B-Top3 Contents General ........................ 7 1.1 Information about this manual ..............7 1.2 Key to symbols .................... 7 1.3 Definition of terms ..................8 1.3.1 Release setting ................8 1.3.2 Complete clamping reserve ............8 1.4 Limitation of liability ..................9 1.5 Copyright .....................
Page 4
B-Top3 4.3.2 MANDO Adapt ................26 4.3.3 SPANNTOP Adapt ..............26 4.3.4 SPANNTOP Adapt M ..............27 4.4 Special aids ....................27 4.4.1 Release key ................. 27 Use and limits of use ..................28 5.1 Use......................28 5.2 Limits of use ....................28 5.2.1...
Page 5
B-Top3 8.1 Commissioning safety ................61 8.2 Checking the total stroke ................62 8.3 Tests ......................63 8.4 Workpiece ....................64 8.5 Procedure after a collision ................. 65 Activities after end of production ............... 66 Removal ......................67 10.1 Safe removal ..................... 67 10.2 Preparing the machine for removal ............
B-Top3 General 1 General 1.1 Information about this manual This manual enables you to work safely and efficiently with the product. This manual is part of the product and must be kept in a lo- cation directly beside the product that is accessible to the personnel at all times.
B-Top3 General Tips and INFORMATION recommendations … highlights useful tips and recommendations as well as information for efficient and problem-free opera- tion. … refers to other documents relating to personal and general safety. Warning symbols may appear on the product or its compo- nents.
B-Top3 General 1.4 Limitation of liability All details and notices in this manual were compiled with due reference to applicable standards and specifications, state- of-the-art technology and our many years of expertise and experience. The manufacturer accepts no liability for damage arising...
B-Top3 General 1.7 Spare parts and accessories WARNING Serious injuries can be caused by incorrect or de- fective spare parts! Always use genuine spare parts made by the orig- inal manufacturer. WARNING Serious injuries can be caused by incorrect or de-...
No modifications must be made to the product. The operator is wholly and solely responsible for any resultant personal injury and/or damage to materials. Excepted from this are changing parts that HAINBUCH ap- proved explicitly for autonomous machining, but specified limits must never be exceeded.
B-Top3 Safety 2.2 Personnel requirements WARNING Serious injuries caused by incorrect handling of the product by insufficiently skilled or trained per- sonnel! All activities must be performed by skilled staff from the relevant specialist field. WARNING Serious injuries caused by unauthorized presence...
B-Top3 Safety Electricians Electricians are trained in the specific task profile for which they are employed, and are familiar with the relevant stand- ards and legislative provisions. Due to their vocational training and experience, electricians can work on electrical systems and can independently iden- tify and avoid potential hazards.
Page 14
B-Top3 Safety DANGER Serious injuries caused by misuse of the product! Only in a CE-compliant machine tool with a sepa- rating set of guards. Only use for the type of use indicated [see »Use« chapter]. Only skilled staff from the appropriate specialist ...
B-Top3 Safety If the product is used on machines, workpieces and/or changing parts for which it is not intended. 2.4 Personal protective equipment During work, it is essential to wear personal protective equip- ment to minimize the health hazards.
B-Top3 Safety Hard hat To protect against falling and projectile parts and materials. 2.5 Particular hazards The following section names residual risks resulting from the installation of the product in a machine tool. In all cases, the residual risks detected during a risk assessment of the ma- chine tool need to be named by the operator.
B-Top3 Safety Insufficient workpiece WARNING clamping Serious injuries caused by breakage of individual components of the product when actuating force is too high! Check actuating force on a regular basis and ad- just if necessary. Sharp-edged parts WARNING Serious cut injuries caused by sharp-edged parts...
Page 18
B-Top3 Safety WARNING Serious injuries caused by snagging body parts on the rotating machine spindle! Never reach into the product while the machine spindle is still rotating. Before working on the product, ensure that the machine spindle is unable to start up.
B-Top3 Safety NOTE Serious damage to materials / the machine tool / the product caused by workpieces being ejected centrifugally if clamping is released while they are still rotating! Never release the clamping of the workpiece while it is still rotating.
B-Top3 Safety 2.9 Environmental protection NOTE Substantial damage to the environment can result from non-compliant handling or incorrect dis- posal of environmentally hazardous substances! If environmentally hazardous substances enter the environment accidentally, take immediate re- medial action. If in doubt, notify the relevant municipal authori- ...
