Translation of the Original operating manual
3-finger centric gripper
JGZ 40 - 160
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 module.
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: 0389161
Edition: 08.01 |29/05/2013|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. +49-7133-103-2503
Fax +49-7133-103-2189
[email protected]
www.schunk.com
2
08.01|JGZ 40 - 160|en
Table of contents
Table of contents
1
About this manual .................................................................................................... 5
1.1 Warnings ................................................................................................................... 5
1.1.1 Key words ...................................................................................................... 5
1.1.2 Symbols ......................................................................................................... 5
1.2 Variants ..................................................................................................................... 6
1.3 Applicable documents .............................................................................................. 6
2
Basic safety notes .................................................................................................... 7
2.1 Intended use ............................................................................................................. 7
2.2 Not intended use ...................................................................................................... 7
2.3 Environmental and operating conditions................................................................. 7
2.4 Product safety........................................................................................................... 8
2.4.1 Protective equipment ................................................................................... 8
2.4.2 Demands on the top jaws ............................................................................. 8
2.4.3 Constructional changes, attachments, or modifications .............................. 8
2.5 Personnel qualification ............................................................................................. 8
2.6 Using personal protective equipment...................................................................... 9
2.7 Notes on particular risks........................................................................................... 9
2.7.1 Variant gripping force maintenance .......................................................... 10
3
Warranty ................................................................................................................. 11
4
Scope of delivery ..................................................................................................... 11
5
Accessories .............................................................................................................. 12
5.1 Sensors.................................................................................................................... 12
6
Technical data ......................................................................................................... 13
7
Assembly ................................................................................................................. 14
7.1 Mechanical connection .......................................................................................... 14
7.2 Mounting of the gripper by using a spring loaded pressure-piece........................ 16
7.3 Air connection ........................................................................................................ 16
7.4 Sensors.................................................................................................................... 18
7.4.1 Inductive proximity switch IN 80 ................................................................ 18
7.4.2 Magnetic switch MMS 22 / RMS 22 ............................................................ 21
7.4.3 Programmable magnetic switch (MMS-P) .................................................. 24
7.4.4 Flexible position sensor FPS ........................................................................ 29
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3
Table of contents
8
Troubleshooting ...................................................................................................... 31
8.1 Modul does not move? .......................................................................................... 31
8.2 The module does not travel through the entire stroke? ....................................... 31
8.3 Module opens or closes abruptly? ......................................................................... 32
8.4 The gripping force drops? ...................................................................................... 32
8.5 Module does not achieve the opening and closing times? ................................... 33
9
Maintenance and Care ............................................................................................ 34
9.1 Notes....................................................................................................................... 34
9.2 Maintenance and lubrication intervals .................................................................. 34
9.3 Lubricants/Lubrication points (basic lubrication) ................................................. 35
9.4 Disassembly of the module ................................................................................... 36
9.4.1 Version without gripping force maintenance ............................................. 36
9.4.2 Maintencance of module with gripping force maintenance "O.D. gripping"
(O.D.) .......................................................................................................... 37
9.4.3 Version with gripping force maintenance I.D. ............................................ 39
9.5 Servicing and assembling the module .................................................................... 40
9.5.1 Assembly device .......................................................................................... 41
9.5.2 Screw tightening torques ............................................................................ 44
10 Assembly drawing ................................................................................................... 45
11 Seal kit .................................................................................................................... 46
12 Accessory pack ........................................................................................................ 46
13 Translation of original declaration of incorporation ................................................. 47
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08.01|JGZ 40 - 160|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
The following key words and symbols are used to highlight dangers.
1.1.1 Key words
DANGER
Dangers for persons.
Non-compliance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons.
Non-compliance may cause irreversible injury or death.
CAUTION
Dangers for persons.
Non-observance may cause minor injuries.
