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SCHUNK VERO-S NSR 138 Translation Of Original Operating Manual

Robot coupling for pallet handling
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Translation of Original Operating Manual
VERO-S Robot Coupling for
Pallet Handling
NSR 138 / PKL 138
Assembly and Operating Manual

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Summary of Contents for SCHUNK VERO-S NSR 138

  • Page 1 Translation of Original Operating Manual VERO-S Robot Coupling for Pallet Handling NSR 138 / PKL 138 Assembly and Operating Manual...
  • Page 2 Imprint Imprint Copyright: This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights reserved. Technical changes: We reserve the right to make alterations for the purpose of technical improvement. Document number: 1509378 Version: 01.00 | 25/07/2022 | en...

  • Page 3: Table Of Contents

    Table of Contents Table of Contents General........................ 5 Presentation of Warning Labels ................ 5 Applicable documents .................. 6 Basic safety notes .................... 7 Intended use...................... 7 Not intended use .................... 7 Notes on particular risks.................. 7 Notes on safe operation .................. 9 2.4.1 Holding force and screw strength............ 10 2.4.2 Constructional changes ................ 10 Personnel qualification..................
  • Page 4 Table of Contents 10 Assembly drawings .................... 48 11 Monitoring ...................... 51 12 Cone seal ........................ 52 13 Declaration of incorporation................... 55 14 Appendix on Declaration of Incorporation .............. 56 01.00 | NSR 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en | 1509378...

  • Page 5: General

    General 1 General This operating manual is an integral component of the product and contains important information on safe and proper assembly, commissioning, operation, care, maintenance and disposal. This manual must be stored in the immediate vicinity of the product where it is accessible to all users at all times.

  • Page 6: Applicable Documents

    • General terms of business * • Catalog data sheet of the purchased product * The documents labeled with an asterisk (*) can be downloaded from schunk.com. 01.00 | NSR 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en | 1509378...

  • Page 7: Basic Safety Notes

    The VERO-S robot coupling for pallet handling is not being used as intended if, for example: • It is used as load handling or lifting equipment. • it is used for turning applications without consulting SCHUNK. • It is used as a quick-change pallet system for milling applications without consulting SCHUNK.
  • Page 8 Basic safety notes • Perform maintenance, modifications, or installations outside of the danger zone. • For all work, secure the system against accidental operation. • Do not reach into the open mechanism or the movement area of the system. • Only specialist personnel may perform assembly, modification and disassembly work.

  • Page 9: Notes On Safe Operation

    Basic safety notes  CAUTION Risk of injury due to compressed air hoses coming loose when connected improperly. Use check valves or safety switches. • The danger zone must be surrounded by a protective • enclosure during operation.  CAUTION Risk of slipping or falling if the operational environment is not clean (e.g.

  • Page 10: Holding Force And Screw Strength

    This is why only screws of strength class 12.9 may be used. Only original SCHUNK clamping pins may be used. If the clamping pin is to be used in customer-specific devices, the customer must provide a sufficiently dimensioned pallet coupling or a sufficiently thick mounting material.

  • Page 11: Personnel Qualification

    Only allow specialists to remedy malfunctions. Spare parts Only use original SCHUNK spare parts. Environmental regulations The applicable environmental regulations must be observed for all maintenance and repair work.

  • Page 12: Warranty

    Warranty 3 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: } 1.2 [/ 6] • Observe the applicable documents, • Observe the ambient conditions and operating conditions •...

  • Page 13: Scope Of Delivery

    Scope of delivery 4 Scope of delivery • Robot Coupling for Pallet Handling NSR 138 • Assembly and Operating Manual • Accessory kit NSR 138 4 cover plugs 8 O-rings Ø 6 x 1.5 3 screws DIN EN ISO 4762 - M8 x 45 - 10.9 1 fitting screw M8 x 45 4.1 Accessories (see catalog or data sheets when ordering separately)

  • Page 14: Technical Data

    Technical data 5 Technical data 5.1 NSR 138 Designation / type Robot coupling NSR 138 1492479 Max. torque Mx with PKL 138 * 1500 Nm Max. torque Mx with PKL 160 * 600 Nm Max. torque Mz * 1600 Nm Pull down force without turbo 8.0 kN Pull down force with Turbo...