B-Top3 Technical data 3 Technical data 3.1 General information Capture data [see »Calcula- 27.7- 1.9- 5400 25.8 tion of jaw cen- 6.3/1 44.4 18.6 trifugal forces« chapter]. Table 1: Technical data 3.2 Performance values NOTE Material damage to the products use and/or to the...
B-Top3 Technical data 3.3 Balancing quality The product is balanced before leaving the factory [balanc- ing quality - see »General information« chapter]. DANGER Serious injuries caused by parts being ejected centrifugally if products are not balanced cor- rectly! Do not clamp rotationally symmetrical work- ...
(OD) of the chuck. Here, the chuck is in perfect condition and is lubricated with HAINBUCH special grease. These diagrams cease to be valid if changes are made to one or more of these requirements.
B-Top3 Technical data 3.5.2 Size 215 GST201 [1.6 kg] SHF200 [0.8 kg] SFA200 [2.0 kg] Required minimum clamping force 33% 3.6 Operating conditions Indication Value Unit Ambient temperature range 15 - 60 °C ≤ 80 Workpiece temperature °C ≤ 80...
B-Top3 Layout and function 4 Layout and function 4.1 Overview and brief description Spindle flange Functional unit Base chuck Top chuck Integrated liner The clamping device covers a big range of clamping diame- ters. The clamping device can be used as a through-chuck for machining bar stock and also as an end-stop chuck.
B-Top3 Layout and function 4.2 Accessories required 4.2.1 Spindle flange The spindle flange helps to adapt the clamping device to suit the machine tool. Depending on the scope of delivery, the spindle flange can either be supplied with the unit or provided by the customer.
B-Top3 Layout and function 4.3.4 SPANNTOP Adapt M Through adaptation of the SPANNTOP Adapt M, external clamping of the workpiece can be achieved. 4.4 Special aids 4.4.1 Release key The release key is used for installation and removal of the chuck jaws.
B-Top3 Use and limits of use 5 Use and limits of use 5.1 Use The product is a clamping device that may only be used to clamp a rotationally symmetrical workpiece to enable it to be machined. As well as for its general field of application, this product...
B-Top3 Use and limits of use Brief de- Unit Explanation signation Centrifugal torque of top jaws Centrifugal force of base jaws −1 Speed Center of gravity spacing of jaw Cen- ...
B-Top3 Use and limits of use 5.2.3 Calculation of the required clamping force at a given rotational speed The initial clamping force is the total force applied to the 0 workpiece through the chucks when the clamping device is actuated radially while stationary.
Page 31
B-Top3 Use and limits of use From this, the initial clamping force while stationary can be derived: = ∗ ( ± )[] 0 (+) for clamping from outside inwards (-) for clamping from inside outwards...
B-Top3 Use and limits of use 5.2.4 Sample calculation Required initial clamping force for a given rotational speed n The following data are known for the machining task: Clamping from outside inwards [application-specific] Machining force = 3000 [application-specific] ...
B-Top3 Use and limits of use Now the total centrifugal force can be calculated. ∗ ∗ 1200 = ∑ ∗ ( = 2.668 ∗ ( = 42131 Initial clamping force while stationary: ) = 1.5 ∗...
B-Top3 Use and limits of use 5.2.6 Sample calculation Permitted speed for a given effective clamping force The following data are known from the previous calculation: Initial clamping force while stationary = 17723 0 Machining force for the machining task ...
B-Top3 Transport, packaging, storage 6 Transport, packaging, storage 6.1 Safety, transport, packaging, storage WARNING High level of physical strain due to the weight of the product or of its components if not trans- ported properly! From a weight of 10 kg, use appropriate transport ...
B-Top3 Transport, packaging, storage NOTE Damage to materials caused by falling parts if transported incorrectly! Ensure that the product cannot roll away or fall. Place on a non-slip surface. When using lifting gear, use appropriate load- bearing equipment and lifting tackle.
B-Top3 Transport, packaging, storage 6.4 Unpacking and internal transportation The total weight of the product depends on its size. Depending on the weight involved, it may be necessary to use lifting gear to lift the product or its components out of the packaging safely, to transport them and to position and in- stall them in the machine tool or on the machine table.
B-Top3 Transport, packaging, storage 6.6 Storage INFORMATION The packaged items may display information relating to storage and readmission to storage that extend be- yond the scope of these requirements. Pay attention to these notices. Store packaged items under the following conditions: Safe for storage.
B-Top3 Installation 7 Installation 7.1 Installation safety WARNING Serious injuries caused by unskilled staff during installation / removal! Installation and removal must be performed by skilled staff from the relevant specialist field. WARNING Serious injuries can be caused if the machine tool starts up accidentally! Set the machine tool into set-up mode.
