Original operating manual
Quick-Change System
SWS 005 - 300
Assembly and Operating Manual
Superior Clamping and Gripping
Imprint
Imprint
Copyright:
This manual remains the copyrighted property of SCHUNK GmbH & Co. KG. It is solely
supplied to our customers and operators of our products and forms part of the product.
This documentation may not be duplicated or made accessible to third parties, in particular competitive companies,
without our prior permission.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 0389456
Edition: 06.06 |24/08/2016|en
© SCHUNK GmbH & Co. KG
All rights reserved.
Dear customer,
congratulations on choosing a SCHUNK product. By choosing SCHUNK, you have opted for
the highest precision, top quality and best service.
You are going to increase the process reliability of your production and achieve best
machining results – to the customer's complete satisfaction.
SCHUNK products are inspiring.
Our detailed assembly and operation manual will support you.
Do you have further questions? You may contact us at any time – even after purchase.
Kindest Regards
Yours SCHUNK GmbH & Co. KG
Spann- und Greiftechnik
Bahnhofstr. 106 – 134
D-74348 Lauffen/Neckar
Tel. +49-7133-103-0
Fax +49-7133-103-2399
[email protected]
www.schunk.com
2
06.06|SWS 005 - 300 |en
Table of Contents
Table of Contents
1
About this manual .................................................................................................... 5
1.1 Warnings ................................................................................................................... 5
1.2 Applicable documents .............................................................................................. 5
2
Basic safety notes .................................................................................................... 6
2.1 Intended use ............................................................................................................. 6
2.2 Not intended use ...................................................................................................... 6
2.3 Environmental and operating conditions................................................................. 6
2.4 Product safety........................................................................................................... 7
2.4.1 Protective equipment ................................................................................... 7
2.4.2 Constructional changes ................................................................................. 7
2.5 Personnel qualification ............................................................................................. 7
2.6 Using personal protective equipment ...................................................................... 8
2.7 Notes on particular risks........................................................................................... 9
3
Warranty ................................................................................................................. 12
4
Scope of delivery ..................................................................................................... 12
5
Product Overview .................................................................................................... 13
5.1 Quick-change Head (SWK) ...................................................................................... 13
5.2 Quick-change adapter (SWA) ................................................................................. 14
5.3 Optional Modules ................................................................................................... 14
6
Accessories .............................................................................................................. 15
6.1 SWD Dust Cover for SWA quick-change adapter ................................................... 15
7
Technical Data ........................................................................................................ 17
8
Assembly ................................................................................................................. 18
8.1 Example of mounting ............................................................................................. 18
8.2 Interface Plate Design and Mounting .................................................................... 19
8.3 Requirements of the storage magazine ................................................................. 20
8.4 Mechanical connection .......................................................................................... 22
8.4.1 Fastening of the quick-change head (SWK) ................................................ 23
8.4.2 Fastening the quick-change adapter (SWA) ............................................... 24
8.4.3 Tightening torque........................................................................................ 24
8.5 Air connection ........................................................................................................ 27
8.6 Valve Requirements and Connections ................................................................... 28
8.7 Pneumatic plan ....................................................................................................... 28
8.8 Sensors - Piston Stroke Control .............................................................................. 29
8.8.1 Function Stroke Control of the piston – SWS-011 and Larger .................... 29
8.8.2 Integrated Proximity Switch - SWS 040Q/076/110/160............................. 30
8.8.3 Typ Lock and Unlock Sensors ...................................................................... 31
8.8.4 Sensors ........................................................................................................ 31
8.9 Optional Module Installation ................................................................................. 31
06.06|SWS 005 - 300 |en
3
Table of Contents
8.9.1
8.9.2
8.9.3
8.9.4
8.9.5
8.9.6
8.9.7
8.9.8
9
Electrical Module Installation - SWS-005 and SWS-011 ......................................
Electrical Module Removal - SWS-005 and SWS-011 ...........................................
SWK Electrical Module Installation A15/B15 - SWS-005 and SWS-011 ...............
SWA Electrical Module Removal E10/E20 - SWS-005 and SWS-011 ...................
Flat A Optional K Series Module Installation - SWS-020 and SWS-021 ...............
Flat A Optional K Series Module Removal - SWS-020 and SWS-021 ...................
Flat B Optional Module Installation - SWS-021 ....................................................
Flat B Optional Module Removal - SWS-021 ........................................................
32
32
33
34
35
35
36
36
Operation ................................................................................................................ 37
9.1
9.2
9.3
Conditions for Coupling .................................................................................................... 37
Fail-Safe Operation ........................................................................................................... 38
Conditions for Uncoupling ................................................................................................ 39
10 Trouble shooting ..................................................................................................... 40
10.1 The Quick-Change-Head (balls) doesn’t move?................................................................ 40
10.2 The Quick Change Head does not clamp the Quick- Change-Adaptor correctly? ............ 40
10.3 The clamping force between SWK and SWA is reducing? ................................................ 40
11 Maintenance and Care ............................................................................................ 41
11.1 Preventive Maintenance ................................................................................................... 41
11.2 Lubrication ........................................................................................................................ 43
11.2.1 External ................................................................................................................. 43
11.2.2 Internal.................................................................................................................. 43
11.3 Cleaning and Lubrication of the Locking Mechanism ...................................................... 43
11.3.1 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins .......... 43
11.3.2 Cleaning the Bearing Race and Alignment Pin Bushings (SWA) ........................... 44
11.4 Service of the sensors ....................................................................................................... 45
11.4.1 Proximity Sensor Adjustment, Test, or Replacement - SWS-011 ........................ 45
11.4.2 Proximity Sensor Adjustment, Test, or Replacement - SWS 020/021/
040/060/071/100/150 .......................................................................................... 47
11.4.3 Lock and Unlock Sensor Assembly Replacement (with Sensor Assemblies for SWS
040Q, 076, 110, 160) ............................................................................................ 49
11.5 Rubber Bushings ............................................................................................................... 50
11.5.1 Seal Inspection and Replacement for Electrical Modules .......................... 51
11.6 Alignment Pins ..................................................................................................................
11.7 Disassembly of the SWK Quick-Change Master................................................................
11.7.1 Disassembly of SWK 005 - 011 .............................................................................
11.7.2 Disassembly of SWK 020 - 300 .............................................................................
52
52
52
54
12 Assembly drawings .................................................................................................. 55
12.1
12.2
12.3
12.4
Assembly SWS-005/011 ....................................................................................................
Assembly SWS-020/021/041/060/071/150/300 .............................................................
Assembly SWK-027 ...........................................................................................................
Assembly SWK-076/110/160 ............................................................................................
55
56
57
58
13 Seal kit .............................................................................................................................. 59
14 Translation of original declaration of incorporation ........................................................... 60
4
06.06|SWS 005 - 300 |en
About this manual
1 About this manual
This instruction is an integral part of the product and contains important information for a safe and proper assembly, commissioning, operation, maintenance and help for easier trouble shooting.
Before using the product, read and note the instructions, especially the chapter "Basic safety notes".
1.1 Warnings
To make risks clear, the following signal words and symbols are
used for safety notes.
WARNING
Dangers for persons.
Ignoring a safety note like this can lead to irreversible injury and
even death.
CAUTION
Dangers for persons.
Non-observance can cause minor injuries.
NOTICE
Material damage
Information about avoiding material damage.
1.2 Applicable documents
• General terms of business
• Catalog data sheet of the purchased product
• Assembly and Operating manuals of the accessories
The documents listed here, can be downloaded on our homepage
www.schunk.com
06.06|SWS 005 - 300 |en
5
Basic safety notes
2 Basic safety notes
2.1 Intended use
The module (SWS quick-change systems, consisting of SWK quickchange head and SWA quick-change adapter) was designed for a
quick change of parts and automation components on a robot in
the context of its technical data.
