160 +2 ± 2 ± 0.7 ± 1 SWS 300 + 2.5 ± 3 ± 0.6 ± 1 Twisting Offset (Max) [degrees] * Maximum values shown. Decreasing actual values will minimize wear during coupling/uncoupling. ** Actual allowable values may be higher in some cases, but higher offsets will increase wear during coupling. 26
Assembly 5.4 Mechanical connection WARNING Risk of injury when the machine/system moves unexpectedly! Switch off power supply. Evenness of the mounting surface The values apply to the whole mounting surface to which the product is mounted. Requirements for evenness of the mounting surface (Dimensions in mm) Edge length Permissible unevenness < 100 < 0.02 > 100 < 0.05 5.4.1 Fastening of the quick-change head (SWK) Fastening of the quick-change master For centering purposes, use the cylinder pin (2) out of the enclosed pack. You can fasten the quick-change head (SWK) with the screws (1). mounting screws Size screws (1) Quantity 005 M3 x 25 mm / DIN EN ISO 4762 4 * 011 M3 x 25 mm / DIN EN ISO 4762 4 * 011 HM M3 x 30 mm 12.9 / DIN EN ISO 4762 4 * 020 M4 x 30 mm / DIN EN ISO 10642 4 * 020 HM M4 x 30 mm / DIN EN ISO 4762 5 * 021 M4 x 35 mm / DIN EN ISO 10642 4 * 021 HM M4 x 30 mm 12.9 / DIN EN ISO 4762 6 * 022 M6 x 30 mm / DIN EN ISO 4762 4 * 027 M4 x 50 mm / DIN EN ISO 4762 6 * 040 M5 x 35 / DIN EN ISO 4762 6 * 040Q M5 x 45 / DIN EN ISO 4762 6 * 27
Assembly Size screws (1) Quantity 041 M5 x 40 / DIN EN ISO 4762 6 * 060 M6 x 40 / DIN EN ISO 10642 6 * 071 M6 x 40 / DIN EN ISO 4762 6 * 076 M10 x 55 / DIN EN ISO 4762 6 110 M10 x 50 / DIN EN ISO 4762 6 150 M10 x 60 / DIN EN ISO 4762 6 160 M10 x 60 / DIN EN ISO 4762 6 300 M12 x 70 / DIN EN ISO 4762 6 * screws are contained in the accessory pack 5.4.2 Fastening the quick-change adapter (SWA) Size of the fastening screws Size SWA 005/011 020/021 040/040Q/ 041/060/ 071 076/110/ 150/160 300 M5 M6 M8 M10 M12 5.4.3 Tightening torque NOTE The listed tightening torques are recommendations. The material of the adapter plates and the conditions during the assembly must be always taken into account. Size 005, 011 Type of Screw Thread Size Strength Class Tightening Torque [Nm] Thread Locker Robot-side adapter plate on SWK Socket head cap M3 12.9 1.2 Loctite 222 Tool-side adapter plate on SWA Socket head cap M5 12.9 5.1 Loctite 222 Socket flat head cap 4 Size 020, 021 Type of Screw Thread Size Strength Class Tightening Torque [Nm] Thread Locker Robot-side adapter plate on SWK Socket flat head cap M4 12.9 1.2 Loctite 222 Tool-side adapter plate on SWA 28
Assembly Type of Screw Thread Size Strength Class Tightening Torque [Nm] Thread Locker Socket head cap M6 12.9 10.2 Loctite 242 Socket flat head cap 6.8 Size 040, 040Q, 041 Type of Screw Thread Size Strength Class Tightening Torque [Nm] Thread Locker Robot-side adapter plate on SWK Socket head cap M5 12.9 5.1 Loctite 222 Tool-side adapter plate on SWA Socket head cap M8 12.9 16 Loctite 242 Socket flat head cap 9.6 Size 060 Type of Screw Thread Size Strength Class Tightening Torque [Nm] Thread Locker Robot-side adapter plate on SWK Socket flat head cap M6 12.9 6.8 Loctite 242 Tool-side adapter plate on SWA Socket head cap M8 12.9 16 Loctite 242 Socket flat head cap 9.6 Size 071 Type of Screw Thread Size Strength Class Tightening Torque [Nm] Thread Locker Robot-side adapter plate on SWK Socket head cap M6 12.9 10.2 Loctite 242 Tool-side adapter plate on SWA Socket head cap M8 12.9 16 Loctite 242 Socket flat head cap 9.6 Size 076 Type of Screw Thread Size Strength Class Tightening Torque [Nm] Thread Locker Robot-side adapter plate on SWK Socket head cap M10 12.9 52 Loctite 242 Tool-side adapter plate on SWA Socket head cap M10 12.9 52 Loctite 242 29
Assembly Size 110 Type of Screw Thread Size Strength Class Tightening Torque [Nm] Thread Locker Robot-side adapter plate on SWK Socket head cap M10 12.9 75 Loctite 242 Tool-side adapter plate on SWA Socket head cap M10 12.9 52 Loctite 242 Size 150 Type of Screw Thread Size Strength Class Tightening Torque [Nm] Thread Locker Robot-side adapter plate on SWK Socket head cap M10 12.9 75 Loctite 242 Tool-side adapter plate on SWA Socket head cap M10 12.9 75 Loctite 242 Size 160 Type of Screw Thread Size Strength Class Tightening Torque [Nm] Thread Locker Robot-side adapter plate on SWK Socket head cap M10 12.9 75 Loctite 242 Tool-side adapter plate on SWA Socket head cap M10 12.9 52 Loctite 242 Size 300 Type of Screw Thread Size Strength Class Tightening Torque [Nm] Thread Locker Robot-side adapter plate on SWK Socket head cap M12 12.9 120 Loctite 242 Tool-side adapter plate on SWA Socket head cap M12 12.9 95 Loctite 242 30