Page 40
B-Top3 Installation WARNING Serious head injuries caused by bending into the working area of the machine! Only ever bend into the working area of the ma- chine if there are no cutting tools or sharp objects in it, or if these are covered.
Damage to materials caused by defective screw tightening torques! To secure the product to the machine, pay attention to the values specified by HAINBUCH and by the machine manufacturer for screw tightening torques. If the machine manufacturer stipulates different values, you must consult HAINBUCH.
Page 42
B-Top3 Installation Product The following table lists the screw tightening torques for se- curing the product to a machine tool. Tightening torque at screw quality [Nm] Thread designation 10.9 1050 1500 Table 4: Screw tightening torques Order hotline +49 7144.907-333...
B-Top3 Installation Top jaws The following table lists the screw tightening torques for se- curing the top jaws to the product. Tightening torque at screw quality [Nm] Thread designation 12.9 Table 5: Screw tightening torques 7.4 Preparation of the machine for installation Set the machine into set-up mode.
B-Top3 Installation 7.5 Installation of the product Spindle flange Fixing screws on spindle flange Functional unit Fixing screws, function unit Base jaws Test surface, axial run-out, spindle flange Test surface, face run-out, spindle flange Test surface, face run-out, functional unit Test surface, axial run-out, functional unit As described in the »Preparation of the machine for in-...
B-Top3 Installation 7.5.2 Preparation of the product The product is supplied in assembled condition. The following preparatory steps are needed to install the product. Relocate the base chucks to prevent them from protrud- ing beyond the outside edge of the chuck.
B-Top3 Installation Take down the functional unit from the spindle flange. 7.5.3 Installation of the drawtube adapter INFORMATION Depending on the geometry of the drawtube adapter, it must be installed either on the machine drawtube or in the bayonet drawtube adapter.
B-Top3 Installation 7.5.4 Installation of a spindle flange that cannot be aligned Attach any lifting gear that may be required. If necessary, fit the mounting aid onto a vertically sus- pended spindle. INFORMATION The positioning block on the machine spindle and the positioning bore in the spindle flange can be used for positioning.
Page 48
B-Top3 Installation Unfasten and remove any lifting gear that may have been required. Remove the mounting aid on a vertically suspended spindle if one was used. Check face run-out on the test surface of the spindle flange [ideally ≤ 0.005 mm].
B-Top3 Installation 7.5.5 Installation of a spindle flange that can be aligned Attach any lifting gear that may be required. If necessary, fit the mounting aid onto a vertically sus- pended spindle. INFORMATION The positioning block on the machine spindle and the positioning bore in the spindle flange can be used for positioning.
Page 50
B-Top3 Installation Unfasten and remove any lifting gear that may have been required. Remove the mounting aid on a vertically suspended spindle if one was used. Check the face run-out on the test surface of the spindle flange [ideally ≤ 0.005 mm] and, if necessary, correct carefully with a plastic hammer.
B-Top3 Installation 7.5.6 Installation of the functional unit of an alignable clamping device Attach any lifting gear that may be required. If necessary, fit the mounting aid onto a vertically sus- pended spindle. Move the machine drawtube to the front limit stop.
Page 52
B-Top3 Installation Turn back the functional unit until the balancing marks on the spindle flange are aligned with those on the func- tional unit. Screw in the fixing screws on the functional unit and tighten them gently. Unfasten and remove any lifting gear that may have been required.
Page 53
B-Top3 Installation 10. Tighten the fixing screws on the functional unit to the specified tightening torque [see »Screw tightening tor- ques« chapter]. 11. Check face run-out on the test surface of the functional unit [ideally ≤ 0.01 mm]. Whenever the face run-out is greater than the maximum per- mitted value: 12.
B-Top3 Installation 18. Use the release key to unlock the tapered rods and move the base chuck as indicated by the lettering, or into the jaw guide on the functional unit. 19. Check the base chuck for ease of movement and check the jaw stroke.
B-Top3 Installation As described in the »Preparation of the machine for in- stallation« chapter, prepare for the following steps. Special aids needed: Release key 7.6.1 Position of base chucks Move the clamping device into release position. Base chuck Marker line...
B-Top3 Installation 7.6.2 Replacement of jaw chuck Move the clamping device into release position. INFORMATION For safety reasons, the teeth on the base chucks are not in mesh in release position to prevent the base chucks from dropping out. Use the release key to release the release pin in the jaw.
