SCHUNK SWS Series Assembly And Operating Manual
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SCHUNK SWS Series Assembly And Operating Manual

Quick-change-system
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Original Operating Manual
Assembly and Operating Manual
SWS 005 – 300
Quick-Change-System

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Summary of Contents for SCHUNK SWS Series

  • Page 1 Original Operating Manual Assembly and Operating Manual SWS 005 – 300 Quick-Change-System...
  • Page 2 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.

  • Page 3: Table Of Contents

    Table of contents Table of contents General........................ 6 About this manual .................... 6 1.1.1 Presentation of Warning Labels ............... 6 1.1.2 Applicable documents ................ 7 1.1.3 Sizes ...................... 7 Warranty ...................... 7 Scope of delivery .................... 8 Accessories ...................... 8 1.4.1 SWD Dust Cover for SWA quick-change adapter........ 8 1.4.2 Seal kit .................... 10 Basic safety notes .................... 11 Intended use.......................
  • Page 4 Table of contents Assembly ........................ 22 Example of mounting .................. 22 Interface Plate Design and Mounting.............. 23 Requirements of the storage magazine .............  24 Mechanical connection .................. 27 5.4.1 Fastening of the quick-change head (SWK) .......... 27 5.4.2 Fastening the quick-change adapter (SWA) ........... 28 5.4.3 Tightening torque ................... 28 Pneumatic connection..................
  • Page 5 Table of contents Maintenance and Care.................... 45 Preventive Maintenance .................. 45 Lubrication...................... 47 8.2.1 External.................... 47 8.2.2 Internal .................... 47 Cleaning and Lubrication of the Locking Mechanism ........ 47 8.3.1 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins...  47 8.3.2 Cleaning the Bearing Race and Alignment Pin Bushings (SWA).... 49 Service of the sensors..................

  • Page 6: General

    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.

  • Page 7: Applicable Documents

    • 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 1.1.3 Sizes This operating manual applies to the following sizes: •...

  • Page 8: Scope Of Delivery

    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 quick- change head (SWK)  27]...
  • Page 9 General Size Designation ID number for electrical option (1) 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)

  • Page 10: Seal Kit

    General 1.4.2 Seal kit Seal kit for ID number SWK 005 0370819 SWK 011 0370977 SWK 011 - High-temperature-version 39370977 SWK 020 0370821 SWA 020 0370822 SWK 021 0370978 SWK 027 30087124 SWK 040 0370823 SWK 040Q 0370949 SWK 041 0370979 SWK 060 0370824...

  • Page 11: Basic Safety Notes

    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. 10.00 | SWS 005 – 300 | Assembly and Operating Manual | en | 389456...

  • Page 12: Environmental And Operating Conditions

    Basic safety notes 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.

  • Page 13: Personal Protective Equipment

    Basic safety notes 2.7 Personal protective equipment Use of personal protective equipment Personal protective equipment serves to protect staff against danger which may interfere with their health or safety at work. • When working on and with the product, observe the occupational health and safety regulations and wear the required personal protective equipment.

  • Page 14: Malfunctions

    Basic safety notes 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.

  • Page 15: Protection During Commissioning And Operation

    Basic safety notes 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...

  • Page 16: Notes On Particular Risks

    Basic safety notes 2.13 Notes on particular risks  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.
  • Page 17 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.

  • Page 18: Technical Data

    Technical Data 3 Technical Data More technical data is included in the catalog data sheet. Whichever is the latest version. Designation 040 040Q 041 Weight [kg] 0.36 0.24 0.22 0.99 1.39 1.85 1.85 Recommended handling weight [kg] Locking force 1100 2300 2300 3500 4500 5600 4500...
  • Page 19 * 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. 10.00 | SWS 005 – 300 | Assembly and Operating Manual | en | 389456...

  • Page 20: Product Overview

    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.

  • Page 21: Quick-Change Adapter (Swa)

    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.

  • Page 22: Assembly

    Assembly 5 Assembly  WARNING Risk of injury due to falling tool! The tool can fall off during assembly, adjustment and maintenance work. Only carry out assembly, adjustment and maintenance work • when the tool is placed in the storage rack or secured against falling.

  • Page 23: Interface Plate Design And Mounting

    Assembly 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).