Assembly 5.5 Pneumatic connection WARNING Risk of injury due to unexpected movements! If the power supply is switched on or residual energy remains in the system, components can move unexpectedly and cause serious injuries. Before starting any work on the product: Switch off the power supply and secure against restarting. Ensure that no residual energy remains in the system. NOTICE Observe the requirements for the air supply Technical Data [} 18]. Size SWS 005 011 020 021 022 027 040 040Q Connection L (A) locked, U (B) unlocked M5 M5 M5 M5 M5 G 1/8" G 1/8" G 1/8" Size SWS 041 060 071 076 110 150 160 300 Connection L (A) locked, U (B) unlocked G 1/8" G 1/8" G 1/8" G 1/8" G 1/8" G 1/8" G 1/8" The air feed throughs for the SWA are marked on the SWK. G 1/4" 5.6 Valve Requirements and Connections As with all pneumatic piston arrangements, smooth operation requires proper porting of the supplied and vented air. It is recommended that a single 4-way valve be used to actuate the locking mechanism in the SWK. The valve may be of either 4-port or 5-port configuration. It is imperative that when air is supplied to the Lock or Unlock Port on the SWK, that the opposite port be vented to atmosphere (i.e., when air is supplied to the Lock Port, the Unlock Port must be open to the atmosphere.) Failure to vent trapped air or vacuum on the inactive port will negate the locking force of the quick-change mechanism. 31
Assembly WARNING Risk of injury for personnel caused by a released quick-change adapter. The quick-change mechanism will not function properly when connected to a single 3-way valve as this type of valve is incapable of venting trapped air pressure from within the Tool Changer. 5.7 Pneumatic plan Lock port L (A) Unlock port U (B) Exhaust Air connection 4.1-6.9 bar SWK (Shown Unlocked) 5.8 Sensors - Piston Stroke Control SWS Tool Changers provide Lock and Unlock sensing to detect when the locking mechanism is in the Locked or Unlocked position and send a signal to the controller. Many Standard Series Tool Changer models such as the SWS-011/020/021/040/041/ 060/071/100/150/300 can be equipped with Lock and Unlock sensing using a Piston Stroke Control (SIP) that attaches to the SWK. The SIP consists of Lock and Unlock sensors, detection shaft, SIP-plate. Some Tool Changer models are equipped with integrated Lock and Unlock sensing built into the Tool Changer body, like SWS-040Q/076/ 110/160. If sensors are not used, plugs will be provided to seal the locking mechanism. 32
Assembly 5.8.1 Function Stroke Control of the piston SWS-011 and Larger The piston stroke control system for the SWS utilizes 3-wire proximity switches (PNP). Following Figures show the position of the locking mechanism piston and Detection Shaft relative to the proximity switches for various conditions. These signals will indicate two possible conditions for the SWK: Unlocked or Locked. The SIP system utilizes switches to detect the position of the pneumatically-actuated piston in the SWK. These switches are available in various configurations (PNP, NPN) depending on customer requirements, Quick-Change model, and sensor availability. Unlock Sensor On Off Lock Sensor SWK in the unlocked position. The unlock sensor is activated by the Detection Shaft. Unlock Sensor Off On Lock Sensor SWKin the locked position with a SWA in place. The Lock sensor is activated by the Detection Shaft. 33
Assembly 5.8.2 Integrated Proximity Switch - SWS 040Q/076/110/160 Unlock Sensor Assembly Lock Sensor Assembly Some Tool Changer sizes are equipped as a standard with integrated Lock and Unlock sensing built into the Tool Changer body, like SWS-040Q/076/110/160. The sensors of the sensor assemblies are precision aligned at the factory and there is no need to adjust them. You should only change the whole assemblies. If sensors are not used, plugs will be provided to seal the locking mechanism. 5.8.3 Typ Lock and Unlock Sensors Description Voltage Supply Range Output Current Nominal Sensing Distance Sn Output Circuit PNP (Current Sourcing) Brown (1) Value 10-30 VDC < 150 ma 2.0 mm PNP make function (NO) Connector Black (4) PNP Black (4) Blue (3) Brown (1) Blue (3) 5.8.4 Sensors Overview of the compatible sensors Designation Inductive proximity switches Type IN Exact type designation of the compatible sensors see catalog. 34
