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Hainbuch centroteX M Operating Instructions Manual

B-top with quick change-over adapter
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Operating instructions
[incl. installation manual]
B-Top
EN
with quick change-over adapter
centroteX M

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Summary of Contents for Hainbuch centroteX M

  • Page 1 Operating instructions [incl. installation manual] B-Top with quick change-over adapter centroteX M...
  • Page 2 B-Top Translation of the original operating instructions Order hotli ne + 49 7144.907-333 Order hotline +49 7144.907-333...

  • Page 3: Table Of Contents

    B-Top 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-Top 4.3.1 Integrated liner ................29 4.4 Special aids ....................29 4.4.1 Release key ................. 29 Use and limits of use ..................30 5.1 Use......................30 5.2 Limits of use ....................30 5.2.1 Nomenclature ................30 5.2.2 Calculation of jaw centrifugal forces ..........31 5.2.3 Calculation of the required clamping force at a given rotational speed ...................
  • Page 5 B-Top Activities after end of production ............... 58 Removal ......................59 10.1 Safe removal ..................... 59 10.2 Preparing the machine for removal ............61 10.3 Removal of the clamping element ............. 61 10.3.1 Removal of jaw chucks with base chuck ........62 10.3.2 Removal of jaw chucks without base chuck ........
  • Page 6 B-Top Directory of tables Table 1: Technical data ................23 Table 2: Operating conditions ..............27 Table 3: Nomenclature ................31 Table 4: Screw tightening torques .............. 44 Table 5: Screw tightening torques .............. 45 Table 6: Maintenance table ................ 67 Table 7: Number of strokes ................

  • Page 7: General

    B-Top 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.

  • Page 8: Definition Of Terms

    B-Top General Tips and recommenda- INFORMATION tions … 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.

  • Page 9: Limitation Of Liability

    B-Top 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 from any of the following: Non-compliance with this manual ...

  • Page 10: Spare Parts And Accessories

    B-Top 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- fective clamping elements! Always use genuine clamping elements made by ...

  • Page 11: Warranty Terms

    B-Top General 1.8 Warranty terms The warranty terms are included in the manufacturer's Gen- eral Terms & Conditions of Business. 1.9 Warranty The warranty period extends for 24 months from delivery date to the plant and covers intended use over a maximum of 500000 clamping cycles with due consideration of the specified maintenance and lubrication intervals.

  • Page 12: Safety

    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.

  • Page 13: Personnel Requirements

    B-Top Safety DANGER Serious injuries caused by parts being ejected centrifugally after defective setting of the ma- chine!  Set up the end-stop requests by the machine tool on the product involved. On a regular basis, check the end-stop requests ...
  • Page 14 B-Top Safety NOTE Serious damage to materials caused by incorrect handling of the product by insufficiently skilled or trained personnel!  All activities must be performed by skilled staff from the relevant specialist field. This manual name the following skills sets required for vari- ous different areas of activity: Skilled specialist Skilled specialists, due to their professional training,...

  • Page 15: Intended Use

    B-Top Safety 2.3 Intended use The product is only intended for installation in a CE-compli- ant machine tool with a separating set of guards. The product is only intended for the type of use described in this manual [see »Use« chapter]. Furthermore, an ex- tended form of use can be agreed contractually between manufacturer and operator.

  • Page 16: Personal Protective Equipment

    B-Top Safety NOTE Damage to materials caused by incorrect use 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 ...

  • Page 17: Particular Hazards

    B-Top Safety Safety footwear To protect the wearer from any heavy items that may fall, and from losing their footing on slippery ground. Protective goggles To protect the eyes from projectile parts and liquid splashes. Hair net To protect long hair from getting snagged in rotating parts on the machine tool.
  • Page 18 B-Top Safety Moving parts WARNING Serious injuries caused by touching rotating and/or moving parts!  Do not open guards while the system is operating. During operation, do not reach for rotating and/or  moving parts. Pay attention to the gap dimensions of moving ...

  • Page 19: Other Safety Instructions

    B-Top 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 and burrs! All installation of individual parts must be per- ...
  • Page 20 B-Top 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. WARNING Serious injuries caused by reaching into slots and bores!

  • Page 21: Screws

    B-Top 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. NOTE Damage to materials caused by untightening the wrong screws!

  • Page 22: Environmental Protection

    B-Top 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- ...

  • Page 23: Technical Data

    B-Top Technical data 3 Technical data 3.1 General information Ø 320 x 198.2 6000 Ø 320 x 217.5 4000 Ø 320 x 243.3 3600 Table 1: Technical data 3.2 Performance values NOTE Material damage to the products use and/or to the machine tool caused by exceeding the maximum performance values! ...

  • Page 24: Balancing Quality

    B-Top Technical data The clamping force measured must be in the approved range [see »Clamping force speed diagram« chapter]. 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-...