NOTICE
Information about avoiding material damage
1.1.2 Symbols
Warning about a danger point
Warning about hand injuries
General mandatory sign to prevent material damage
08.01|JGZ 40 - 160|en
5
About this manual
1.2 Variants
This operating manual applies for the following variations
• JGZ without gripping force maintenance
• JGZ with gripping force maintenance device "O.D. gripping"
• JGZ with gripping force maintenance device "I.D. gripping"
1.3 Applicable documents
• General terms of business
• Catalog data sheet of the purchased product
• Assembly and Operating Manuals of the accessories
• Calculation program for gripping modules (SSG)
The documents listed up here, can be download on our homepage
www.schunk.com
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08.01|JGZ 40 - 160|en
Basic safety notes
2 Basic safety notes
2.1 Intended use
The module was designed to grip and to temporarily and securely
hold workpieces and objects.
The module is intended for installation in a machine/system. The
requirements of the applicable guidelines must be observed and
complied with.
The module may be used only in the context of its defined application parameters ( 6, Page 13).
SCHUNK assumes that application in question was tested with the
calculation program for gripping modules (SSG).
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 an intended use if the module is used, for example, as a
pressing tool, stamping tool, lifting gear, guide for tools, cutting
tool, clamping device or a drilling tool.
2.3 Environmental and operating conditions
• Make sure that the module and the top jaws are a sufficient
size for the application.
• Ensure that the environment is clean. Observe the maintenance and lubrication intervals ( 9.2, Page 34).
• Make sure that the environment is free from splash water and
vapors as well as from abrasion or processing dust. This excludes modules that are designed specially for contaminated
environments.
08.01|JGZ 40 - 160|en
7
Basic safety notes
2.4 Product safety
Dangers arise from the module, if:
• the module is not used in accordance with its intended purpose.
• the module 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 module.
Wear protective equipment.
NOTE
More information are contained in the relevant chapters.
2.4.1 Protective equipment
Provide protective equipment per EC Machinery Directive.
2.4.2 Demands on the top jaws
Arrange the top jaws such that when the module is depressurized
it can reach one of the end positions either open or closed and
therefore no residual energy can be released when changing the
top jaws.
2.4.3 Constructional changes, attachments, or modifications
Additional drill holes, threads, or attachments that are not offered
as accessories by SCHUNK may be attached only with permission
of SCHUNK.
2.5 Personnel qualification
The assembly, initial commissioning, maintenance, and repair of
the module may be performed only by trained specialist personnel. Every person called upon by the operator to work on the
module must have read and understood the complete assembly
and operating manual, especially the chapter "Basic safety notes"
( 2, Page 7). This applies particularly to personnel only used occasionally, such as maintenance personnel.
8
08.01|JGZ 40 - 160|en
Basic safety notes
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.
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 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.
08.01|JGZ 40 - 160|en
9
Basic safety notes
WARNING
Risk of injury due to squeezing and bumping during movement of
the gripper jaws and breaking or loosening of the gripper fingers !
WARNING
Risk of injury from objects falling and being ejected
• The danger zone must be surrounded by a safety fence during
operation.
WARNING
While disassembling uncontrollable moves of parts of the gripper possible!
2.7.1 Variant gripping force maintenance
WARNING
Risk of injury from objects falling during energy supply failure
Modules with a mechanical gripping force maintenance can, during energy supply failure, still move independently in the direction specified by the mechanical gripping force maintenance.
• Secure the end positions of the module with SCHUNK SDV-P
pressure maintenance valves.
WARNING
Risk of injury due to residual energy in the gripper because of
gripping force maintenance by springs!
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Scope of delivery
3 Warranty
The warranty is valid for 24 months from the delivery date to the
production facility under the following conditions:
• Intended use in 1-shift operation
• Observe the mandatory maintenance and lubrication intervals
• Observe the environmental and operating conditions
Parts touching the work piece and wear parts are not part of the
warranty.
If necessary, check the application with the calculation program
for gripping modules (SSG).
4 Scope of delivery
The scope of delivery includes:
• 3-finger centric gripper JGZ in the ordered model.
• Accessory pack
08.01|JGZ 40 - 160|en
11
Accessories
5 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.