  • Page 15: Calculation Of Permissible Transport Load

    Technical data 5.2 Calculation of Permissible Transport Load The robot coupling is limited to a maximum permissible torque at the coupling interface. The dynamic load when using the robot system for handling results in acceleration and deceleration forces that have to be taken into consideration for the transport load. To operate the robot coupling with dynamic handling, it is essential for the maximum acceleration of the machine to be known.
  • Page 16 Technical data Calculating the acceleration force: Maximum permissible torque for NSR 138: M = 1500* Nm Result of calculation: Taking into account the robot acceleration, the loading weight obtained in the calculation example is permissible. * When using the PKL 138. If the PKL 160 is used, reduced load values apply (} 5.1 [/ 14]).

  • Page 17: Assembly

    Assembly 6 Assembly Pre-assembly measures Carefully lift the product out of the packaging (e.g. with suitable lifting equipment).  CAUTION Risk of injury due to sharp edges and rough or slippery surfaces Wear personal protective equipment, particularly protective gloves. Check that the delivery is complete and that there is no transport damage.

  • Page 18: Screw Tightening Torques

    Assembly 6.1 Screw tightening torques For mounting the robot coupling on the robot flange: Screw size Strength class Tightening torque [Nm] 10.9 For fastening the clamping pin to the pallet coupling: Screw size Strength class Tightening torque [Nm] 12.9 For fastening the clamping pallet to the pallet coupling: Screw size Strength class Tightening torque [Nm]...

  • Page 19: General Installation Notes

    Assembly 6.2 General installation notes Request our installation drawings if doing the installation yourself. If several linked clamping units are mounted, make sure that the flatness and height deviation of the locating surface from module to module (based on a gauge of 200 mm) lies within 0.01 mm. NOTE When connecting the quick-change pallet systems, ensure that it is only possible to completely ventilate the piston chamber via the...
  • Page 20 Assembly Mounting NSR 138 A: Cylindrical screw (3x) B: Fitting screw for position orientation diagonally offset C: O-rings for sealing the direct connections on the bottom side D: Customized robot flange E: Locking screw G1/8 The air connection takes place via the G1/8 coupling holes at the side as standard.
  • Page 21 Assembly A: Unlocking connection on the bottom side B: Turbo connection on the bottom side C: Cleaning air connections on the bottom side D: Unlocking connection on side G1/8 E: Turbo connection on side G1/8 F: Cleaning air connections on side G1/8 G: Torque pin variant I via mold inclines on both sides H: Torque pin variant II via cylindrical pins I: Air outlets cleaning function...

  • Page 22: Unlocking Connection

    Assembly When the turbo connection is used, the spring-actuated locking procedure is actively supported with air pressure. If the turbo connection is not used, the relevant side of the piston must be able to ventilate. 6.3.1 Unlocking connection If compressed air is constantly applied to the unlocking connection of the robot coupling, the clamping system is unlocked.

  • Page 23: Air Purge Connection With Cleaning Function

    Assembly 6.3.3 Air purge connection with cleaning function For interface cleaning, the NSR 138 has two side air purge connections with G1/8 connection thread and 2 hose-free direct connections on the bottom side. The side air connections must be closed with G1/8 locking screws when not in use. The hose-free direct connections on the bottom side must be sealed with O-rings (Item 32;...

  • Page 24: Pneumatic Circuit Diagram

    Assembly 6.3.4 Pneumatic circuit diagram NSR 138 01.00 | NSR 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en | 1509378...

  • Page 25: Coupling Interface

    Assembly A: Actuation with 6 bar (also on the bottom side via hose-free direct connections) B: 15 l/min C: Exhaust air max. 6 bar (also on the bottom side via hose-free direct connections) D: Pneumatic circuit symbols E: 5/3 directional control valve, center position ventilated F: 3/2 directional control valve G: Pressure switch H: Pressure gauge...
  • Page 26 Assembly Torque pin version I 01.00 | NSR 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en | 1509378...
  • Page 27 Assembly Torque pin variant II 01.00 | NSR 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en | 1509378...
  • Page 28 E: Torque pin variant II: Position orientation by means of alignment pins and fitting bores F: Pallet coupling PKL 160 Only an original SCHUNK clamping pin may be mounted on the coupling interface with the designated mounting screw. (The screw must be tightened with the specified torque } 6.1...