B-Top3 Installation Install the jaw and slide it to the desired diameter. Rotate the release key until the serrations on the jaw chuck mesh with those in the jaw. Remove the release key. Also replace the other jaws as described.
B-Top3 Installation Screw in the top chuck fixing screws and tighten to the specified tightening torque [see »Screw tightening tor- ques« chapter]. Install the other top chucks as described. 7.6.4 Installation of jaws without base chucks Unlock the wedge rod with the release key.
Page 59
B-Top3 Installation Remove the base chuck. Clean the jaw guide with a cloth. Clean the contact surfaces on the jaw. Install the jaw up to the marker line. Order hotline +49 7144.907-333...
B-Top3 Installation Rotate the release key until the serrations on the jaw chuck mesh with those in the jaw. Remove the release key. Install the other jaws as described. 7.6.5 Unscrewing and removing the jaws For ultimate standard of repeatability, the unscrew the jaws in the jaw chuck at clamping pressure, or grind them out.
B-Top3 Commissioning 8 Commissioning For commissioning purposes, set the operating pressure to the permitted, established machining value. The machine tool must not start up until full operating pres- sure has built up. 8.1 Commissioning safety DANGER Serious injuries caused by workpieces being...
B-Top3 Commissioning NOTE Damage to components caused by cooling lubri- cants with sufficient levels of corrosion inhibitor! The components made of steel materials must be protected before the usual oxidation process. Only ever use cooling lubricants with sufficient ...
B-Top3 Commissioning figure must then be equal to or greater than the nominal total stroke. For the radial nominal total stroke, the values of radial clamp- ing reserve and radial opening stroke must be added to- gether [see »General inforamtion« chapter].
B-Top3 Commissioning 8.4 Workpiece DANGER Serious injuries caused by parts being ejected centrifugally if level of workpiece clamping is in- sufficient! Never utilize the full clamping reserve. Do not exceed the permitted maximum clamping reserve stroke. The remaining clamping reserve must always be ...
B-Top3 Commissioning 8.5 Procedure after a collision In the event of a collision, the product and its components must be checked for cracks and damage before being used again. For this, remove the product from the machine [see »Re- moval of the product« chapter] and dismantle it [for level of disassembly, see »Cleaning«...
B-Top3 Activities after end of production 9 Activities after end of production Switch off machine tool and secure it to prevent it from being switched back on. Open the safety door / hood. WARNING Eye injuries and cuts caused by failure to wear protective clothing during cleaning operation! Never use compressed air to clean the product.
B-Top3 Removal 10 Removal If a break in production occurs that lasts for more than three days, the product must be removed and stored safely in ac- cordance with manufacturer's stipulations [see »Transport, packaging, storage« chapter]. 10.1 Safe removal WARNING...
Page 68
B-Top3 Removal WARNING Serious crushing injuries caused by improper ma- chine movement during installation or removal! Machine movements are only permitted in set-up mode during installation and removal. Never reach into a gap. Pay attention to the gap dimensions of moving ...
B-Top3 Removal NOTE Damage to materials caused by prohibited move- ment of the chuck piston! Do not move the chuck piston if the release key is located in one of the release pins. INFORMATION If necessary, use any forcing / extraction threads in the components of the product, changing parts or clamping elements.
B-Top3 Removal 10.3 Removal of the clamping element Release pin Base jaws Top jaws C1 Fixing screws on top jaw Special aids needed: Release key As described in the »Preparing the machine for re- moval« chapter, prepare for the following steps.
B-Top3 Removal 10.3.1 Removal of jaw chucks with base chuck Unfasten and remove the fixing screws on the top chuck. Remove the top chuck. Remove the other top chucks as described. Order hotline +49 7144.907-333...
B-Top3 Removal 10.3.2 Removal of jaw chucks without base chuck Unlock the wedge rod with the release key. Pull the jaw outwards to remove it from the groove. Order hotline +49 7144.907-333...
Page 73
B-Top3 Removal Install the base chuck up to the outermost marker line. Rotate the release key until the serrations on the jaw chuck mesh with those in the jaw. Remove the release key. Remove the other jaws as described. Order hotline +49 7144.907-333...
B-Top3 Removal 10.4 Removal of the product Spindle flange Fixing screws on spindle flange Functional unit Fixing screws, function unit Base jaws Test surface, axial run-out, spindle flange Test surface, face run-out, spindle flange Test surface, face run-out, functional unit Test surface, axial run-out, functional unit As described in the »Preparing the machine for re-...