5.1 Sensors
Overview of the compatible sensors
Designation
Type
Inductive proximity switches
IN
Magnetic switch
MMS
Magnetic switch
RMS
Position monitoring
FPS
Position monitoring
APS
Programmable magnetic switch
MMS-P
• Exact type designation of the compatible sensors see ☞ catalog
• If you require further information on sensor operation, contact
your SCHUNK contact person or download information from
our homepage.
• For mounting the sensors, mounting kits are partly necessary.
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08.01|JGZ 40 - 160|en
Technical data
6 Technical data
Size
Pressure medium
40
50
64
2.0
4.0
Max. pressure [bar]
Without gripping force maintenance
with gripping force maintenance device
8.0
6.5
Pressure range for sealed air [bar]
0.5 - 1.0
0.10
0.18
Noise emission [dB(A)]
Pressure medium
0.35
1.10
40
125
160
Compressed air, standard for quality of the compressed air according to ISO 8573-1: 6 4 4
Min. pressure [bar]
Without gripping force maintenance
with gripping force maintenance device
2.0
4.0
Max. pressure [bar]
Without gripping force maintenance
with gripping force maintenance device
8.0
6.5
Pressure range for sealed air [bar]
Max. permitted weight per top jaw [kg]
0.60
≤ 70
IP rating
Size
100
Compressed air, standard for quality of the compressed air according to ISO 8573-1: 6 4 4
Min. pressure [bar]
Without gripping force maintenance
with gripping force maintenance device
Max. permitted weight per top jaw [kg]
80
0.5 - 1.0
2.10
Noise emission [dB(A)]
IP rating
3.50
≤ 70
40
Further technical data can be found in the catalog data sheet.
The most recent version applies.
08.01|JGZ 40 - 160|en
13
Assembly
7 Assembly
7.1 Mechanical connection
Check the evenness The values relate to the entire bolting surface.
of the bolting surface
Requirements for levelness of the bolting surface (Dimensions in mm)
Diameter
Permissible unevenness
< 100
< 0.02
> 100
< 0.05
NOTE
For modules with spring-loaded pressure pieces, the spring-loaded
pressure pieces have to be removed before the assembly of the
gripper ( 7.2, Page 16).
Mounting
Fig. 1 Assembly options
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08.01|JGZ 40 - 160|en
Assembly
Mounting material
Item
Mounting
40
50
64
80
100
1
Thread Ø
-
M4
M6
M8
M8
2
Max. depth of engagement
-
10.0
13.3
17.3
18.3
3*
Centering sleeve
4
Thread Ø and max. depth of
engagement Top jaws
M2.5
6 deep
M3
8 deep
M4
M5
M6
10 deep 10 deep 13 deep
5
Thread Ø gripper fastening
M3 (3x)
M3 (3x)
M5 (3x)
M6 (3x)
M6 (3x)
6*
Ø of the fixing bore
for cylindrical pins
Ø 2H7
Ø 3H7
Ø 4H7
Ø 5H7
Ø 5H7
Ø4 x 3.95 Ø5 x 4.35 Ø6 x 5.35 Ø8 x 5.35
Ø10 x
6.65
Mounting material
Item
Mounting
125
160
1
Thread Ø
M10
M10
2
Max. depth of engagement
21.0
21.5
3*
Centering sleeve
Ø10 x 6.65
Ø14 x 8.60
4
Thread Ø and max. depth of
engagement Top jaws
M6
13 deep
M10
17 deep
5
Thread Ø gripper fastening
M8 (3x)
M8 (3x)
6*
Ø of the fixing bore
for cylindrical pins
Ø 6H7
Ø 6H7
* contained in accessory pack.
NOTE
• When mounting the module from the rear, mount the module
using the fixing bores provided.
• Mount the module using the mounting bores provided.
• Attach the top jaws using the mounting bores provided.
08.01|JGZ 40 - 160|en
15
Assembly
7.2 Mounting of the gripper by using a spring loaded pressure-piece
CAUTION
The spring-loaded pressure piece is under spring tension.
The pressure piece can fly out in an uncontrolled fashion and
cause contusions.
• During assembly or disassembly, be especially careful with the
springs.