The product is intended for installation in a machine/system. The
requirements of the applicable guidelines must be observed and
complied with.
The product may be used only in the context of its defined application parameters ( 7, Page 17).
The product is designed for industrial use.
To use this unit as intended, it is also essential to observe the
technical data and installation and operation notes in this manual
and to comply with the maintenance intervals.
2.2 Not intended use
It is not intended use if the product is used, for example, as a
pressing tool, stamping tool, lifting gear, guide for tools, cutting
tool, clamping device or a drilling tool.
• Any use beyonde the intended use or other types of use are
considered misuse.
2.3 Environmental and operating conditions
Requirements for the ambient and operating conditions
Due to incorrect ambient and operating conditions, dangers may
arise from the product, which can cause serious injury and substantial property damage.
• Make sure that the product has a sufficient size for the application.
• Observe maintenance and lubrication intervals, ( 11.1, Page 41).
• Make sure that the environment is free from splash water and
vapors as well as from abrasion or processing dust. Exceptions
are products that are designed especially for contaminated environments.
6
06.06|SWS 005 - 300 |en
Basic safety notes
2.4 Product safety
Dangers arise from the product, if:
• the product is not used in accordance with its intended purpose.
• the product is not installed or maintained properly.
• the safety and installation notes are not observed.
Avoid any manner of working that may interfere with the function
and operational safety of the product.
Wear protective equipment.
NOTE
More information is contained in the relevant chapters.
2.4.1 Protective equipment
Provide protective equipment per EC Machinery Directive.
2.4.2 Constructional changes
Making constructional changes
Attachements and modifications, constructional changes and subsequent work, e.g. additional threads, drill holes and safety devices, can
compromise the operation and safety or damage the product.
• Constructional changes may be only done with permission from
SCHUNK.
2.5 Personnel qualification
Inadequate qualifications of the personnel
If the personnel working with the product is not sufficiently qualified, the result may be serious injuries and significant property
damage.
• All work may be only performed by qualified personnel.
• Before working with the product, the personnel must have read
and understood the complete assembly and operating manual.
• Observe the national safety regulations and rules and general
safety instructions.
06.06|SWS 005 - 300 |en
7
Basic safety notes
The following personal qualifications are necessary for the various
activities related to the product:
Trained electrician Due to their technical training, knowledge and experience, trained
electrician are able to work on electrical systems, recognize and
avoid possible dangers and know the relevant standards and regulations.
Pneumatics specialist Pneumatics specialists have been trained for this particular area of
responsibility and know the relevant standards and regulations.
Hydraulic specialist Hydraulic specialists have been trained for this particular area of
responsibility and knows the relevant standards and regulations.
Qualified personnel Due to their technical training, knowledge and experience, qualified personnel is able to perform the delegated tasks, recognize
and avoid possible dangers and knows the relevant standards and
regulations.
Instructed person Instructed persons were instructed by the operator about the delegated tasks and possible dangers due to improper behaviour.
Service personnel of Due to their technical training, knowledge and experience, service
the manufacturer personnel of the manufacturer is able to perform the delegated
tasks and to recognize and avoid possible dangers.
2.6 Using personal protective equipment
When using this product, observe the relevant industrial safety
regulations and use the personal protective equipment (PPE) required!
• Use protective gloves, safety shoes and safety goggles.
• Observe safe distances.
• Minimal safety requirements for the use of equipment.
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06.06|SWS 005 - 300 |en
Basic safety notes
2.7 Notes on particular risks
Generally valid:
• Remove the energy supplies before installation, modification,
maintenance, or adjustment work.
• Make sure that no residual energy remains in the system.
• Do not move parts by hand when the energy supply is connected.
• Do not reach into the open mechanism or the movement area
of the module.
• Perform maintenance, modifications, and additions outside of
the danger zone.
• For all work, secure the unit against accidental operation.
• Take a precautionary approach by maintenance and disassembly.
• Only specially trained staff should disassemble the module.
CAUTION
Possible risk of injury due to electrostatic energy!
Components or assembly groups may become electrostatically
charged. When touched, the electrostatic discharge can trigger a
startle response, which can result in injuries.
• The operator must ensure that all components and assembly
groups are included in the local equipotential bonding in line
with the applicable regulations.
NOTE
• The equipotential bonding must be installed by a specialist electrician in line with the applicable regulations, paying particular attention to the actual conditions in the working environment.
• The effectiveness of the equipotential bonding must be verified
by a specialist electrician through regular safety measurements.
06.06|SWS 005 - 300 |en
9
Basic safety notes
WARNING
Risk of injury from objects falling and being ejected
During operation, falling or ejected objects may cause serious
injuries or death.
• The danger zone must be surrounded by a safety fence during
operation.
WARNING
Risk of injury due to unexpected movement of the machine/system!
• Switch off the energy supply.
WARNING
Remove all temporary protective materials (caps, plugs, tape,
etc.) on locking face of Tool Changer and modules prior to operation. Failure to do so will result in damage to Tool Changers,
modules, and end-of-arm tooling and could cause injury to personnel.
WARNING
Injury or equipment damage can occur with power or air on.
• Do not perform maintenance or repair on Tool Changer or
modules with power or air on.
• Turn off power and air before performing maintenance or repair on Tool Changer or modules.
10
06.06|SWS 005 - 300 |en
Basic safety notes
WARNING
During operation, the area between the Quick-Chance-Head
SWK and Quick Change Adapter SWA must be kept clear.
Failure to keep area clear will result in damage to Tool Changer,
modules , or end-of-arm tooling and could cause injury to personnel.
WARNING
Using the Tool Changer in applications other than intended will
result in damage to Tool Changer, modules, or end-of-arm tooling and could cause injury to personnel.
• The Tool Changer is only to be used for intended applications
and applications approved by the manufacturer.
CAUTION
The SWK locking mechanism must not be actuated without being mounted to the robot interface plate.
Damage to the Cover Plate and O-ring may result.
• Always attach the SWK to the Robot interface plate prior to
attempting any operations.
06.06|SWS 005 - 300 |en
11
Scope of delivery
3 Warranty
If the product is used as intended, the warranty is valid for 24
months from the date of delivery from the production facility under the following conditions:
• Observe the applicable documents( 1.2, Page 5)
• Observe the environmental and operating conditions ( 2.3,
Page 6)
• Observe the mandatory maintenance and lubrication intervals.( 11, Page 41)
Parts touching the work piece and wearing parts are not part of
the warranty.
4 Scope of delivery
The scope of delivery includes
• Quick-Change-System SWS in the ordered model, containing
the following components:
– SWK quick-change head
– SWA quick-change adapter
• Accessory pack
12
06.06|SWS 005 - 300 |en
Product Overview
5 Product Overview
5.1 Quick-change Head (SWK)
The Quick-change Head (SWK) includes an anodized aluminum
body, a hardened stainless-steel locking mechanism, and hardened
steel alignment pins.
The SWK has sides for mounting of optional modules.
The locking mechanism consists of a cam, a male coupling, and
chrome-steel ball bearings.
Tapered pins located on the SWK are inserted in the bushings in
the SWA to ensure repeatable alignment during the coupling process. An extreme pressure grease is applied to the cam, male coupling, ball bearings, and pins to enhance performance and maximize the life of the SWK
Two port connections are available to supply air pressure for coupling and uncoupling the tool changer, ( 8.5, Page 27)
Port connections are available for pass through air for supplying air
to tools.
A mounting pattern is machined into the SWK for mounting to a
robot arm or a robot interface plate.
SWK
For safe monitoring of the end position of the SWK’s locking
mechanism we are recommending the use of a piston stroke control.
Stroke control of the piston available for Models SWS-011 and
Larger.
06.06|SWS 005 - 300 |en
13
Product Overview
5.2 Quick-change adapter (SWA)
A mounting pattern is machined into the quick-change head (SWA)
for mounting to a customer tooling or a tooling interface plate.