Assembly 5.9 Optional Module Installation The optional modules are typically installed on tool changers by SCHUNK prior to shipment. The steps below outline field installation or removal as required. Tool Changers are compatible with many different types of modules. Some modules will require an adapter plate to be installed to the Tool Changer. 5.9.1 Electrical Module Installation E10/E20 - SWS-005 and SWS-011 SWK (SWK-011 Shown) Electrical Module (SWO-E10-011-K shown) M3 Socket Head Cap Screws (2x) M3 Socket Head Cap Screws (2x) SWA (SWA-011 shown) Electrical Module (SWO-E10-011-A shown) Ø Make all soldered connections to the electrical module as desired. Ø Align the module to the lateral side of the SWK or SWA. Ø Apply Loctite 222 to M3 socket head cap screws. Ø Secure the module with two M3 socket head cap screws. Tighten to 0,77 Nm. Ø Remove all protective caps, plugs, tape, etc from the module prior to operation. 5.9.2 Electrical Module Removal E10/E20 - SWS-005 and SWS-011 Ø Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to the SWK or SWA. Ø Turn off all energized circuits (e.g. electrical, air, water, etc.) Ø Disconnect any cables, if required. Ø Supporting the module, remove the two M3 socket head cap screws. Ø Remove the module from the SWK or SWA. 35
Assembly 5.9.3 SWK Electrical Module Installation A15/B15 - SWS-005 and SWS-011 M3Socket Flat Head Cap Screws (Long) (2x) M3 Socket Flat Head Cap Screws (Short) (2x) M3 Socket Head Cap Screws (2x) SWK (SWK-011 shown) Elektrical Module (SWO-A15-K shown) Ø Remove the four M3 socket head cap screws securing the cover to the module. Ø Align the cover to the SWK. Ø Apply Loctite 222 to M3 socket head cap screws. Ø Secure the cover with two M3 socket head cap screws. Tighten to 0.34 Nm. Ø Apply Loctite 222 to the four M3 socket flat head cap screws. Ø Attach the module to the cover using the two long and two short M3 socket flat head cap screws as shown in the figure. Tighten to 0.34 Nm. Ø Remove all protective caps, plugs, tape, etc from the module prior to operation. 36
Assembly 5.9.4 SWA Electrical Module Removal E10/E20 - SWS-005 and SWS-011 (2x) M3 Socket Head Screws Connector (2x) Screw Locks Elektrical Module (SWO-A15-A shown) SWA (SWA-011 shown) Ø Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to the SWK or SWA. Ø Turn off all energized circuits (e.g. electrical, air, water, etc.). Ø Disconnect any cables, if required. Ø Remove the two screw locks securing the connector to the module. Ø Carefully remove the connector to expose the mounting screws. Ø Support the module, while removing the two M3 socket head cap screws holding the module to the SWA. Ø Remove the module from the SWA. 37
Assembly 5.9.5 Flat A Optional K Series Module Installation - SWS-020 and SWS-021 M3 Socket Head Cap Screws (2x) SWK (SWK-021 shown) Electrical Module (SWO-K19-K shown) SWA (SWA-021 shown) Electrical Module (9SWO-K19-A shown) M3 Socket Head Cap Screws (2x) Ø Align optional module on flat A of SWK or SWA. Ø Apply Loctite 222 to M3 socket head cap screws. Ø Secure module with two M3 socket head cap screws. Tighten to 0.8-1.2 Nm. Ø Remove all protective caps, plugs, tape, etc from the module prior to operation. 5.9.6 Flat A Optional K Series Module Removal - SWS-020 and SWS-021 Ø Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to the SWK or SWA. Ø Turn off all energized circuits (e.g. electrical, air, water, etc.). Ø Disconnect any cables, air line, etc. if required. Ø Supporting the module, remove the two M3 socket head cap screws. Ø Remove the module from the SWK or SWA. 38