When mounting the gripper from the side of the gripper fingers,
the assembly of the pressure piece must be done after the mounting of the gripper.
Mounting the pressure piece is described in the insert "Installation
instructions - pressure piece", which is included in the pressure
piece's scope of delivery.
7.3 Air connection
NOTICE
The maximum permissible mass per jaw is exceeded:
• Attach flow control couplings to the module.
NOTICE
Observe the requirements for the air supply.
( 6, Page 13) "Technical Data"
16
08.01|JGZ 40 - 160|en
Assembly
Fig. 2 Air connections
Thread diamteter of the air connections
Item
connection
JGZ 40
JGZ 80
JGZ 100
1
Thread Ø hose-free direct connection (a = open, b = closed)
M3 (2x) M3 (2x) M4 (2x) M5 (2x)
M5 (2x)
2
Thread Ø Air purge connection
3
Thread Ø Air purge connection
(A = open, B = closed)
M5
JGZ 50
M5
JGZ 64
M5
M5
M3 (2x) M5 (2x) M5 (2x) M5 (2x)
M5
G 1/8"
(2x)
Thread diamteter of the air connections
Item
Connection
JGZ 125
JGZ 160
1
Thread Ø Hose-free direct connection (a = open, b = closed)
M5 (2x)
M5 (2x)
2
Thread Ø Air purge connection
M5
M5
3
Thread Ø Air purge connection
(A = open, B = closed)
G 1/8" (2x)
G 1/8" (2x)
NOTE
Observe the requirements for the air purge (from 0.5 up to max. 1
bar).
• Only open the air connections required.
• Seal air connections not required using
the locking screws from the enclosed pack.
• For hose-free direct connections use the two O-rings from the
enclosed pack.
Further information on the hose-free direct connection contains
the catalog data sheet.
08.01|JGZ 40 - 160|en
17
Assembly
7.4 Sensors
The module is prepared for a number of sensors. Other sensors
can be used with a mounting kit.
• If you require further information on sensor operation, contact
your SCHUNK contact person or download information from
our homepage.
• Technical data for the sensors can be found in the data sheets
(included in the scope of delivery).
7.4.1 Inductive proximity switch IN 80
Fig. 3 Connection example for IN 80
1
brown
2
black
3
blue
The inductive proximity switches used are equipped with reverse
polarity protection and are short-circuit-proof.
Make sure that you handle the proximity switches properly:
• Do not pull on the cable.
• Do not allow the sensor to dangle from the cable.
• Do not overtighten the mounting screw or mounting clip.
• Please adhere to a permitted warpage of the cable. (☞ catalog)
• Avoid contact of the proximity switches with hard objects and
with chemicals, in particular nitric acid, chromic acid and sulphuric acid.
18
08.01|JGZ 40 - 160|en
Assembly
The inductive proximity switches are electronic components,
which can react sensitively to high-frequency interference or electromagnetic fields.
• Check to make sure that the cable is fastened and installed correctly. Provide for sufficient clearance to sources of highfrequency interference and their supply cables.
• Parallel switching of several sensor outputs of the same type
(npn, pnp) is permissible, but does not increase the permissible
load current.
• Note that the leakage current of the individual sensors (ca. 2
mA) is cumulative.
NOTICE
Blockade of the gripper after setting or replacing of the switching cam!
The switching cam can be tilt in the guide, if it was not fixed exactly in the base jaw.
• Apply the switching cam in the direction of the base jaw, so
that the cam does not contact the housing of the gripper.
Installation of the SCHUNK previously sets the switching points for the positions
proximity switch "open" and "closed".
Fig. 4
Gripper open:
1 Insert proximity switch 1 (3) into the bracket (1) as far as it will
go.
2 Fasten the proximity switch by tightening the screw (4).
3 Move the gripper to the "Open" position and test its function.
08.01|JGZ 40 - 160|en
19
Assembly
Gripper closed:
1 Insert proximity switch 2 (2) into the bracket (1) as far as it will go.
2 Fasten the proximity switch by tightening the screw (4).
3 Move the gripper to the "Closed" position and test its function.
Part gripped (O.D. gripping):
1 Insert proximity switch 2 (2) into the bracket (1) as far as it will
go.