  • Page 24: Requirements Of The Storage Magazine

    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.
  • Page 25 Assembly 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  41] It is highly recommended that the customer provide a sensor that detects the presence of a properly seated SWA in the Tool Stand.
  • Page 26 Assembly Cocking Offset (About X and Y) X, Y and Z Offset Twisting Offset (About Z) Offset Definitions Maximum Recommended Offsets Prior to Coupling Size No-Touch™ X and Y Offset Cocking Offset Twisting Offset Z Offset (Max)* [mm] (Max)** [mm] (Max) [degrees] (Max) [degrees] SWS 005...

  • Page 27: Mechanical Connection

    Assembly 5.4 Mechanical connection  WARNING Risk of injury when the machine/system moves unexpectedly! Switch off power supply. Evenness of the The values apply to the whole mounting surface to which the product is mounted. mounting surface Requirements for evenness of the mounting surface (Dimensions in mm) Edge length Permissible unevenness <...

  • Page 28: Fastening The Quick-Change Adapter (Swa)

    Assembly Size screws (1) Quantity 040Q M5 x 45 / DIN EN ISO 4762 M5 x 40 / DIN EN ISO 4762 M6 x 40 mm / DIN EN ISO 4762 M6 x 40 / DIN EN ISO 10642 M6 x 40 / DIN EN ISO 4762 M10 x 55 / DIN EN ISO 4762 M10 x 50 / DIN EN ISO 4762 M10 x 60 / DIN EN ISO 4762...
  • Page 29 Assembly Size 007 Type of Screw Thread Size Strength Class Tightening Thread Locker Torque [Nm] Robot-side adapter plate on SWK Socket head cap 12.9 Loctite 222 Tool-side adapter plate on SWA Socket head cap 12.9 Loctite 222 Socket flat head cap 12.9 Loctite 222 Size 020, 021...
  • Page 30 Assembly Size 060 Type of Screw Thread Size Strength Class Tightening Thread Locker Torque [Nm] Robot-side adapter plate on SWK Socket flat head cap 12.9 Loctite 242 Tool-side adapter plate on SWA Socket head cap 12.9 Loctite 242 Socket flat head cap Size 071 Type of Screw Thread Size...

  • Page 31: Pneumatic Connection

    Assembly Size 160 Type of Screw Thread Size Strength Class Tightening Thread Locker Torque [Nm] Robot-side adapter plate on SWK Socket head cap 12.9 Loctite 242 Tool-side adapter plate on SWA Socket head cap 12.9 Loctite 242 Size 300 Type of Screw Thread Size Strength Class Tightening Thread Locker...

  • Page 32: Valve Requirements And Connections

    Assembly 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.

  • Page 33: Sensors - Piston Stroke Control

    Assembly 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.

  • Page 34: Piston Stroke Control Integrated In The Body

    Assembly Unlock Sensor Lock Sensor SWK in the locked position with a SWA in place. The lock sensor is activated by the detection shaft. 5.8.2 Piston Stroke Control integrated in the body Integrated proximity NOTE switch Sizes SWS-040Q/046/076/110/160 are equipped as a standard with integrated Lock and Unlock sensing built into the Tool Changer body.

  • Page 35: Typ Lock And Unlock Sensors

    Assembly Integrated magnetic NOTE switch Size SWS 007 is equipped as standard with grooves into the Tool Changer body. Magnetic Switch Groove Lock Socket Set Screw Magnetic switch Unlock 5.8.3 Typ Lock and Unlock Sensors Description Value Voltage Supply Range 10 - 30 VDC Output Current <...

  • Page 36: Optional Module Installation

    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.

  • Page 37: Swa Electrical Module Removal E10/E20 - Sws-005 And Sws-011

    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 (SWK-011 Head Cap Screws shown) (Short) (2x) M3 Socket Head Cap Screws (2x) Elektrical Module (SWO-A15-K shown) Remove the four M3 socket head cap screws securing the cover Ø...

  • Page 38: Flat A Optional K Series Module Installation - Sws-020 And Sws-021

    Assembly Dock the Tool safely in the tool stand and uncouple the Tool Ø Changer to allow clear access to the SWK or SWA. Turn off all energized circuits (e.g. electrical, air, water, etc.). Ø Disconnect any cables, if required. Ø...

  • Page 39: Flat A Optional K Series Module Removal - Sws-020 And Sws-021

    Assembly 5.9.6 Flat A Optional K Series Module Removal - SWS-020 and SWS-021 Dock the Tool safely in the tool stand and uncouple the Tool Ø Changer to allow clear access to the SWK or SWA. Turn off all energized circuits (e.g. electrical, air, water, etc.). Ø...