Assembly 5.9.7 Flat B Optional Module Installation - SWS-021 M4 Socket Head Cap Screws (4x) Air Module (SWO-P18-K shown) M4 Socket Flat Head Cap Screws (2x) SWK (SWK-021 shown) Adapter Plate (9948319 shown) Air Module (SWO-P18-A shown) Adapter Plate (9948320 shown) M4 Socket Head Cap Screws (4x) M4 Socket Flat Head Cap Screws (2x) SWA (SWA-021 shown) Ø Align adapter plate to Flat B of the SWS-021 SWK or SWA. Ø Apply Loctite 222 to M4 socket flat head cap screws. Ø Secure adapter plate to the tool changer with two M3 socket flat head cap screws. Tighten to 0.8-1.2 Nm. Ø Align optional module on the adapter plate. Ø Apply Loctite 222 to four M4 socket head cap screws. Ø Secure module with four M3 socket head cap screws. Tighten to 1.3-1.7 Nm. Ø Remove all protective caps, plugs, tape, etc from the module prior to operation. 5.9.8 Flat B Optional Module Removal - SWS-021 Ø Dock the tool safely in the tool stand and uncouple the tool changer to allow clear access to the SWK or SWA. Ø Turn off all energized circuits (electrical, air, water, etc.). Ø Disconnect any cables, air line, etc. if required. Ø Supporting the module, remove the four M4 socket head cap screws. Ø Remove the module from the adapter plate. Ø Remove the two M4 socket head cap screws securing the adapter plate to the SWK or SWA. Ø Remove the adapter plate. 39
Operation 6 Operation 6.1 Conditions for Coupling CAUTION The locking mechanism must be in the unlock position when attempting to couple the Tool Changer. Failure to adhere to this condition may result in damage to the unit and/or the robot. Ø Position the SWK above the SWA and move the SWK into locking position. The mating surfaces of the SWK and SWA should be parallel and not touching. Make sure that the tapered alignment pins from the SWK center the alignment holes on the Tool. The alignment pins should be relatively concentric with the alignment holes such that they do not rub against the edge. Ø When using electrical feed-through-modules the voltages from 24 V have to be switched off prior to coupling. Contacts could be damaged due to sparking. Coupling without power shutdown may shorten the life extremely. Ø It is recommended that the mating faces of SWK and SWA not be touching, but be within a offset of each other when coupling to minimize stress and wear on the locking mechanism. The locking mechanism allows the SWK to pull up the Tool with relatively large gaps between the two sides. Ø Turn the Lock output on. Air is supplied to the locking mechanism to couple the Tool Changer. Ø A sufficient delay must be programmed between the Lock output being activated and reading the state of the Lock/Unlock signals, so that the coupling process is completed before checking the locked state. Ø The Lock signal should read on (true) and the Unlock signal should read off (false). Ø As an option RTL (Ready-To-Lock) - Models SWS-076/110/160 sensing is built into the Tool Changer, providing the ability to sense Tool proximity to theswk prior to coupling. RTL signals are not required to couple the Tool Changer, but are recommended as a further confirmation of coupling prior to removing the Tool from the tool stand. Ø Verify that the RTL signals are read as on (true), if being utilized. The locking mechanism must be in the Unlock state before another attempt is made to couple or damage could occur to the robot and/or the Tool Changer. 40
Operation NOTICE No-Touch locking technology allows the unit to couple with a separation distance between the SWK and SWA. Direct contact of the SWK and SWA mating surfaces is not suggested or required just prior to coupling. Contact may result in damage to the unit and/or the robot. 6.2 Fail-Safe Operation A fail-safe condition occurs, when there is an unintended loss of air pressure to the SWK. When air pressure is lost, the Tool Changer relaxes and there may be a slight separation between the SWK and the SWA. The lock sensor may indicate that the unit is not locked. The fail-safe feature utilizes a multi-tapered cam to trap the ball bearings and prevent unintended release of the SWA. Positional accuracy of the tooling is not maintained during this fail-safe condition. Do not operate the Tool Changer in the fail-safe condition. If source air is lost to the unit, movement should be halted until air pressure is restored. After air pressure is re-established to the SWK, the locking mechanism will energize and securely lock the SWK and the SWA