  • Page 29: Pallet Adapters

    Assembly 6.4.1 Pallet adapters The pallet coupling PKL 138 (ID 1492512) was designed as a pallet changing interface for the robot coupling NSR 138. Alternatively, the PKL 160 (ID 0471930) can also be used in conjunction with the robot coupling NSR 138, but with reduced permissible moment Mx.
  • Page 30 Assembly 01.00 | NSR 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en | 1509378...
  • Page 31 Assembly A: Clamping pin SPA 40-16 B: Screw-in depth C: Contact surface on robot module D: Lag screw E: Mounting screw DIN EN ISO 4762 - M16 - 12.9 F: Bearing surface for clamping pallet G: Centering slants for torque pin variant I H: Alignment pin 01.00 | NSR 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en | 1509378...
  • Page 32 Assembly 01.00 | NSR 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en | 1509378...
  • Page 33 Assembly A: Clamping pin SPA 40-16 B: Screw-in depth C: Contact surface on robot module D: Lag screw E: Mounting screw DIN EN ISO 4762 - M16 - 12.9 F: Bearing surface for clamping pallet G: Centering slants for torque pin variant I 01.00 | NSR 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en | 1509378...
  • Page 34 Assembly Connection interface between the clamping pallet and pallet coupling PKL 138 * The clamping pallet height must be at least 35 mm. 01.00 | NSR 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en | 1509378...
  • Page 35 Assembly A: Clamping surface of clamping pallet B: Screw-in depth Connection interface between the clamping pallet and pallet coupling PKL 160 * The clamping pallet height must be at least 25 mm. A: Clamping surface of clamping pallet B: Screw-in depth 01.00 | NSR 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en | 1509378...

  • Page 36: Specific Pallet Coupling

    M16 screw, strength class 12.9. The specified screw torque must be observed } 6.1 [/ 18]. Only original SCHUNK clamping pins may be used. • If the clamping pin is to be used in customer-specific devices, • the customer must provide a sufficiently dimensioned depth of engagement in the clamping pin or a sufficiently thick mounting material in the adapter strip for the pallet coupling.
  • Page 37 3: Screw DIN EN ISO 4762 - M16 - 12.9 4: Customized pallet or device, steel version 5: Customized pallet or device, aluminum version 6: Steel washer (SCHUNK) Tolerances and installation conditions for installation in a customer-specific pallet coupling SPA 40-16 0471064 >...

  • Page 38: Application Example For Automated Pallet Loading

    Assembly 6.6 Application example for automated pallet loading The NSR 138 clamping system was designed for automated pallet loading. The robot coupling, with the handling system, is the interface between the machine work area and pallet rack. Application example for automated pallet loading A: Robots B: Robot flange C: Robot coupling NSR 138...

  • Page 39: Connection And Disconnection Of Transport Loads

    Assembly 6.6.1 Connection and disconnection of transport loads The following must be taken into account during automated connection and disconnection of transport loads: • Approach the coupling interfaces between the robot module and robot coupling or clamping pallet and clamping station at an early stage without a tilt angle and eccentricity (see illustration above) •...
  • Page 40 Assembly Automated connection and disconnection of transport loads A: Position the clamping pallet on the clamping station or remove it from the clamping station B: Traverse path of the movement axes during loading C: Clamping pallet D: Clamping station E: Connect or disconnect pallet coupling F: Robot module unlocked during coupling process, switch on blast air (cleaning function) during loading 01.00 | NSR 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en |...

  • Page 41: Maintenance And Care

    Risk of injury and risk of damage to the clamping module when opening the housing cover. If the clamping module has to be disassembled, ship the module to SCHUNK for repair. The cover of the clamping module is spring pre-loaded and must only be removed by trained specialist personnel.

  • Page 42: Regular Inspection Of Robot And Pallet Coupling

    Maintenance and care 7.1 Regular Inspection of Robot and Pallet Coupling A visual inspection of the robot coupling and the associated PKL pallet coupling for possible damage to the components must be carried out at regular intervals. This visual inspection must be carried out every 50,000 clamping cycles.

  • Page 43: Troubleshooting

    Defective air connections Check air supply Pressure below minimum Check operating pressure (min. 5 bar) A component is broken (e.g. due to Replace the module or send it to SCHUNK for overloading) repair Excess tensile load on clamping pins Reduce support weight...
  • Page 44 Troubleshooting The cone seal does not seal Possible cause Solution(s) Sealing ring is damaged or deformed Remove seal and replace sealing ring Sealing ring is damaged Initiate loading and unloading process only when clamping slides are fully retracted Sealing ring insufficiently splayed when Ensure that the components are installed in the closing the clamping module correct position...