  • Page 40: Flat B Optional Module Removal - Sws-021

    Assembly 5.9.8 Flat B Optional Module Removal - SWS-021 Dock the tool safely in the tool stand and uncouple the tool Ø changer to allow clear access to the SWK or SWA. Turn off all energized circuits (electrical, air, water, etc.). Ø...

  • Page 41: Operation

    Operation 6 Operation  WARNING Risk of injury due to falling tool! The tool can fall off during assembly, adjustment and maintenance work. Only carry out assembly, adjustment and maintenance work • when the tool is placed in the storage rack or secured against falling.

  • Page 42: Fail-Safe Operation

    Operation As an option RTL (Ready-To-Lock) - Models SWS-076/110/160 Ø 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.

  • Page 43: Conditions For Uncoupling

    Operation 6.3 Conditions for Uncoupling The Tool Changer should be positioned in the tool stand in the Ø same location as that when coupling took place. When using electrical feed-through-modules the voltages from Ø 24 V have to be switched off prior to uncoupling. Contacts could be damaged due to sparking.

  • Page 44: Trouble Shooting

    Trouble shooting 7 Trouble shooting 7.1 Quick-change head (balls) doesn’t move 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. 7.2 Quick-change head doesn't clamp the quick-change adapter correctly Possible cause...

  • Page 45: Maintenance And Care

    Maintenance and Care 8 Maintenance and Care  WARNING Risk of injury due to falling tool! The tool can fall off during assembly, adjustment and maintenance work. Only carry out assembly, adjustment and maintenance work • when the tool is placed in the storage rack or secured against falling.
  • Page 46 Maintenance and Care 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  47]. For this purpose, tubes of lubricant are shipped with every Tool Changer.

  • Page 47: Lubrication

    Maintenance and Care Sensors and Cables Inspect sensor cables and connectors for any damage, cuts, and abrasion. Electrical Contacts/ Inspect for wear and abrasion. Pin Block (Modules) 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.
  • Page 48 Maintenance and Care Use a clean rag to thoroughly remove the existing lubricant and Ø debris from the balls, the male coupling, the cam and the alignment pins. Check each ball to make sure it moves freely in the male Ø...

  • Page 49: Cleaning The Bearing Race And Alignment Pin Bushings (Swa)

    Maintenance and Care 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. 8.4 Service of the sensors  WARNING Risk of injury in the event of unexpected unlocking!
  • Page 50 Maintenance and Care To test the suspect sensor, place a ferrous target in front of the Ø 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...

  • Page 51: Proximity Sensor Adjustment, Test, Or Replacement - Sws 020/021/040/060/071/100/150

    Maintenance and Care 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. Attach the SWK-011 to the Sensor Interface Plate using the four Ø...
  • Page 52 Maintenance and Care If the proximity sensor is not functioning properly replace. Ø Disconnect the sensor cable and discard. 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 Ø...

  • Page 53: Magnetic Proximity Sensor Test Or Replacement - Sws-007

    Maintenance and Care 8.4.3 Magnetic Proximity Sensor Test or Replacement - SWS-007 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 Place the SWS in a secure location.

  • Page 54: Lock And Unlock Sensor Assembly Replacement (With Sensor Assemblies For Sws 040Q, 046, 076, 110, 160)

    Maintenance and Care Using a 0.9 mm allen wrench, secure the new sensor to the SWK Ø with the socket set screw. Tighten to 0.08 Nm. Connect to the M8 end cable connector of the sensor. When Ø power is turned on to the sensor LED should be illuminated and sensor signal should be ON.

  • Page 55: Rubber Bushings

    Maintenance and Care Insert the Lock and/or Unlock sensor into the Tool Changer Ø body. Secure the sensor assembly using the two M3 socket flat head Ø screws. Tighten to 1.4 Nm. Connect the Lock and/or Unlock sensor cable connector to the Ø...
  • Page 56 Maintenance and Care 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.

  • Page 57: Seal Inspection And Replacement For Electrical Modules

    In heavy-duty applications, alignment (locating) pins Assembly drawings  62] may need to be replaced due to wear. When replacing alignment pins always use original SCHUNK parts. 8.6.1 Replacemanent - SWS 005 / 011 /007 Excessive alignment pin/bushing wear could indicate poor robot positioning during pickup/drop- off.