SWA
5.3 Optional Modules
There are flats available for mounting of the optional modules for
support of various utility pass-through, such as signal, fluid/air,
and electric.
SCHUNK website gives assistance in choosing the right modules.
For information about which optional modules can be used with
the appropriate product version, see catalog.
14
06.06|SWS 005 - 300 |en
Accessories
6 Accessories
A wide range of accessories is available for this module.
For information about which accessories can be used with the appropriate product version ☞ catalog.
6.1 SWD Dust Cover for SWA quick-change adapter
SWD dust cover
1
electrical option
3
SWD
2
SWK
4
SWA
The SWD dust cover is available in the following sizes
Size Designation
ID number
for electrical option (1)
020
SWD-020-K00-000 0302252
K19/K26 (connection side A)
021
SWD-021-K00-000 0302253
K19/K26 (connection side A)
040
SWD-040-R00-000 0302254
R19/R26 (connection side A)
041
SWD-041-R00-000 0302255
R19/R26 (connection side A)
060
SWD-060-K00-000 0302256
K19/K26 (connection side A)
071
SWD-071-R00-000 0302257
R19/R26 (connection side A)
076
SWD-076-000-R00 0302258
R19/R26 (connection side B)
110
SWD-110-R00-000 0302260
R19/R26 (connection side A)
150
SWD-150-R00-000 0302261
R19/R26 (connection side A)
06.06|SWS 005 - 300 |en
15
Accessories
In order to avoid contamination of the pneumatic feedthrough
openings, as well as of the contacts of the electric options at the
SWA quick- change tool, an SWD dust cover has to be used while it
is located in the storage rack.
The SWD is equipped with an integrated clamping device, which is
actuated by locking/ unlocking the SWK quick-change head. Hereby the SWD dust cover can be removed from the SWA quickchange adapter and can be located onto a further SWA quickchange adapter.
The SWD dust cover (material PA2220) is protecting the SWA
quick-change adapter against the following contaminations:
• Dust
• Chips
• Various liquids (e.g. coolant)
NOTE
• The SWD dust cover is only suitable for covering the SWA
quick-change tool. It never should be used for transporting the
SWA quick-change tool together with the attached tools.
• If the SWD dust cover should be used in extremely dirty conditions, an excessive filling of the interior of the SWK quickchange master mounting with dirt particles has to be avoided.
Therefore, regular control and possible cleaning of the SWK will
be necessary.
• In case of excessive contamination there will be the risk that
the locking mechanism of the SWK will not completely move into its final position, and the SWD will get damaged.
16
06.06|SWS 005 - 300 |en
Technical Data
7 Technical Data
More technical data are included in the catalog data sheet. Whichever is the latest version.
Size SWS
005
011
020
021
022
027
040 040Q 041
Weight [kg]
0.36
0.22
0.99
0.8
0.8
1.39
1.85
8
16
Recommended handling
weight [kg]
Locking force
(at 5.5 bar) [N]
690
25
1100 2300
Maximum distance on locking [mm]
min.
1.5
max.
3.0
2300
0.015
Noise emission [dB(A)]
50
2.1
50
3500 4500 5600 4500
0
3.0
Repeatability
[at 2 Mio. cycles]
Pressure medium
38
1.85
0
2.0
0
3.0
0
3.0
0.01
0.015
0.015
≤ 70
Compressed air, compressed air quality according to ISO
8573-1:7 4 4
Size SWS
060
071
076
110
150
160
300
Weight [kg]
2.0
3.1
3.65
6.2
7.5
9.3
19.1
Recommended handling
weight [kg]
75
79
100
150
200
300
450
7400
8100
16000
31000
35000
0
2.0
0
2.0
0
2.5
Locking force
(at 5.5 bar) [N]
Maximum distance on
locking [mm]
min.
max.
0
3.0
12000
0
2.0
0
3.0
Repeatability
[at 2 Mio. cycles]
0.015
Noise emission [dB(A)]
≤ 70
Pressure medium
Compressed air, compressed air quality according to ISO 85731:7 4 4
06.06|SWS 005 - 300 |en
17
Assembly
8 Assembly
8.1 Example of mounting
1
Robot arm
2
Interface plate (optional or supplied by user)
3
Piston cover plate (not necessary if sealing is provided by
interface plate (2))
4
Fastening screws (provided)
5
SWK
6
SWA
7
Interface plate for end-effector (supplied by user)
An optional custom interface plate with a mounting hole pattern
on one side for the robot and the other for the SWK provides adaptation between the two (consult the catalog for fastener and locating pin specifics).
The end-effector is attached to the tool typically by using an interface plate designed and provided by the user (The required information is provided in the catalog for each model).
Pneumatic lines and electrical cables attached, bundled, and strain
relieved in such a manner to allow for freedom of movement during operation.
18
06.06|SWS 005 - 300 |en
Assembly
8.2 Interface Plate Design and Mounting
All interface plates should be designed using two locating features
per interface.
The SWA/end-effector interface should utilize the diameter of the
SWA and a dowel pin for location.
A piston cover plate is provided with the sizes SWS
005/011/020/021/040/041/060/071/150/300 at the SWK quickchange head. If the robot interface plate provides sealing for the
piston cylinder, then the cover plate is not necessary.
Be careful when installing the O-ring, if the O-ring is not properly
seated in the groove, it can be cut or damaged, resulting in a bad
seal and air leakage. This can cause improper and/or unsafe operation.
The robot interface plate must be properly designed to provide rigid mounting on the boss surfaces. The recommended dimensions
for the interface plate bore, with and without the cover plate, are
given on the respective catalog drawing for each model.
The mating diameters must provide sufficient clearance so that
mating corner radius do not interfere.
NOTICE
Failure to follow this advice when designing the robot interface
plate may result in cover plate O-ring damage or loosening of
the interface during operation.
NOTICE
Removable thread locker should be used for all mounting bolts.
Failure to do so may cause vibration to loosen bolts over time.
NOTICE
Be careful when installing the O-ring. If the O-ring is not properly seated in the groove it can be cut or damaged, resulting in a
bad seal.
06.06|SWS 005 - 300 |en
19
Assembly
8.3 Requirements of the storage magazine
CAUTION
Tool Stand design is critical to proper operation of the quick
changer.
Improperly designed Tool Stands can cause misalignments that
will cause jamming and/or excessive wear of SWS components.
The SWAs may be stored in a Tool Stand when not being used by
the robot. SCHUNK provides compatible Tool Stands designed for
durability, longevity, and maximum adaptability to fit most customers’ applications. The SCHUNK Tool Stand system is compatible
with SCHUNK quick-change sizes SWS-005 to SWS-300. The Tool
Stand systems can be equipped with horizontal modules and different types of tool sensing. Visit the SCHUNK Web Site for products available for your specific application or contact SCHUNK for
recommendations and assistance.
If the customer is supplying the tool stand, it should be designed
to provide a fixed, repeatable, level, and stable positions for tool
pick-up and drop-off. The tool stand must support the weight of
the SWA, Tool Interface Plate, optional modules, cables, hoses,
and customer tooling without allowing deflection in excess of the
offsets specified in ( 9, Page 37).
Ideally, the SWA should be hanging vertically in the Tool Stand so
that gravity assists to uncouple the SWA from the SWK during unlocking. It is possible to design Tool Stands that hold tools in the
horizontal position, but care must be taken that the necessary
compliance is provided during coupling and uncoupling. In general,
“horizontal-position” Tool Stands cause more wear on the locking
mechanism and locating features of the SWA and Tool Stand.
A variety of methods may be used to position the SWA in the Tool
Stand. A common method is to use tapered alignment pins and
bushings. Robot programming and positional repeatability are vital
in tool pickup and drop-off ( 9, Page 37)
It is highly recommended that the customer provide a sensor that
detects the presence of a properly seated SWA in the Tool Stand.