2 Fasten the proximity switch by tightening the screw (4).
3 Clamp the part to be gripped.
4 Undo the screw (6).
5 Turn the screw (7) to push the position of the control cam (5).
The control cam (5) has to be positioned far enough outside
that the proximity switch no longer responds.
6 Move the control cam (5) back towards the inside until the
proximity switch begins to switch.
7 Re-tighten the screw (6) to fix the switching point.
8 Open and close the gripper to test its function.
Part gripped (I.D. gripping):
1 Insert proximity switch 1 (3) into the bracket (1) as far as it will go.
2 Fasten the proximity switch by tightening the screw (4).
3 Clamp the part to be gripped.
4 Undo the screw (6).
5 Turn the screw (7) to push the position of the control cam (5).
The control cam (5) has to be positioned far enough inside
that the proximity switch no longer responds.
6 Move the control cam (5) back towards the outside until the
proximity switch begins to switch.
7 Re-tighten the screw (6) to fix the switching point.
8 Close and close the gripper to test its function.
20
08.01|JGZ 40 - 160|en
Assembly
7.4.2 Magnetic switch MMS 22 / RMS 22
Fig. 5
NOTICE
Sensor can be damaged during assembly.
Do not exceed the maximum tightening torque of 10 Ncm for the
set screws.
NOTE
Ferromagnetic material changes the switching positions of the
sensor. For example: Adapter plate made of ordinary steel.
At ferromagnetic adapter plates:
• The module must firstly be mounted on the adapter plate
• Then, the positions of the magnetic switch have to be set
The RMS sensors have a larger hysteresis than the MMS sensors.
This means that short gripper strokes may not be able to be monitored with the RMS sensors.
08.01|JGZ 40 - 160|en
21
Assembly
Positioning of the
magnetic switch
Fig. 6 Positioning the magnetic switch
Gripper open:
1 Set the gripper to the "Open" position.
2 Push the magnetic switch 1 (1) into the groove (4) until it
stops at the housing.
3 Pull the magnetic switch 1 (1) back again slowly until it switches.
4 Tighten the set-screw (3) to clamp the magnetic switch 1 (1) in
this position in the groove (4).
5 Close and close the gripper to test its function.
Gripper closed:
1 Set the gripper to the "Closed" position.
2 Push the magnetic switch 2 (2) into the groove (4) towards the
middle of the gripper until it switches.
3 Tighten the set-screw (3) to clamp the magnetic switch 2 (2) in
this position in the groove (4).
4 Open and close the gripper to test its function.
22
08.01|JGZ 40 - 160|en
Assembly
Part gripped (O.D. gripping):
1 Clamp the part to be gripped.
2 Push the magnetic switch 2 (2) into the groove (4) towards the
middle of the gripper until it switches.
3 Tighten the set-screw (3) to clamp the magnetic switch 2 (2) in
this position in the groove (4).
4 Open and close the gripper to test its function.
Part gripped (I.D. gripping):
1 Clamp the part to be gripped.
2 Push the magnetic switch 1 (1) into the groove (4) until it
stops at the housing.
3 Pull the magnetic switch 1 (1) back again slowly until it switches.
4 Tighten the set-screw (3) to clamp the magnetic switch 1 (1) in
this position in the groove (4).
5 Close and close the gripper to test its function.
08.01|JGZ 40 - 160|en
23
Assembly
7.4.3 Programmable magnetic switch (MMS-P)
M2
.5
2.95
1
8. 9
2
1 9.5
L = 1 00
6
5
4
3
0.5
4.4
30
L = 500
36 – 40
Fig. 7 Magnetic switch (MMS-P 22)
1
Mounting screw
4
Teach-button
2
Center sensor elements
5
LED display
3
LED display
6
Rips for cable tires
Fig. 8 Connection diagram PNP-4 conductor (MMS-P 22)
Types available for order (see catalog):
• MMS-P 22-S-M8-PNP
• MMSK-P 22-S-PNP
• V2-M8-4-2XM8-3
The MMSK-P 22-S-PNP features a cable with open strands so that
it can be connected by means of terminal contacts.