  • Page 58: Replacemanent - Sws 046 / 076 / 110 /160

    Maintenance and Care Using a 2.5 mm Allen wrench, remove the M3 socket head cap Ø screw from the SWA. Remove the alignment pin from the SWA. Discard the old Ø alignment pin. Insert the new alignment pin into the SWA. Ø...
  • Page 59 Maintenance and Care 4mm hexagon socket Centering pin Ratchet Setscrew Another approach would be to use the access hole in the back Ø side of the SWK. If not already removed, remove the SWK. Use a 3 mm Allen Wrench to remove the alignment pin from the back side of the SWK by turning the set screw clockwise to drive the pin out the front of the plate.

  • Page 60: Disassembly Of The Swk Quick-Change Head

    Maintenance and Care 8.7 Disassembly of the SWK Quick-change head 8.7.1 Disassembly of SWK 005 - 011  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.

  • Page 61: Disassembly Of Swk 020 - 300

    Maintenance and Care 8.7.2 Disassembly of SWK 020 - 300  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 •...

  • Page 62: Assembly Drawings

    Assembly drawings 9 Assembly drawings 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. 9.1 Assembly SWS-005/011 Assembly SWS 5-11 Contained in accessory pack. Included in the seal kit.

  • Page 63: Assembly Sws-007

    Assembly drawings 9.2 Assembly SWS-007 Included in the seal kit. Seal kit can only be ordered completely. 10.00 | SWS 005 – 300 | Assembly and Operating Manual | en | 389456...

  • Page 64: Assembly Sws-020/021/041/060/071/150/300

    Assembly drawings 9.3 Assembly SWS-020/021/041/060/071/150/300 Contained in accessory pack. Included in the seal kit. Seal kit can only be ordered completely. 10.00 | SWS 005 – 300 | Assembly and Operating Manual | en | 389456...

  • Page 65: Assembly Sws-027

    Assembly drawings 9.4 Assembly SWS-027 Contained in accessory pack. Included in the seal kit. Seal kit can only be ordered completely. 10.00 | SWS 005 – 300 | Assembly and Operating Manual | en | 389456...

  • Page 66: Assembly Sws-046

    Assembly drawings 9.5 Assembly SWS-046 Included in the seal kit. Seal kit can only be ordered completely. 10.00 | SWS 005 – 300 | Assembly and Operating Manual | en | 389456...

  • Page 67: Assembly Sws-076/110/160

    Assembly drawings 9.6 Assembly SWS-076/110/160 Included in the seal kit. Seal kit can only be ordered completely. 10.00 | SWS 005 – 300 | Assembly and Operating Manual | en | 389456...

  • Page 68: Translation Of Original Declaration Of Incorporation

    10 Translation of original declaration of incorporation in terms of the Directive 2006/42/EG, Annex II, Part 1.B of the European Parliament and of the Council on machinery. Manufacturer/ SCHUNK GmbH & Co. KG Spann- und Greiftechnik Distributor Bahnhofstr. 106 – 134 D-74348 Lauffen/Neckar...

  • Page 69: Annex To Declaration Of Incorporation

    Annex to Declaration of Incorporation 11 Annex to Declaration of Incorporation according 2006/42/EG, Annex II, No. 1 B 1.Description of the essential health and safety requirements pursuant to 2006/42/EC, Annex I that are applicable and that have been fulfilled with: Product designation Quick-Change-System Type designation To be provided by the System Integrator for the overall machine ⇓...
  • Page 70 Annex to Declaration of Incorporation Protection against mechanical hazards 1.3.1 Risk of loss of stability 1.3.2 Risk of break-up during operation 1.3.3 Risks due to falling or ejected objects 1.3.4 Risks due to surfaces, edges or angles 1.3.5 Risks related to combined machinery 1.3.6 Risks related to variations in operating conditions 1.3.7...
  • Page 71 Annex to Declaration of Incorporation Maintenance 1.6.1 Machinery maintenance 1.6.2 Access to operating positions and servicing points 1.6.3 Isolation of energy sources 1.6.4 Operator intervention 1.6.5 Cleaning of internal parts Information 1.7.1 Information and warnings on the machinery 1.7.1.1 Information and information devices 1.7.1.2 Warning devices 1.7.2...
  • Page 72 10.00 | SWS 005 – 300 | Assembly and Operating Manual | en | 389456...

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