The sensor may be used prior to coupling to ensure there is a SWA
properly seated in the stand. Sensors may also be used as the robot starts to move away after uncoupling. This provides a safety
measure in the event that a SWA should become jammed in the
stand or if the SWA should fail to release properly from the robot.
20
06.06|SWS 005 - 300 |en
Assembly
Proximity sensors should be positioned so that the sensing face is
vertical to prevent metal shavings, weld spatter, or other debris
from falling on the sensor and creating false readings.
Tool Stands may also need to incorporate means for covering
SWAs and modules to protect them in dirty environments, such as
grinding or welding. Alternatively, positioning Tool Stands in areas
shielded from weld spatter, fluids, adhesives, or other debris
would eliminate the need for tool covers.
In order to avoid contamination of the pneumatic feedthrough
openings, as well as of the contacts of the electric options at the
SWA quick-change tool, an SWD dust cover has to be used while it
is located in the storage rack. ( 6.1, Page 15)
Offset Definitions
Maximum Recommended Offsets Prior to Coupling
Size
No-Touch™
Z Offset (Max)*
[mm]
X and Y Offset
(Max)** [mm]
Cocking Offset
(Max) [degrees]
Twisting Offset
(Max) [degrees]
SWS 005
+3
±1
± 1.1
±2
SWS 011
SWS 020
SWS 021
SWS 022
+3
±1
± 0.8
±2
SWS 027
+2
±1
± 0.8
±2
SWS 040
+3
±2
±1
±2
SWS 040Q
+3
±2
±1
±2
SWS 041
+3
±2
±1
±2
SWS 060
SWS 071
+3
±2
± 0.6
±1
SWS 076
+2
±1
± 0.7
±1
SWS 110
+3
±1
± 0.7
±1
06.06|SWS 005 - 300 |en
21
Assembly
Size
No-Touch™
Z Offset (Max)*
[mm]
X and Y Offset
(Max)** [mm]
Cocking Offset
(Max) [degrees]
Twisting Offset
(Max) [degrees]
SWS 150
+2
±2
± 0.7
±1
SWS 160
+2
±2
± 0.7
±1
SWS 300
+ 2.5
±3
± 0.6
±1
*
Maximum values shown. Decreasing actual values will minimize wear during coupling/uncoupling.
**
Actual allowable values may be higher in some cases, but
higher offsets will increase wear during coupling.
8.4 Mechanical connection
WARNING
Risk of injury when the machine/system moves unexpectedly!
Switch off power supply.
Check levelness of The values apply to the whole bolting surface.
the bolting surface
Requirements for levelness of the bolting surface (Dimensions in mm)
22
Diameter
Permissible unevenness
< 100
< 0.02
> 100
< 0.05
06.06|SWS 005 - 300 |en
Assembly
8.4.1 Fastening of the quick-change head (SWK)
Fastening of the quick-change master
You can fasten the quick-change head (SWK) with the screws (1)
(for Type SWS 005 - 071 the screws (1) are in the enclosed pack).
For centering purposes, use the cylinder pin (2) out of the enclosed
pack.
mounting screws
Size
screws (1)
Quantity
005
M3 x 20 / DIN EN ISO 4762
4
011
M3 x 20 / DIN EN ISO 4762
4
020
M4 x 30 / DIN EN ISO 10642
4
021
M4 x 30 / DIN EN ISO 10642
4
040
M5 x 35 / DIN EN ISO 4762
6
040Q
M5 x 40 / DIN EN ISO 4762
6
041
M5 x 35 / DIN EN ISO 4762
6
060
M6 x 40 / DIN EN ISO 10642
6
071
M6 x 40 / DIN EN ISO 10642
6
076
M10 x 55 / DIN EN ISO 4762
6
110
M10 x 55 / DIN EN ISO 4762
6
150
M10 x 60 / DIN EN ISO 4762
6
160
M10 x 55 / DIN EN ISO 4762
6
300
M12 x 70 / DIN EN ISO 4762
6
06.06|SWS 005 - 300 |en
23
Assembly
8.4.2 Fastening the quick-change adapter (SWA)
Size of the fastening screws
Size SWA
005/011
020/021
M5
M6
040/040Q/ 076/110/
041/060/071 150/160
M8
M10
300
M12
8.4.3 Tightening torque
NOTE
The listed tightening torques are recommendations. The material
of the adapter plates and the conditions during the assembly must
be always taken into account.
Size 005, 011
Type of Screw
Thread Size
Strength Class Tightening
Torque [Nm]
Thread Locker
Robot-side adapter plate on SWK
Socket head cap
M3
12.9
1.2
Loctite 222
M5
12.9
5.1
Loctite 222
Tool-side adapter plate on SWA
Socket head cap
Socket flat head cap
4
Size 020, 021
Type of Screw
Thread Size
Strength Class Tightening
Torque [Nm]
Thread Locker
Robot-side adapter plate on SWK
Socket flat head cap
M4
12.9
1.2
Loctite 222
M6
12.9
10.2
Loctite 242
Tool-side adapter plate on SWA
Socket head cap
Socket flat head cap
24
06.06|SWS 005 - 300 |en
6.8
Assembly
Size 040, 040Q, 041
Type of Screw
Thread Size
Strength Class Tightening
Torque [Nm]
Thread Locker
Robot-side adapter plate on SWK
Socket head cap
M5
12.9
5.1
Loctite 222
M8
12.9
16
Loctite 242
Tool-side adapter plate on SWA
Socket head cap
Socket flat head cap
9.6
Size 060
Type of Screw
Thread Size
Strength Class Tightening
Torque [Nm]
Thread Locker
Robot-side adapter plate on SWK
Socket flat head cap
M6
12.9
6.8
Loctite 242
M8
12.9
16
Loctite 242
Tool-side adapter plate on SWA
Socket head cap
Socket flat head cap
9.6
Size 071
Type of Screw
Thread Size
Strength Class Tightening
Torque [Nm]
Thread Locker
Robot-side adapter plate on SWK
Socket head cap
M6
12.9
10.2
Loctite 242
M8
12.9
16
Loctite 242
Tool-side adapter plate on SWA
Socket head cap
Socket flat head cap
9.6
Size 076
Type of Screw
Thread Size
Strength Class Tightening
Torque [Nm]
Thread Locker
Robot-side adapter plate on SWK
Socket head cap
M10
12.9
52
Loctite 242
12.9
52
Loctite 242
Tool-side adapter plate on SWA
Socket head cap
M10
06.06|SWS 005 - 300 |en
25
Assembly
Size 110
Type of Screw
Thread Size
Strength Class Tightening
Torque [Nm]
Thread Locker
Robot-side adapter plate on SWK
Socket head cap
M10
12.9
75
Loctite 242
12.9
52
Loctite 242
Tool-side adapter plate on SWA
Socket head cap
M10
Size 150
Type of Screw
Thread Size
Strength Class Tightening
Torque [Nm]
Thread Locker
Robot-side adapter plate on SWK
Socket head cap
M10
12.9
75
Loctite 242
12.9
75
Loctite 242
Tool-side adapter plate on SWA
Socket head cap
M10
Size 160
Type of Screw
Thread Size
Strength Class Tightening
Torque [Nm]
Thread Locker
Robot-side adapter plate on SWK
Socket head cap
M10
12.9
75
Loctite 242
12.9
52
Loctite 242
Tool-side adapter plate on SWA
Socket head cap
M10
Size 300
Type of Screw
Thread Size
Strength Class Tightening
Torque [Nm]
Thread Locker
Robot-side adapter plate on SWK
Socket head cap
M12
12.9
120
Loctite 242
12.9
95
Loctite 242
Tool-side adapter plate on SWA
Socket head cap
26
06.06|SWS 005 - 300 |en
M12
Assembly
8.5 Air connection
WARNING
Risk of injury due to unexpected movement of the machine/system!