B-Top3 Removal 10.4.1 Removal of the functional unit Attach any lifting gear that may be required. If necessary, fit the mounting aid onto a vertically sus- pended spindle. Move the machine drawtube to the front limit stop. Relocate the base chucks to prevent them from protrud- ing beyond the outside edge of the chuck.
B-Top3 Removal 10.4.2 Removal of the spindle flange Attach any lifting gear that may be required. If necessary, fit the mounting aid onto a vertically sus- pended spindle. Unfasten and remove the fixing screws on the spindle flange. Take down the spindle flange from the machine spindle.
B-Top3 Removal 10.4.3 Removal of the drawtube adapter If the drawtube adapter was mounted on the machine drawtube, use its thread to unscrew and remove it from the machine drawtube. Order hotline +49 7144.907-333...
B-Top3 Maintenance 11 Maintenance 11.1 Maintenance safety WARNING Serious injuries caused by parts being ejected centrifugally after a loss of clamping power! Maintain the maintenance and cleaning intervals of the product at all times. It is essential to check the maintenance status of ...
B-Top3 Maintenance Interval Maintenance work six-monthly or after 1200 Lubricate the product [see »Lubricating the product« chapter] operating hours* with storage See »Storage« chapter depending upon which stipulation is achieved first Table 6: Maintenance table 11.3 Cleaning Chuck body Fixing screws on chuck body...
Page 80
B-Top3 Maintenance NOTE Damage to seals caused by the wrong solvent! To clean the product, never use a solvent that at- tacks and damages the sealing elements in- stalled. Those installed sealing elements can be made of NBR, Viton and PUR materials.
B-Top3 Maintenance Tighten all fixing screws to the specified tightening torque [see nomenclature and/or »Screw tightening torques« chapter]. When tightening the screws, do so evenly to prevent any distortion under load. Only apply lubricant to the mechanical mating sur- ...
B-Top3 Maintenance 11.5 Lubricating the product DANGER Serious injuries caused by workpiece being ejected centrifugally due to insufficient lubrication of the product! Never drop below the lower limit value for clamp- ing force [see »Clamping force speed diagram« chapter].
Furthermore, there must be no particles of dirt in the grease because these cause an operational malfunc- tion if they come between two interference fit surfaces. For this, the following lubricants are recommended: GP 355 universal grease [see the HAINBUCH product catalogue] Alternatively: Product designa- Lubricants Manufacturer...
B-Top3 Disposal 12 Disposal If no agreement exists for return or disposal, send disman- tled components off for recycling. NOTE Substantial damage to the environment can result from incorrect disposal of environmentally haz- ardous substances! Lubricants, auxiliary materials and operating flu- ...
B-Top3 Faults 13 Faults The following chapter describes possible causes for faults, and the work involved in remedial action. If multiple faults occur, shorten the maintenance intervals in accordance with actual load levels. Contact the manufacturer if faults occur that cannot be rem- edied by following these instructions [see »Contact«...
B-Top3 Faults 13.2 Fault table Fault Possible cause Remedial action Remedied by Remove and clean the clamping Dirt in the parts in elements, and remove, dismantle Skilled specia- the power flow and clean the clamping device if list necessary Incorrect axial...
B-Top3 Faults Fault Possible cause Remedial action Remedied by Check the workpiece material Reduce the clamping force to the Clamping force is level applicable for the clamping too high device and the workpiece Incorrect type of Use a suitable clamping element...
Our experts are there for you around the clock: +49 7144. 907-444 For advice or help, you can contact the sales partners and service staff listed in www.hainbuch.com. 14.2 Manufacturer certification Manufacturer certification is supplied with the product and with this manual.
Page 89
B-Top3 Annex Order hotline +49 7144.907-333...
Page 90
B-Top3 Index directory Limits of use ........28 Accessories, optional Lubricants ........20, 83 Integrated liner ......26 MANDO Adapt ......26 Maintenance schedule ...... 78 SPANNTOP Adapt ......26 Misuse ..........14 SPANNTOP Adapt M ....27 Accessories, required Operating conditions ......
Page 91
B-Top3 Storage ..........38 Type designation ....... 24 Symbols on the packaging ....36 Unpacking ......... 37 Technical data........21 Use ............ 28 Tests ..........63 Transport inspection ......36 Warranty ..........10 Transportation, internal ..... 37 Order hotline +49 7144.907-333...
Need help?
Do you have a question about the B-Top3 and is the answer not in the manual?
Questions and answers