together. In some cases when to load on the Tool Changer is significantly off center, it may be necessary to position the load underneath the Tool Changer or return the tool to the tool storage location to ensure a secure lock condition. If equipped, make sure the lock sensor indicates the Tool Changer is in the locked position before resuming normal operations. Consult your Control/Signal Module manual for specific error recovery information. CAUTION Do not use the Tool Changer in a fail-safe condition. Damage to the locking mechanism could occur. Re-establish air pressure and ensure the Tool Changer is in a secure lock position before returning to normal operations. 41
Operation 6.3 Conditions for Uncoupling Ø The Tool Changer should be positioned in the tool stand in the same location as that when coupling took place. Ø When using electrical feed-through-modules the voltages from 24 V have to be switched off prior to uncoupling. Contacts could be damaged due to sparking. Uncoupling without power shutdown may shorten the life extremely. Ø Turn the lock output off. Ø Issue the unlock output. Air is supplied to the locking mechanism to uncouple the tool changer. Ø A sufficient delay must be programmed between the unlock output being activated and reading the state of the lock/unlock signals, so that the coupling process is completed before checking the locked state. Ø The unlock signal should read on (true) and the lock signal should read off (false). Any other condition indicates a problem and the robot program should be halted. Once the Lock and Unlock signals are verified to be in the proper state the SWK may be moved away from the SWA in the axial direction. The robot and SWK can now proceed to another SWA for coupling and subsequent operations. 42
7 Trouble shooting 7.1 The Quick-Change-Head (balls) doesn t move? Trouble shooting Possible cause Corrective action Pressure drops below minimum. Check air supply. Pneumatic connection [} 31] Compressed air lines switched. Check compressed air lines. Proximity switch defective or set incorrect. Readjust or change sensor. Possible cause Dirt deposits between SWK and SWA Pressure drops below minimum. 7.2 The Quick Change Head does not clamp the Quick- Change- Adaptor correctly? Mounting surface is not sufficiently flat. Possible cause Compressed air can escape. Corrective action Disassemble and clean the product. Check air supply. Pneumatic connection [} 31] Check the evenness of the mounting surface. Mechanical connection [} 27] 7.3 The clamping force between SWK and SWA is reducing? Too much grease in the mechanical movement space. Pressure drops below minimum. Corrective action Check sealings, if needed disassemble the module and replace the sealings. Clean and lubricate product. Maintenance and Care [} 44] Check air supply. Pneumatic connection [} 31] 43
Maintenance and Care 8 Maintenance and Care NOTE The cleanliness of the work environment strongly influences the error-free operation of the change system. If the work environment is prone to heavy contamination, it is very important that the entire unit is protected from contamination with appropriate measures. Protective measures: Locate quick-change adapters at a distance from sources of dust Include protective equipment in the storage rack (install deflectors, air curtains or similar equipment on the unit) Requirements of the storage magazine [} 24] NOTICE Locking mechanism components are subject to corrosion from water. If these components get wet, they must be dried and regreased immediately. In wet or humid environments, inspect components and regrease weekly. 8.1 Preventive Maintenance The Tool Changer and optional modules are designed to provide a long life with regular maintenance. A visual inspection and preventive maintenance schedule is provided in the table below depending upon the application. Detailed assembly drawings, Assembly drawings [} 58]. NOTE All Tool Changers are initially lubricated using MobilGrease XHP222 Special grease. The end-user must apply additional lubricant to the locking mechanism components and alignment pins prior to start of service Lubrication [} 46]. For this purpose, tubes of lubricant are shipped with every Tool Changer. NOTE: MobiGrease XHP222 Special is a NLGI#2 lithium complex grease with molybdenum disulfide. 44