Components may move unexpectedly and cause injuries if the power supply is still on or if there is residual energy in the system left.
• Switch off power supply.
• Ensure that no residual energy remains in the system.
NOTICE
Observe the requirements for the air supply
( 7, Page 17).
Size SWS
005 011 020 021 022
027
040
040Q
Connection
(A = open, ‘B =
closed)
M5 M5 M5 M5 M5
G
1/8"
G
1/8"
G
1/8"
Size SWS
041 060 071 076 110 150 160 300
Connection
(A = open, ‘B =
closed)
G
G
G
G
G
G
G
G
1/8" 1/8" 1/8" 1/8" 1/8" 1/8" 1/8" 1/4"
The air feed throughs for the SWA are marked on the SWK.
06.06|SWS 005 - 300 |en
27
Assembly
8.6 Valve Requirements and Connections
As with all pneumatic piston arrangements, smooth operation requires proper porting of the supplied and vented air.
It is recommended that a single 4-way valve be used to actuate the
locking mechanism in the SWK. The valve may be of either 4-port
or 5-port configuration.
It is imperative that when air is supplied to the Lock or Unlock Port
on the SWK, that the opposite port be vented to atmosphere (i.e.,
when air is supplied to the Lock Port, the Unlock Port must be
open to the atmosphere.)
Failure to vent trapped air or vacuum on the inactive port will negate the locking force of the quick-change mechanism.
WARNING
Risk of injury for personnel caused by a released quick-change
adapter.
The quick-change mechanism will not function properly when
connected to a single 3-way valve as this type of valve is incapable of venting trapped air pressure from within the Tool Changer.
8.7 Pneumatic plan
28
06.06|SWS 005 - 300 |en
Assembly
8.8 Sensors - Piston Stroke Control
SWS Tool Changers provide Lock and Unlock sensing to detect
when the locking mechanism is in the Locked or Unlocked position
and send a signal to the controller. Many Standard Series Tool
Changer models such as the SWS-011/020/021/040/041/
060/071/100/150/300 can be equipped with Lock and Unlock
sensing using a Piston Stroke Control (SIP) that attaches to the
SWK. The SIP consists of Lock and Unlock sensors, detection shaft,
SIP-plate. Some Tool Changer models are equipped with integrated Lock and Unlock sensing built into the Tool Changer body, like
SWS-040Q/076/ 110/160. If sensors are not used, plugs will be
provided to seal the locking mechanism.
8.8.1 Function Stroke Control of the piston – SWS-011 and Larger
The piston stroke control system for the SWS utilizes 3-wire proximity switches (PNP). Following Figures show the position of the
locking mechanism piston and Detection Shaft relative to the proximity switches for various conditions.
These signals will indicate two possible conditions for the SWK:
Unlocked or Locked. The SIP system utilizes switches to detect the
position of the pneumatically-actuated piston in the SWK. These
switches are available in various configurations (PNP, NPN) depending on customer requirements, Quick-Change model, and
sensor availability.
SWK in the unlocked position. The unlock sensor is activated by
the Detection Shaft.
06.06|SWS 005 - 300 |en
29
Assembly
SWKin the locked position with a SWA in place. The Lock sensor is
activated by the Detection Shaft.
8.8.2 Integrated Proximity Switch - SWS 040Q/076/110/160
Some Tool Changer sizes are equipped as a standard with integrated Lock and Unlock sensing built into the Tool Changer body, like
SWS-040Q/076/110/160. The sensors of the sensor assemblies are
precision aligned at the factory and there is no need to adjust
them. You should only change the whole assemblies. If sensors are
not used, plugs will be provided to seal the locking mechanism.
30
06.06|SWS 005 - 300 |en
Assembly
8.8.3 Typ Lock and Unlock Sensors
Description
Value
Voltage Supply Range
10 - 30 VDC
Output Current
< 150 mA
Nominal Sensing Distance Sn
Output Circuit
2.0 mm
PNP make function (NO)
8.8.4 Sensors
Overview of the compatible sensors
Designation
Type
Inductive proximity switches
IN
Exact type designation of the compatible sensors see catalog.
8.9 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.
06.06|SWS 005 - 300 |en
31
Assembly
8.9.1 Electrical Module Installation E10/E20 - SWS-005 and SWS-011
1 Make all soldered connections to the electrical module as desired.
2 Align the module to the lateral side of the SWK or SWA.
3 Apply Loctite 222® to M3 socket head cap screws.
4 Secure the module with two M3 socket head cap screws.
Tighten to 0,77 Nm.
5 Remove all protective caps, plugs, tape, etc from the module
prior to operation.
8.9.2 Electrical Module Removal E10/E20 - SWS-005 and SWS-011
1 Dock the Tool safely in the tool stand and uncouple the Tool
Changer to allow clear access to the SWK or SWA.
2 Turn off all energized circuits (e.g. electrical, air, water, etc.)
3 Disconnect any cables, if required.
4 Supporting the module, remove the two M3 socket head cap
screws.
5 Remove the module from the SWK or SWA.
32
06.06|SWS 005 - 300 |en
Assembly
8.9.3 SWK Electrical Module Installation A15/B15 - SWS-005 and SWS-011
1 Remove the four M3 socket head cap screws securing the
cover to the module.
2 Align the cover to the SWK.
3 Apply Loctite 222® to M3 socket head cap screws.
4 Secure the cover with two M3 socket head cap screws. Tighten to 0.34 Nm.
5 Apply Loctite 222® to the four M3 socket flat head cap screws.
6 Attach the module to the cover using the two long and two
short M3 socket flat head cap screws as shown in the figure.
Tighten to 0.34 Nm.
7 Remove all protective caps, plugs, tape, etc from the module
prior to operation.
06.06|SWS 005 - 300 |en
33
Assembly
8.9.4 SWA Electrical Module Removal E10/E20 - SWS-005 and SWS-011
1 Dock the Tool safely in the tool stand and uncouple the Tool
Changer to allow clear access to the SWK or SWA.
2 Turn off all energized circuits (e.g. electrical, air, water, etc.).
3 Disconnect any cables, if required.
4 Remove the two screw locks securing the connector to the
module.
5 Carefully remove the connector to expose the mounting
screws.
6 Support the module, while removing the two M3 socket head
cap screws holding the module to the SWA.
7 Remove the module from the SWA.
34
06.06|SWS 005 - 300 |en
Assembly
8.9.5 Flat A Optional K Series Module Installation - SWS-020 and SWS021
1 Align optional module on flat A of SWK or SWA.
2 Apply Loctite 222® to M3 socket head cap screws.
3 Secure module with two M3 socket head cap screws. Tighten
to 0.8-1.2 Nm.
4 Remove all protective caps, plugs, tape, etc from the module
prior to operation.
8.9.6 Flat A Optional K Series Module Removal - SWS-020 and SWS-021
1 Dock the Tool safely in the tool stand and uncouple the Tool
Changer to allow clear access to the SWK or SWA.
2 Turn off all energized circuits (e.g. electrical, air, water, etc.).
3 Disconnect any cables, air line, etc. if required.
4 Supporting the module, remove the two M3 socket head cap
screws.
5 Remove the module from the SWK or SWA.
06.06|SWS 005 - 300 |en
35
Assembly
8.9.7 Flat B Optional Module Installation - SWS-021
1 Align adapter plate to Flat B of the SWS-021 SWK or SWA.
2 Apply Loctite 222® to M4 socket flat head cap screws.
3 Secure adapter plate to the tool changer with two M3 socket
flat head cap screws. Tighten to 0.8-1.2 Nm.
4 Align optional module on the adapter plate.
5 Apply Loctite 222® to four M4 socket head cap screws.
6 Secure module with four M3 socket head cap screws. Tighten
to 1.3-1.7 Nm.