  • Page 25: Clamping Force Speed Diagram

    (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.

  • Page 26: Size 165

    B-Top Technical data 3.5.2 Size 165 GST140 [0.7 kg] SHF160 [0.6 kg] SFA160 [1.2 kg] Required minimum clamping force 33% 3.5.3 Size 260 GST251 [2.8 kg] SHF250 [1.9 kg] SFA250 [3.7 kg] Required minimum clamping force 33% 3.5.4 Size 315 GST315 [3.5 kg] SHF250 [1.9 kg] SFA250 [3.7 kg]...

  • Page 27: Operating Conditions

    B-Top Technical data 3.6 Operating conditions Indication Value Unit Ambient temperature range 15 - 60 °C ≤ 80 Workpiece temperature °C ≤ 80 Humidity Table 2: Operating conditions 3.7 Type designation The type designation is on the product and it includes the following indications: Manufacturer ...

  • Page 28: Layout And Function

    B-Top Layout and function 4 Layout and function 4.1 Overview and brief description Machine adapter Quick change-over adapter Clamping device Integrated liner Base jaw [clamping ele- ment kit] Top jaw [clamping ele- ment kit] The clamping device covers a big range of clamping diame- ters.

  • Page 29: Accessories Required

    B-Top Layout and function 4.2 Accessories required Machine adapter 4.2.1 The machine adapter is used to adapt the quick change-over unit to the machine tool. 4.2.2 Chuck jaws The jaw chuck can be equipped with the following variety of jaws: Base jaws ...

  • Page 30: Use And Limits Of Use

    The product can only be used in combination with a suitable machine adapter from HAINBUCH. As well as for its general field of application, this product was designed and developed for use, when necessary, in a specific and documented application [see clamping situa- tion drawing or order confirmation].

  • Page 31: Calculation Of Jaw Centrifugal Forces

    B-Top Use and limits of use Brief des- Unit Explanation ignation �� ������ Centrifugal force of base jaws ������ −1 �� ������ Speed Center of gravity spacing of jaw Cen- �� �� �� ter of gravity spacing of jaw �� ��...

  • Page 32: Calculation Of The Required Clamping Force At A Given Rotational Speed

    B-Top 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 33 B-Top 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 NOTE Material damage to the clamping device and ma- chine tool caused by exceeding the clamping...

  • Page 34: Sample Calculation

    B-Top 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] ...

  • Page 35: Calculation Of Permitted Speed At A Given Clamping Force

    B-Top Use and limits of use Now the total centrifugal force can be calculated. �� ∗ �� �� ∗ 1200 �� = ∑ �� ∗ ( = 2.668 ∗ ( �� �� �� = 42131�� �� Initial clamping force while stationary: ) = 1.5 ∗...

  • Page 36: Sample Calculation

    B-Top 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 �� = 3000��...

  • Page 37: Transport, Packaging, Storage

    B-Top 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 ...

  • Page 38: Symbols On The Packaging

    B-Top 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. 6.2 Symbols on the packaging Fragile Designates packaging items with fragile or breakable con-...

  • Page 39: Unpacking And Internal Transportation

    B-Top 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.

  • Page 40: Storage

    B-Top 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.

  • Page 41: Installation

    B-Top 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 42 B-Top 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. Never move body parts under parts in the working ...

  • Page 43: Preliminary Remarks

    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 44 B-Top 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 Top jaws The following table lists the screw tightening torques for se- curing the top jaws to the product.

  • Page 45: Preparation Of The Machine For Installation

    B-Top Installation 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. Reduce the operating pressure to a minimum. Remove cutting tools and/or sharp objects from the working area of the machine, or cover them.

  • Page 46: Preparation Of The Product

    B-Top Installation 7.5.2 Preparation of the product The product is supplied in assembled condition. No preparatory steps are needed to install the product. 7.5.3 Installation of the product on a machine adapter INFORMATION Installation / removal of the product is described in the operating instructions for the machine adapter.

  • Page 47: Position Of Base Chucks

    B-Top Installation 7.6.1 Position of base chucks Move the clamping device into release position. Base chuck Marker line INFORMATION A marker line is drawn between the jaw guides on the flat side of the clamping device with helps to position the base chuck and/or block chucks.
  • Page 48 B-Top Installation Use the release key to release the release pin in the jaw. INFORMATION The release key cannot be removed in this position. Pull the jaw outwards to remove it from the groove. Order hotline +49 7144.907-333...

  • Page 49: Installation Of Jaws With Base Chucks

    B-Top 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. 7.6.3 Installation of jaws with base chucks Clean the contact surfaces on the base chuck and the top-mounted chuck.

  • Page 50: Installation Of Jaws Without Base Chucks

    B-Top 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. Order hotline +49 7144.907-333...
  • Page 51 B-Top 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...