Maintenance and Care Application(s) Schedule General Usage Material Handling Docking Station General Usage Material Handling Docking Station Welding/Servo/Deburring Foundry Operations (Dirty Environments) Tool Change Frequency > 1 per minute Weekly < 1 per minute Monthly All Inspection Schedule Weekly Balls/Alignment Pins/Holes/Bearing Race Mounting Hardware / /Interface Connections Seals Sensors and Cables Electrical Contacts/ Pin Block (Modules) Checklist Inspect for lubrication and wear. A NLGI #2, lithium-based grease with molybdenum disulfide additive is suggested for locking mechanism and alignment pin lubrication. Over time, lubricants can become contaminated with process debris. Therefore, it is recommended to thoroughly clean the existing grease and replace with new as needed. Lubrication [} 46]. Excessive alignment pin/bushing wear may be an indication of poor robot position during pickup/drop-off. Adjust robot position as needed. Check Tool Stand for wear and alignment problems. Wear on the balls/bearing race could be an indication of excessive loading. Inspect for proper torque and interference or wear, abrasions, cuts of hoses, and electrical cables. Tighten and correct as required. Inspect for wear, abrasion, and cuts. Exposed O-rings and rubber bushings may be subject to damage during normal operation. Replace damaged o-rings and rubber bushings as needed. Inspect sensor cables and connectors for any damage, cuts, and abrasion. Inspect for wear and abrasion. Exposed contacts may be subject to damage during normal operation. Clear debris from the area of the contacts using compressed air. Do not directly clean contacts as abrasion may occur and the performance of the contact may be compromised. 45
Maintenance and Care 8.2 Lubrication 8.2.1 External The quick-change is factory-lubricated. For many applications this lubrication is sufficient for the life of the product. In some high-cycle applications or applications subject to moisture, the Tool Changer locking mechanism wear and oxidation can be reduced by applying a thin film of anti-seize compound (molybdenum disulfide grease) to the locking balls, cam, and bearing race at periodic intervals (e.g., every 250,000 cycles). 8.2.2 Internal The internal piston and O-ring do not need lubrication unless the unit is disassembled. In this case, a Teflon-based lubricant such as Magnalube is recommended. 8.3 Cleaning and Lubrication of the Locking Mechanism 8.3.1 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins Cleaning balls and outer surfaces of male coupling Cleaning balls, cam an inner surfaces of male coupling Ø The locking mechanism must be in the unlock state before cleaning. Ø Use a clean rag to thoroughly remove the existing lubricant and debris from the balls, the male coupling, the cam and the alignment pins. 46
Maintenance and Care Ø Check each ball to make sure it moves freely in the male coupling. Additional cleaning may be necessary to free up any balls that are sticking in place. Ø Apply a liberal coating of lubricant to the balls, the male coupling (inside and out), and the alignment pins. 8.3.2 Cleaning the Bearing Race and Alignment Pin Bushings (SWA) 1. Use a clean rag to thoroughly remove any lubricant and debris from the bearing race and the bushings. 2. No re-lubrication is necessary on the SWA components. 47
Maintenance and Care 8.4 Service of the sensors 8.4.1 Proximity Sensor Adjustment, Test, or Replacement - SWS-011 The Proximity sensors are very reliable and normally do not need to be replaced. Exhaust all other possible solutions, check continuity, air supply, lubrication, and pneumatic components prior to testing or replacing the sensor Ø Dock the SWA safely in the tool stand and uncouple the quickchange system to allow clear access to the SWK. Ø Turn off and de-energize all energized circuits (electrical, air, water, etc.). Ø If you are testing or replacing the Lock sensor make sure the SWK-011 is in the locked position, if you are replacing the Unlock sensor make sure the SWK-011 is in the unlocked position before continuing. Ø Disconnect any cables, air line, etc. if required. Ø Remove