The V2-M8-4-2XM8-3 distributor is used to convert the 4-pin connector plug of the MMS-P 22-S-M8-PNP sensor to two standard
M8 plugs with 3 pins each.
24
08.01|JGZ 40 - 160|en
Assembly
Mounting of the sensor
NOTICE
Sensor can be damaged during assembly.
• Do not exceed the maximum tightening torque of 10 Ncm for
the set screws.
NOTE
Ferromagnetic material changes the switching positions of the
sensor. For example: Adapter plate made of ordinary steel.
At ferromagnetic adapter plates:
• The module must firstly be mounted on the adapter plate
• Then, the positions of the magnetic switch have to be set
Fig. 9
1 Slide or turn in the magnetic switch (1) into the groove until it
bears against the stop (2) (if available).
2 If there is no terminal stop, then slide the magnetic switch according to dimension l2 (bottom edge of gripper up to front
side of sensor) or according to dimension l1 (bottom edge of
gripper up to double arrow on sensor) and then clamp with
the mounting screw.
08.01|JGZ 40 - 160|en
25
Assembly
Type
Dimension l1
Dimension l2 Type
Dimension l1
Dimension l2
JGZ 40
11.4
20.3
JGZ 100
20.9
29.8
JGZ 40-AS
19.3
28.2
JGZ 100-AS
41.0
49.9
JGZ 40-IS
19.4
28.3
JGZ 100-IS
40.9
49.8
JGZ 50
12.8
21.7
JGZ 125
23.6
32.5
JGZ 50-AS
23.3
32.2
JGZ 125-AS
47.9
56.8
JGZ 50-IS
23.2
32.1
JGZ 125-IS
48.1
57.0
JGZ 64
15.6
24.5
JGZ 160
27.0
35.9
JGZ 64-AS
29.1
38.0
JGZ 160-AS
57.3
66.2
JGZ 64-IS
29.1
38.0
JGZ 160-IS
57.0
65.9
JGZ 80
18.0
26.9
JGZ 80-AS
33.6
42.5
JGZ 80-IS
33.0
41.9
7
6
Fig. 10
1
To relieve the cable, the electronics have to be fixed in place
using cable ties (7).
There are ribs (6) in place on the electronics for mounting
purposes.
Fig. 11
2
26
08.01|JGZ 40 - 160|en
Turn in the sensor (1 - 4).
OR
Push the sensor axially into the slot until it contacts the stop (5).
Assembly
3
Fix the sensor with an Allen wrench (6).
1
Press the "Teach" button (4) for 2 seconds.
 After 2 seconds, LED 1 (3) flashes.
2
Move the gripper to position 1 (e.g. "0 position").
3
Briefly press the "Teach" button (4).
 LED 1 (3) lights up and LED 2 (5) flashes.
4 Manually move the gripper to position 2 (e.g. "-2mm").
 LED 1 (3) should go out as soon as switching point 1 is left.
5 5. Briefly press the "Teach" button (4).
 LED 2 (5) lights up.
 The switching points are set.
Adjusting the The hysteresis to both switching points will be adjusted automatihysteresis cally corresponding to the characteristics of the magnetic field.
The user can set the switching and trigging points of each position
a little bit closer than for the automatic mode. The trigging point is
closer to the switching point. At the same time the susceptibility to
trouble and damage increases. In the mode of the lowest hysteresis, an error signal (such as jitter or untimely switch off) can be
avoided, if the sensor is protected against all types of disturbances
(i.e. by shielding). Frequent types of disturbances are change in
temperature and electro-magnetic influences.
Within the closest fine-teach mode, SCHUNK cannot guarantee
EMC-compatibility any more.
The hysteresis adjustment is used for the manual adjustment of
the switching points (if necessary).
In case that the hysteresis automatically determined by the sensor
should be too high or too low after “the adjustment of the switching points”, you may correct the value as follows.
The sensor avoids a too small hysteresis during hysteresis adjustment.