7 Remove all protective caps, plugs, tape, etc from the module
prior to operation.
8.9.8 Flat B Optional Module Removal - SWS-021
1 Dock the tool safely in the tool stand and uncouple the tool
changer to allow clear access to the SWK or SWA.
2 Turn off all energized circuits (electrical, air, water, etc.).
3 Disconnect any cables, air line, etc. if required.
4 Supporting the module, remove the four M4 socket head cap
screws.
5 Remove the module from the adapter plate.
6 Remove the two M4 socket head cap screws securing the
adapter plate to the SWK or SWA.
7 Remove the adapter plate.
36
06.06|SWS 005 - 300 |en
Operation
9 Operation
9.1 Conditions for Coupling
CAUTION
The locking mechanism must be in the unlock position when
attempting to couple the Tool Changer.
Failure to adhere to this condition may result in damage to the
unit and/or the robot.
1 Position the SWK above the SWA and move the SWK into locking position. The mating surfaces of the SWK and SWA should
be parallel and not touching.
Make sure that the tapered alignment pins from the SWK center the alignment holes on the Tool. The alignment pins should
be relatively concentric with the alignment holes such that
they do not rub against the edge.
2 When using electrical feed-through-modules the voltages
from 24 V have to be switched off prior to coupling. Contacts
could be damaged due to sparking. Coupling without power
shutdown may shorten the life extremely.
3 It is recommended that the mating faces of SWK and SWA not
be touching, but be within a offset of each other when coupling to minimize stress and wear on the locking mechanism.
The locking mechanism allows the SWK to “pull up” the Tool
with relatively large gaps between the two sides.
4 Turn the Lock output on. Air is supplied to the locking mechanism to couple the Tool Changer.
5 A sufficient delay must be programmed between the Lock
output being activated and reading the state of the
Lock/Unlock signals, so that the coupling process is completed
before checking the locked state.
6 The Lock signal should read “on” (true) and the Unlock signal
should read “off” (false).
7 As an option RTL (Ready-To-Lock) - Models SWS-076/110/160
sensing is built into the Tool Changer, providing the ability to
sense Tool proximity to theSWK prior to coupling. RTL signals
are not required to couple the Tool Changer, but are recommended as a further confirmation of coupling prior to removing the Tool from the tool stand.
06.06|SWS 005 - 300 |en
37
Operation
8 Verify that the RTL signals are read as “on” (true), if being utilized.
The locking mechanism must be in the Unlock state before another attempt is made to couple or damage could occur to the robot
and/or the Tool Changer.
NOTICE
No-Touch™ locking technology allows the unit to couple with a
separation distance between the SWK and SWA.
Direct contact of the SWK and SWA mating surfaces is not suggested or required just prior to coupling. Contact may result in
damage to the unit and/or the robot.
9.2 Fail-Safe Operation
A fail-safe condition occurs, when there is a loss of air pressure to
the internal locking mechanism of the Tool Changer. The coupled
Tool Changer will not uncouple. The patented fail-safe feature
prevents the SWAe from being released without maintaining air
pressure to the internal locking mechanism through the lock port.
A slight separation between the SWK and SWA Plates occurs just
after air loss, but at this point the locking ball bearings become
trapped until air pressure is re-established to the internal locking
mechanism through the lock port. Positional accuracy will not be
maintained during air loss but will be regained once air pressure is
re-established to the internal locking mechanism through the lock
port. The Tool Changer is not designed to be used in a fail-safe
condition.
CAUTION
Do not use the Tool Changer in a fail-safe condition.
Do not transport the tool changer in a fail-safe condition. Possible
damage to the locking mechanism could occur. Re-establish air
pressure to Tool Changer before returning to normal operations.
38
06.06|SWS 005 - 300 |en
Operation
9.3 Conditions for Uncoupling
1 The Tool Changer should be positioned in the tool stand in the
same location as that when coupling took place.
2 When using electrical feed-through-modules the voltages
from 24 V have to be switched off prior to uncoupling. Contacts could be damaged due to sparking. Uncoupling without
power shutdown may shorten the life extremely.
3 Turn the lock output off.
4 Issue the unlock output. Air is supplied to the locking mechanism to uncouple the tool changer.
5 A sufficient delay must be programmed between the unlock
output being activated and reading the state of the
lock/unlock signals, so that the coupling process is completed
before checking the locked state.
6 The unlock signal should read “on” (true)
and the lock signal should read “off” (false).
Any other condition indicates a problem and the robot program should be halted. Once the Lock and Unlock signals are
verified to be in the proper state the SWK may be moved away
from the SWA in the axial direction.
 The robot and SWK can now proceed to another SWA for coupling and subsequent operations.
06.06|SWS 005 - 300 |en
39
Trouble shooting
10 Trouble shooting
10.1 The Quick-Change-Head (balls) doesn’t move?
Possible cause
Corrective action
Pressure drops below minimum.
Check air supply ( 8.5, Page 27)
Compressed air lines switched
Check compressed air lines
Proximity switch defective or set incorrect.
Readjust or change sensor
10.2 The Quick Change Head does not clamp the Quick- ChangeAdaptor correctly?
Possible cause
Corrective action
Dirt deposits between SWK and SWA
Disassemble and clean the product
Pressure drops below minimum.
Check air supply
( 8.5, Page 27)
Screw-on surface is not sufficiently flat
Check the evenness of the bolting surface
( 8.4, Page 22)
10.3 The clamping force between SWK and SWA is reducing?
Possible cause
Corrective action
Compressed air can escape
Check sealings, if needed disassemble the
module and replace the sealings.
To much grease in the mechanical movement space
Clean and lubricate product
( 11, Page 41)
Pressure drops below minimum.
Check air supply
( 8.5, Page 27)
40
06.06|SWS 005 - 300 |en
Maintenance and Care
11 Maintenance and Care
NOTE
The cleanliness of the work environment strongly influences the
error-free operation of the change system. If the work environment is prone to heavy contamination, it is very important that the
entire unit is protected from contamination with appropriate
measures.
Protective measures:
• Locate quick-change adapters at a distance from sources of dust
• Include protective equipment in the storage rack (install deflectors, air curtains or similar equipment on the unit) ( 8.3,
Page 20)
NOTICE
Locking mechanism components are subject to corrosion from
water.
• If these components get wet, they must be dried and regreased immediately.
• In wet or humid environments, inspect components and regrease weekly.
11.1 Preventive Maintenance
The Tool Changer and optional modules are designed to provide a
long life with regular maintenance.
A visual inspection and preventive maintenance schedule is provided in the table below depending upon the application.
Detailed assembly drawings, ( 12, Page 55).
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 ( 11.2, Page 43).
For this purpose, tubes of lubricant are shipped with every Tool
Changer.
NOTICE:
MobiGrease® XHP222 Special is a NLGI#2 lithium complex grease
with molybdenum disulfide.
06.06|SWS 005 - 300 |en
41
Maintenance and Care
Schedule
Application(s)
General Usage
Material Handling
Docking Station
Tool Change Frequency
Inspection Schedule
> 1 per minute
Weekly
< 1 per minute
Monthly
General Usage
Material Handling
Docking Station
Welding/Servo/Deburring
All
Foundry Operations (Dirty Environments)
Weekly
Checklist
Balls/Alignment
Pins/Holes/Bearing
Race
Inspect for lubrication and wear. A NLGI #2, lithium-based grease
with molybdenum disulfide additive is suggested for locking mechanism and alignment pin lubrication. Over time, lubricants can become contaminated with process debris. Therefore, it is recommended to thoroughly clean the existing grease and replace with
new as needed. ( 11.2, Page 43).
Excessive alignment pin/bushing wear may be an indication of poor
robot position during pickup/drop-off. Adjust robot position as
needed. Check Tool Stand for wear and alignment problems.