  • Page 52: Unscrewing And Removing The Jaws

    B-Top 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.

  • Page 53: Commissioning

    B-Top 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 ejected centrifugally or dropping out if clamping force is insufficient! Workpiece blanks must not be outside the clamp-...

  • Page 54: Checking The Total Stroke

    B-Top 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  levels of corrosion inhibitor.

  • Page 55: Tests

    B-Top 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]. 8.3 Tests NOTE Serious damage to, or destruction of, the machine...

  • Page 56: Workpiece

    B-Top 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 ...

  • Page 57: Procedure After A Collision

    B-Top 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«...

  • Page 58: Activities After End Of Production

    B-Top Activities after end of production 9 Activities after end of production Move product into release position. 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.

  • Page 59: Removal

    B-Top 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 Serious injuries caused by unskilled staff during installation / removal! Installation and removal must be performed by...
  • Page 60 B-Top 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 ...

  • Page 61: Preparing The Machine For Removal

    B-Top 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.

  • Page 62: Removal Of Jaw Chucks With Base Chuck

    B-Top Removal As described in the »Preparing the machine for re- moval« chapter, prepare for the following steps. 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.

  • Page 63: Removal Of Jaw Chucks Without Base Chuck

    B-Top 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 64 B-Top 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...

  • Page 65: Removal Of The Product

    B-Top Removal 10.4 Removal of the product Quick change-over unit Quick-release screws, quick change-over unit As described in the »Preparing the machine for re- moval« chapter, prepare for the following steps. 10.4.1 Removal of the product from a machine adapter INFORMATION Installation / removal of the product is described in the operating instructions for the machine adapter.

  • Page 66: Maintenance

    B-Top 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 ...

  • Page 67: Cleaning

    B-Top Maintenance Interval Maintenance work Conduct a structural clamping force measurement weekly or after 40- operat- Remove, clean and reinstall the CENTREX ring [see the ing hours* »Cleaning« chapter] Completely clean the product [see »Cleaning« chapter] six-monthly or after 1200 Check that the retaining ring is firmly seated operating hours* Lubricate the product [see »Lubricating the product«...
  • Page 68 B-Top Maintenance WARNING Eye injuries and cuts caused by failure to wear protective clothing during cleaning operation!  Never use compressed air to clean the product. Also wear the following items of personal protec-  tive equipment, in addition to the basic equip- ment: NOTE Damage to seals caused by the wrong solvent!
  • Page 69 B-Top Maintenance WARNING Serious injuries caused by imbalance resulting from incorrect reassembly!  The product components must be installed back in the same position. If necessary, mark out the relative positions of  components prior to disassembly. NOTE Damage to materials caused by incorrect Removal of the product! More extensive disassembly than shown on the ...

  • Page 70: Visual Inspection

    B-Top Maintenance INFORMATION The set-up dimension describes the axial distance be- tween the flat surface of the bayonet coupling and the contact surface of the quick change-over adapter / the quick change-over unit on the machine adapter, whenever the product is in its front limit position. INFORMATION The tolerance of the set-up dimension is ±0.2 ����...

  • Page 71: Lubricating The Product

    B-Top 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]. Always comply with the maintenance intervals ...

  • Page 72: Use Of Lubricants

    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...

  • Page 73: Disposal

    B-Top 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- ...

  • Page 74: Faults

    B-Top 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«...

  • Page 75: Fault Table

    B-Top Faults 13.2 Fault table Fault Possible cause Remedial action Remedied by Remove and clean the clamping Incorrect axial Dirt in the parts in elements, and remove, dismantle Skilled special- strokes in the the power flow and clean the clamping device if clamping device necessary Clamping element...

  • Page 76: Commissioning After A Fault Has Been Remedied

    B-Top Faults Fault Possible cause Remedial action Remedied by 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 clamping element Dirty clamping ele- Clean the clamping element Indentations on ment...

  • Page 77: Annex

    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 78 B-Top Index directory Misuse ..........15 Accessories, needed Machine adapter ......29 Operating conditions ......27 Accessories, optional Integrated liner ......29 Packaging ......... 39 Accessories, required Performance values ......23 Chuck jaws ........29 Personnel requirements ....13 Accessories, special aids Electricians ........
  • Page 79 B-Top Transport inspection ......38 Use ............ 30 Transportation, internal ..... 39 Type designation....... 27 Warranty ..........11 Unpacking ......... 39 Order hotline +49 7144.907-333...
  • Page 80 HAINBUCH GMBH  SPANNENDE TECHNIK Postfach 1262  71667 Marbach / Erdmannhäuser Strasse 57  71672 Marbach  Germany Tel. +49 7144.907-0  Fax +49 7144.18826  verkauf@hainbuch.de  www.hainbuch.com 24 hour emergency phone line + 49 7144.907-444...

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