the four M3 socket head cap screws securing the SWK-011 to the Sensor Interface Plate. Support the SWK-011 while loosening the screws. Ø Loosen the M3 socket set screw and unscrew the proximity sensor from the Sensor Plate. Ø To test the suspect sensor, place a ferrous target in front of the Proximity Sensor to confirm that the sensor is functional. The sensor lock or unlock signal should read on (true) and the sensor LED should illuminate. Sensor Interface Plate (SIP) Detection Shaft M3 Socket Set Screw Proximity Sensor SWS-011 SWK (4x) M3 Socket Head Cap Screws Ø If the proximity sensor is not functioning properly replace. Disconnect the sensor cable and discard. 48
Maintenance and Care Ø Thread the proximity sensor into the SWK-011 until it touches the Detection Shaft, then back the sensor off 1/2 turn. Ø Connect the sensor cable. The Proximity Sensor LED should be illuminated. NOTICE Operating the locking mechanism with the sensor touching the detection shaft will damage the sensor. Do not operate locking mechanism with sensor touching the detection shaft. Back off the sensor ½ turn and secure with the set screw before operating the locking mechanism. Ø Turn the M3 socket set screw until it contacts the sensor and tighten 1/4 turn more. NOTICE Over tightening set screw can cause damage to the proximity sensor. Be careful not to over tighten set screw. Tighten until the nylon tip engages with the sensor threads and tighten 1/4 turn more. Ø Attach the SWK-011 to the Sensor Interface Plate using the four M3 socket head cap screws. Tighten to 1,1 Nm. Ø If required, connect other utilities to the optional modules on the SWK. Ø Confirm the operation of the replaced sensor by issuing the Lock command to lock a SWA to the SWK and then checking to see that the LED in the replaced Sensor body is on. Ø After repair is complete, energize all circuits (e.g. electrical, air, water, etc.). 49
Maintenance and Care 8.4.2 Proximity Sensor Adjustment, Test, or Replacement - SWS 020/021/040/060/071/100/150 The proximity sensors normally do not need to be replaced. Exhaust all other possible solutions, check continuity, air supply, lubrication, and pneumatic components prior to testing or replacing the sensor Ø Dock the SWA safely in the tool stand and uncouple the quickchange sytem SWS to allow clear access to the SWK. Ø Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.). Ø If you are testing or replacing the Lock sensor make sure the SWS is in the locked position, if you are replacing the Unlock sensor make sure the SWS is in the unlocked position before continuing. Ø Turn off all energized circuits (e.g. electrical, air, water, etc.). Ø Disconnect any cables, air line, etc. if required. Ø Remove the six socket head cap screws securing the SWK to the adapter plate. Ø Loosen the hex nut and unscrew the proximity sensor from the SWK. Ø To test the suspect sensor, place a ferrous target in front of the proximity sensor to confirm that the sensor is functional. The sensor lock or unlock signal should read on (true) and the sensor LED should illuminate. Ø If the proximity sensor is not functioning properly replace. Disconnect the sensor cable and discard. Ø Back the sensor hex nut to the cable end of the new sensor. Ø Thread the proximity sensor into the SWK until it touches the detection shaft, then back the sensor off 1/2 turn. NOTICE Operating the locking mechanism with the sensor touching the detection shaft will damage the sensor. Do not operate locking mechanism with sensor touching the detection shaft. Back off the sensor ½ turn and secure with the set screw before operating the locking mechanism. 50
Maintenance and Care Sensor Interface Plate (SIP) Detection Shaft Hex Nut Proximity Sensor SWS-021 (SWK Shown) (4x) M4 Socket Flat Head Cap Screws Ø Connect the sensor cable. The proximity sensor LED should be illuminated. Ø Holding the sensor in position apply Loctite 222 to the proximity sensor threads between the hex nut and the SWK. Tighten the hex nut and torque to 0,9 Nm Ø Attach the SWK to the adapter plate using the six M4 socket head cap screws.tighten to 1,1 Nm Ø If required, connect other utilities to the optional modules on the SWK. Ø Confirm the operation of the replaced sensor by issuing the Lock command to lock a SWA to the SWK and then checking to see that the LED in the replaced Sensor body is on. Ø After repair is complete, energize all circuits (electrical, air, water, etc.). 51