Wear on the balls/bearing race could be an indication of excessive
loading.
Mounting Hardware / Inspect for proper torque and interference or wear, abrasions, cuts
Interface Connections of hoses, and electrical cables. Tighten and correct as required.
Seals
Inspect for wear, abrasion, and cuts.
Exposed O-rings and rubber bushings may be subject to damage
during normal operation. Replace damaged o-rings and rubber
bushings as needed.
Sensors and Cables
Inspect sensor cables and connectors for any damage, cuts, and
abrasion.
Electrical Contacts/Pin Block
(Modules)
Inspect for wear and abrasion.
Exposed contacts may be subject to damage during normal operation.
Clear debris from the area of the contacts using compressed air.
Do not directly clean contacts as abrasion may occur and the performance of the contact may be compromised.
42
06.06|SWS 005 - 300 |en
Maintenance and Care
11.2 Lubrication
11.2.1 External
The quick-change is factory-lubricated. For many applications this
lubrication is sufficient for the life of the product.
In some high-cycle applications or applications subject to moisture, the Tool Changer locking mechanism wear and oxidation can
be reduced by applying a thin film of anti-seize compound (molybdenum disulfide grease) to the locking balls, cam, and bearing race
at periodic intervals (e.g., every 250,000 cycles).
11.2.2 Internal
The internal piston and O-ring do not need lubrication unless the
unit is disassembled. In this case, a Teflon-based lubricant such as
Magnalube® is recommended.
11.3 Cleaning and Lubrication of the Locking Mechanism
11.3.1 Cleaning and Lubrication of the Locking Mechanism and
Alignment Pins
1 The locking mechanism must be in the unlock state before
cleaning.
2 Use a clean rag to thoroughly remove the existing lubricant
and debris from the balls, the male coupling, the cam and the
alignment pins.
06.06|SWS 005 - 300 |en
43
Maintenance and Care
3 Check each ball to make sure it moves freely in the male coupling. Additional cleaning may be necessary to free up any
balls that are sticking in place.
4 Apply a liberal coating of lubricant to the balls, the male coupling (inside and out), and the alignment pins.
11.3.2 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.
44
06.06|SWS 005 - 300 |en
Maintenance and Care
11.4 Service of the sensors
11.4.1 Proximity Sensor Adjustment, Test, or Replacement - SWS-011
The Proximity sensors are very reliable and normally do not need
to be replaced. Exhaust all other possible solutions, check continuity, air supply, lubrication, and pneumatic components prior to
testing or replacing the sensor
1 Dock the SWA safely in the tool stand and uncouple the quickchange system to allow clear access to the SWK.
2 Turn off and de-energize all energized circuits (electrical, air,
water, etc.).
3 If you are testing or replacing the Lock sensor make sure the
SWK-011 is in the locked position, if you are replacing the Unlock sensor make sure the SWK-011 is in the unlocked position
before continuing.
4 Disconnect any cables, air line, etc. if required.
5 Remove the four M3 socket head cap screws securing the
SWK-011 to the Sensor Interface Plate. Support the SWK-011
while loosening the screws.
6 Loosen the M3 socket set screw and unscrew the proximity
sensor from the Sensor Plate.
7 To test the suspect sensor, place a ferrous target in front of
the Proximity Sensor to confirm that the sensor is functional.
The sensor lock or unlock signal should read “on”(true) and
the sensor LED should illuminate.
06.06|SWS 005 - 300 |en
45
Maintenance and Care
8 If the proximity sensor is not functioning properly replace. Disconnect the sensor cable and discard.
9 Thread the proximity sensor into the SWK-011 until it touches
the Detection Shaft, then back the sensor off 1/2 turn.
10 Connect the sensor cable. The Proximity Sensor LED should be
illuminated.
NOTICE
Operating the locking mechanism with the sensor touching the
detection shaft will damage the sensor.
• Do not operate locking mechanism with sensor touching the
detection shaft.
• Back off the sensor ½ turn and secure with the set screw before operating the locking mechanism.
11 Turn the M3 socket set screw until it contacts the sensor and
tighten 1/4 turn more.
NOTICE
Over tightening set screw can cause damage to the proximity
sensor.
• Be careful not to over tighten set screw.
• Tighten until the nylon tip engages with the sensor threads
and tighten 1/4 turn more.
46
06.06|SWS 005 - 300 |en
Maintenance and Care
12 Attach the SWK-011 to the Sensor Interface Plate using the
four M3 socket head cap screws. Tighten to 1,1 Nm.
13 If required, connect other utilities to the optional modules on
the SWK.
14 Confirm the operation of the replaced sensor by issuing the
Lock command to lock a SWA to the SWK and then checking to
see that the LED in the replaced Sensor body is on.
15 After repair is complete, energize all circuits (e.g. electrical,
air, water, etc.).
11.4.2 Proximity Sensor Adjustment, Test, or Replacement - SWS
020/021/040/060/071/100/150
The proximity sensors normally do not need to be replaced. Exhaust all other possible solutions, check continuity, air supply, lubrication, and pneumatic components prior to testing or replacing
the sensor
1 Dock the SWA safely in the tool stand and uncouple the quickchange sytem SWS to allow clear access to the SWK.
2 Turn off and de-energize all energized circuits (e.g. electrical,
air, water, etc.).
3 If you are testing or replacing the Lock sensor make sure the
SWS is in the locked position, if you are replacing the Unlock
sensor make sure the SWS is in the unlocked position before
continuing.
4 Turn off all energized circuits (e.g. electrical, air, water, etc.).
5 Disconnect any cables, air line, etc. if required.
6 Remove the six socket head cap screws securing the SWK to
the adapter plate.
7 Loosen the hex nut and unscrew the proximity sensor from
the SWK.
8 To test the suspect sensor, place a ferrous target in front of
the proximity sensor to confirm that the sensor is functional.
The sensor lock or unlock signal should read “on”(true) and
the sensor LED should illuminate.
9 If the proximity sensor is not functioning properly replace. Disconnect the sensor cable and discard.
10 Back the sensor hex nut to the cable end of the new sensor.
11 Thread the proximity sensor into the SWK until it touches the
detection shaft, then back the sensor off 1/2 turn.
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47
Maintenance and Care
NOTICE
Operating the locking mechanism with the sensor touching the
detection shaft will damage the sensor.
• Do not operate locking mechanism with sensor touching the
detection shaft.
• Back off the sensor ½ turn and secure with the set screw before operating the locking mechanism.
12 Connect the sensor cable. The proximity sensor LED should be
illuminated.
13 Holding the sensor in position apply Loctite 222® to the proximity sensor threads between the hex nut and the SWK. Tighten the hex nut and torque to 0,9 Nm
14 Attach the SWK to the adapter plate using the six M4 socket
head cap screws.Tighten to 1,1 Nm
15 If required, connect other utilities to the optional modules on
the SWK.
16 Confirm the operation of the replaced sensor by issuing the
Lock command to lock a SWA to the SWK and then checking to
see that the LED in the replaced Sensor body is on.
17 After repair is complete, energize all circuits (electrical, air,
water, etc.).
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06.06|SWS 005 - 300 |en
Maintenance and Care
11.4.3 Lock and Unlock Sensor Assembly Replacement (with Sensor
Assemblies for SWS 040Q, 076, 110, 160)
1 Depending on the robot and interface plate used, the SWK
may have to be removed.
2 Disconnect the Lock and/or Unlock sensor cable connectors
from the Lock and/or Unlock sensor.
3 Remove the two M3 socket head cap screws that secure the
Lock and/or Unlock sensor to the SWK body.
4 Pull the sensor straight out from the SWK body.
5 Discard the removed sensor.
NOTICE
The Lock and Unlock sensor assemblies are precision aligned
and permanently assembled at the factory.
• Do not attempt to disassemble and rebuild.