  • Page 45: Wearing Parts Kit And Parts Lists

    The bearing shells may only be replaced in case of damage as part of maintenance work by SCHUNK. To do so, the quick-change pallet module must be sent to SCHUNK for maintenance. 01.00 | NSR 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en |...

  • Page 46: Parts List

    Wearing parts kit and parts lists 9.2 Parts list NSR 138 (ID 1492479) Item Designation Quantity Base body NSR 138 Cover Clamping slide Piston Plug Slide washer O-ring Ø 20 x 1.5 O-ring Ø 42 x 3.5 O-ring Ø 94.5 x 3.5 Round cord section Ø...
  • Page 47 Wearing parts kit and parts lists PKL 138 (ID 1492512) Item Designation Quantity Base body PKL 138 Screw DIN EN ISO 4762 - M12 x 90 - 10.9 Cylindrical pin Ø 12 x 32 Clamping pin SPA 40-16 Screw DIN EN ISO 4762 - M12 x 35 - 12.9 M12 cover plug Washer PKL 160 PKL 160 (ID 0471930)

  • Page 48: Assembly Drawings

    Assembly drawings 10 Assembly drawings NSR 138 * Accessories to be ordered separately 01.00 | NSR 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en | 1509378...
  • Page 49 Assembly drawings KVS 40 01.00 | NSR 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en | 1509378...
  • Page 50 Assembly drawings PKL 138 01.00 | NSR 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en | 1509378...

  • Page 51: Monitoring

    Monitoring 11 Monitoring Robot coupling NSR 138 is prepared for monitoring the pallet presence and clamping slide positions by the AFS3-R IOL monitoring module (ID 1491363). Pallet presence monitoring is compatible with pallet couplings PKL 138 (ID 1492512) and PKL 160 (ID 0471930). Notes on mounting and teaching the monitoring module can be found in the corresponding operating manual, which is included in the scope of delivery of the AFS3-R IOL.

  • Page 52: Cone Seal

    Cone seal 12 Cone seal To install the cone seal in the NRS 138, the recessed plug must first be removed from the change interface and replaced with the supplied cover with sealing ring. The installation takes place according to the following installation description and the illustrations "Operational sequence of installation of cone seal"...
  • Page 53 Cone seal 01.00 | NSR 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en | 1509378...
  • Page 54 Cone seal A: Sealing ring spread for sealing B: Clamping slide in closed position, without clamping pin C: Sealing ring unclamped, prepared for loading D: Clamping slide unlocked E: Clamping pin clamped, clamping module closed 01.00 | NSR 138 / PKL 138 | VERO-S Robot Coupling for Pallet Handling | en | 1509378...

  • Page 55: Declaration Of Incorporation

    13 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/ H.-D. SCHUNK GmbH & Co. Spanntechnik KG Distributor Lothringer Str. 23 D-88512 Mengen We hereby declare that on the date of the declaration the following partly completed machine complied with all basic safety and health regulations found in the directive 2006/42/EC of the European Parliament and of the Council on machinery.

  • Page 56: Appendix On Declaration Of Incorporation

    Appendix on Declaration of Incorporation 14 Appendix on 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 pallet system Type designation NSR 138;...
  • Page 57 Appendix on Declaration of Incorporation Protection against mechanical hazards 1.3.7 Risks related to moving parts 1.3.8 Choice of protection against risks arising from moving parts 1.3.8.1 Moving transmission parts 1.3.8.2 Moving parts involved in the process 1.3.9 Risks of uncontrolled movements Required characteristics of guards and protective devices 1.4.1 General requirements...
  • Page 58 Appendix on Declaration of Incorporation 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 Warning of residual risks 1.7.3 Marking of machinery 1.7.4 Instructions 1.7.4.1 General principles for the drafting of instructions 1.7.4.2 Contents of the instructions 1.7.4.3 Sales literature The classification from Annex 1 is to be supplemented from here...
  • Page 60 Translation of Original Operating Manual H.-D. SCHUNK GmbH & Co. Spanntechnik KG Lothringer Str. 23 D-88512 Mengen Tel. +49–7572-7614-0 Fax +49-7572-7614-1099 info@de.schunk.com schunk.com Folgen Sie uns I Follow us...

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