Maintenance and Care 8.4.3 Lock and Unlock Sensor Assembly Replacement (with Sensor Assemblies for SWS 040Q, 076, 110, 160) Ø Depending on the robot and interface plate used, the SWK may have to be removed. Ø Disconnect the Lock and/or Unlock sensor cable connectors from the Lock and/or Unlock sensor. Ø Remove the two M3 socket head cap screws that secure the Lock and/or Unlock sensor to the SWK body. Ø Pull the sensor straight out from the SWK body. Ø Discard the removed sensor. NOTICE The Lock and Unlock sensor assemblies are precision aligned and permanently assembled at the factory. Do not attempt to disassemble and rebuild. Unlock Sensor M3 Socket Head Cap Screws Lock Sensor Ø Insert the Lock and/or Unlock sensor into the Tool Changer body. Ø Secure the sensor assembly using the two M3 socket flat head screws. Tighten to 1.4 Nm. Ø Connect the Lock and/or Unlock sensor cable connector to the proper sensor. Ø Confirm the operation of the Unlock sensor by issuing the Unlock command. Check to see that the LED in the Unlock sensor body is on. Ø Confirm the operation of the Lock sensor by issuing the Lock command to lock a SWA to the SWK. Check to see that the LED in the Lock Sensor body is on. 52
Maintenance and Care 8.5 Rubber Bushings Bushing Collar SWK Rubber Bushing Replacement NOTE Collars only needed for sealings size G 3/8" and G 1/2". If one or more pneumatic pass-through rubber bushings should become cut or damaged in such a way that the seal when coupled is hindered, the bushing(s) require replacement. For models with small ports (G 1/8" and M5): Ø Remove damaged rubber bushing by grasping with a pair of needle-nosed pliers and pulling the bushing out of the body. Ø Dip new bushing in water to aid in installation. Ø Insert the beveled (chamfered) end of the rubber bushing into the bore, leaving ribbed end of the bushing facing outward. NOTICE For SWS-021 models, the rubber bushings must be installed with Loctite 454. A thin film of adhesive should be applied around the diameter of the counter bore in the body prior to installation; do not apply the adhesive to the bushing itself. The dry rubber bushing should then be installed by hand or utilizing soft-faced mallet, if necessary, as described in steps 4 and 4. Ø Press the bushing in by hand until it is seated completely in the bore. If necessary, use a plastic or rubber soft-faced mallet to tap the bushings into place. For larger models with G 3/8" and G 1/2" ports, the rubber bushings require a brass sleeve to retain the bushings in the body. Ø Remove damaged rubber bushing by grasping with a pair of needle-nosed pliers and pulling the bushing out of the body. 53
Maintenance and Care Ø Upon removal of the rubber bushings, remove the brass sleeve from the damaged bushing. Ø Install the rubber bushings as previously described in steps 2 4 for the smaller ports. Ø Insert the beveled end of the brass sleeve into the rubber bushing. Ø Do not use excessive force when pressing in the brass sleeve; too much force can damage the body. Press the brass sleeve into the bushing, using an 10mm Allen key, until it makes contact with the body. Press the brass sleeve only until a firm resistance is felt, then stop pressing. Ø Inspect the bore and remove any rubber slivers that may have resulted from installation of the brass sleeve. 8.5.1 Seal Inspection and Replacement for Electrical Modules V-Ring Seal Stretch seal over shoulder of pin block and push seal hub down against the pin block with finger tip V-Ring Seal Pinch edge of seal with fingers and gently pull away from pin block The seal protects the electrical connection between the SWK and SWA. If the seal becomes worn or damaged it needs to be replaced. Ø To remove the existing seal, pinch edge of seal with fingers and gently pull the seal away from the pin block on the SWK. Ø Pull the seal off the pin block. Ø To install a new seal, stretch the new seal over the shoulder of the pin block. Ø Push the seal s hub down against the pin block using finger tip. 54