6 Insert the Lock and/or Unlock sensor into the Tool Changer body.
7 Secure the sensor assembly using the two M3 socket flat head
screws. Tighten to 1.4 Nm.
8 Connect the Lock and/or Unlock sensor cable connector to the
proper sensor.
9 Confirm the operation of the Unlock sensor by issuing the Unlock command.
 Check to see that the LED in the Unlock sensor body is on.
10 Confirm the operation of the Lock sensor by issuing the Lock
command to lock a SWA to the SWK .
 Check to see that the LED in the Lock Sensor body is on.
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49
Maintenance and Care
11.5 Rubber Bushings
Rubber Bushing Replacement
NOTE
Collars only needed for sealings size G 3/8" and G 1/2".
If one or more pneumatic pass-through rubber bushings should
become cut or damaged in such a way that the seal when coupled
is hindered, the bushing(s) require replacement.
For models with small ports (G 1/8" and M5):
1 Remove damaged rubber bushing by grasping with a pair of
needle-nosed pliers and pulling the bushing out of the body.
2 Dip new bushing in water to aid in installation.
3 Insert the beveled (chamfered) end of the rubber bushing into
the bore, leaving ribbed end of the bushing facing outward.
NOTICE
For SWS-021 models, the rubber bushings must be installed with
Loctite 454®.
A thin film of adhesive should be applied around the diameter of
the counter bore in the body prior to installation; do not apply
the adhesive to the bushing itself. The dry rubber bushing should
then be installed by hand or utilizing soft-faced mallet, if necessary, as described in steps 4 and 4.
4 Press the bushing in by hand until it is seated completely in
the bore. If necessary, use a plastic or rubber soft-faced mallet
to tap the bushings into place.
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06.06|SWS 005 - 300 |en
Maintenance and Care
For larger models with G 3/8" and G 1/2" ports, the rubber bushings require a brass sleeve to retain the bushings in the body.
1 Remove damaged rubber bushing by grasping with a pair of
needle-nosed pliers and pulling the bushing out of the body.
2 Upon removal of the rubber bushings, remove the brass
sleeve from the damaged bushing.
3 Install the rubber bushings as previously described in steps 2–
4 for the smaller ports.
4 Insert the beveled end of the brass sleeve into the rubber
bushing.
5 Do not use excessive force when pressing in the brass sleeve;
too much force can damage the body.
Press the brass sleeve into the bushing, using an 10mm Allen
key, until it makes contact with the body. Press the brass
sleeve only until a firm resistance is felt, then stop pressing.
6 Inspect the bore and remove any rubber slivers that may have
resulted from installation of the brass sleeve.
11.5.1 Seal Inspection and Replacement for Electrical Modules
The seal protects the electrical connection between the SWK and
SWA. If the seal becomes worn or damaged it needs to be replaced.
1 To remove the existing seal, pinch edge of seal with fingers
and gently pull the seal away from the pin block on the SWK.
2 Pull the seal off the pin block.
3 To install a new seal, stretch the new seal over the shoulder of
the pin block.
4 Push the seal’s hub down against the pin block using finger tip.
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51
Maintenance and Care
11.6 Alignment Pins
Alignment pins are the tapered pins located on the face of the
SWK that guide theSWK and SWA together during the locking process. In heavy-duty applications, alignment (locating) pins ( 12,
Page 55) may need to be replaced due to wear. When replacing
alignment pins always use original SCHUNK parts.
Model SWS- Large SWS models (SWS-110/150/160) use front-replaceable
110/150/160 screw-type alignment pins.
NOTICE
Damage to the changing system from incorrect mounting of the
Alignment pins
• Use Loctite 242® on alignment pin threads and tighten to 6.8
Nm of torque using a torque wrench.
• Be careful not to over-tighten alignment pins.
11.7 Disassembly of the SWK Quick-Change Master
11.7.1 Disassembly of SWK 005 - 011
WARNING
Risk of injury due to unexpected movement of the machine/system!
Components may move unexpectedly and cause injuries if the power supply is still on or if there is residual energy in the system left.
• Switch off power supply.
• Ensure that no residual energy remains in the system.
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06.06|SWS 005 - 300 |en
Maintenance and Care
1 Remove the compressed air and the connectors.
2 To remove the SWK, remove the screws (20) from the handling tool.
3 Remove the O-ring (5) from the countersink in the housing (1).
4 Remove the rubber bushing (3) from the housing (1).
5 Remove screw (4) from the piston (7).
6 Carefully push the piston (7) from the housing (1).
NOTICE! Make sure that the balls (2) remain in their given
position.
7 Remove the seal (10) from the piston (7).
8 Remove the seal (9) out of the housing (1).
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53
Maintenance and Care
11.7.2 Disassembly of SWK 020 - 300
WARNING
Risk of injury due to unexpected movement of the machine/system!
Components may move unexpectedly and cause injuries if the power supply is still on or if there is residual energy in the system left.
• Switch off power supply.
• Ensure that no residual energy remains in the system.
1 Remove the compressed air and the connectors.
2 To remove the SWK remove the screws (20) from the handling
tool.
3 Separate the SWK from the adapter plate.
4 Unscrew the screws (10) and remove them from the piston
cover (8).
5 Remove the O-ring (6) from the countersink in the housing (1).
6 Remove the screw completely (17).
7 Remove the locking piece (16).
NOTICE! Make sure that the balls (12) will remain in their
given position.
8 Carefully push the piston (8) out of the housing (1).
9 Remove the seal (7) from the piston (8).
10 Remove the screws (15) and pull the ball fixation (13) out of
the housing (1).
11 Remove the O-ring (19) from the ball fixation of the housing (13).
12 Remove the rubber bushing (21) from the housing (1).
NOTICE! Exception: For the SWS-020, these rubber bushings
are not inside of the SWK but in the SWA!
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Assembly drawings
12 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.
12.1 Assembly SWS-005/011
Assembly SWS 5-11
*
Contained in accessory pack.
**
Included in the seal kit. Seal kit can only be ordered completely.
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55
Assembly drawings
12.2 Assembly SWS-020/021/041/060/071/150/300
56
*
Contained in accessory pack.
**
Included in the seal kit. Seal kit can only be ordered completely.
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Assembly drawings
12.3 Assembly SWK-027
*
Contained in accessory pack.
**
Included in the seal kit. Seal kit can only be ordered completely.
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57
Assembly drawings
12.4 Assembly SWK-076/110/160
*
58
Included in the seal kit. Seal kit can only be ordered completely.
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Seal kit
13 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 040
0370823
SWK 040Q
0370823
SWK 041
0370979
SWK 060
0370824
SWK 071
0370980
SWK 076
0370948
SWK 110
0370806
SWK 150
0370826
SWK 150 - High-temperature-version
39370826
SWK 160
0370992
SWK 300
0370827
SWA 300
0370835
Contents of the sealing kit, ( 12, Page 55).
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59
14 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/
Distributor
SCHUNK GmbH & Co. KG Spann- und Greiftechnik
Bahnhofstr. 106 – 134
D-74348 Lauffen/Neckar
We hereby declare that on the date of the declaration the following incomplete 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. The declaration is rendered
invalid if modifications are made to the product.
Product designation:
Quick-Change-System / SWS 005 - 300 /
The incomplete machine may not be put into operation until conformity of the machine
into which the incomplete machine is to be installed with the provisions of the Machinery
Directive (2006/42/EC) is confirmed.
The manufacturer agrees to forward on demand the relevant technical documentation for
the partly completed machinery to state offices.
The special technical documents according to Appendix VII, Part B belonging to the incomplete machine have been compiled.
Person authorized to compile the technical documentation:
Robert Leuthner, Address: see manufacturer's address
Signature-. See original declaration
Lauffen/Neckar, September 2014
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06.06|SWS 005 - 300 |en
p.p. Ralf Winkler,
Head of Gripping Systems Development