08.01|JGZ 40 - 160|en
27
Assembly
The smallest detectable difference in stroke is defined in the following table:
The smallest detectable difference in stroke based on the nominal stroke
For Grippers with X mm
nominal stroke per jaw
Min. query range per jaw /
min. queried stroke difference per jaw
X ≤ 5mm
30% of the nominal stroke per jaw
X = 5 to 10mm
20% of the nominal stroke per jaw
X ≥ 10mm
10% of the nominal stroke per jaw
3
1
4
5
Press the "Teach" button (4) for 5 seconds.
 LED 1 (3) flashes from 2nd to 5th second.
 LED 1 goes off after 5 sec.
2
Release the "Teach" button.
3 Move the gripper to the "switch-off point for switching point 1"
position.
4
Briefly press the "Teach" button (4). LED 1 (3) flashes twice.
5 Move the gripper to the "switch-off point for switching point 2"
position.
6
Briefly press the "Teach" button (4).
 LED 2 (5) flashes twice.
 The assembly of the MMS-P sensor is completed.
28
08.01|JGZ 40 - 160|en
Assembly
7.4.4 Flexible position sensor FPS
Fig. 12
To use the flexible position sensor FPS-M8, the grippers have to be
retrofitted with a special mounting kit. This mounting kit is available from SCHUNK for the models below (see catalog):
• JGZ 64
• JGZ 80
• JGZ 100
• JGZ 125
• JGZ 160
08.01|JGZ 40 - 160|en
29
Assembly
Monting of the
attachment kit
Fig. 13
1 Remove the screw (38) and the control cam (21) from one side
of the gripper.
2 Push the control cam of the mounting kit (21) with the chamfered side in front into the base jaw (2).
3 Tighten the control cam with the screw of the mounting kit (38).
4 Push the spacer (26) and the flexible FPS-M 8 (18) position
sensor through the bracket (17) into the provided bore hole of
the housing (1) as far as it will go.
5 Clamp the sensor in this position by tightening the screw (19).
 The adjustment of the sensor is described in the operating manual for the sensor.
30
08.01|JGZ 40 - 160|en
Troubleshooting
8 Troubleshooting
8.1 Modul does not move?
Possible cause
Corrective action
Base jaws jam in housing, possible cause:
bolting surface not sufficiently level.
Check the levelness of the bolting surface.
( 7.1, Page 14)
Loosen the mounting screws for the gripper
and actuate the gripper again.
Pressure drops below minimum.
Check the air supply. ( 7.3, Page 16)
Compressed air lines switched
Check compressed air lines.
Proximity switch defective or set incorrect.
Repair the proximity switch.
Unused air connections not closed.
Close the unused air connections.
Component is broken, e.g. through overloading
Replace component or send the module
with a repair order to SCHUNK. Ensure that
the module was only used within its defined
application parameters.If necessary, check
the application with the calculation program
for gripping modules (SSG).
8.2 The module does not travel through the entire stroke?
Possible cause
Corrective action
Dirt deposits between the cover and the
piston
Remove the cover, clean the module and
relubricate it ( 9, Page 34)
Dirt deposits between the base jaws and the Disassemble and clean module
guide
Pressure drops below minimum.
Check the air supply.
( 7.3, Page 16)
Mounting surface is not even enough
Check the levelness of the bolting surface.
( 7.1, Page 14)
Component is broken, e.g. through overloading
Send the module to SCHUNK with a repair
order or disassemble module
08.01|JGZ 40 - 160|en
31
Troubleshooting
8.3 Module opens or closes abruptly?
Possible cause
Corrective action
Too little grease in the mechanical guiding
areas of the module
Clean the module and relubricate it
( 9, Page 34)
Compressed air lines are blocked
Check the compressed air lines for crushing
or damage.
Mounting surface is not even enough
Check the levelness of the bolting surface.
Load too high
Review permissible weight and length of the
jaws
( 7.1, Page 14)
8.4 The gripping force drops?
Possible cause
Corrective action
Compressed air can escape
Check seals, if necessayy disassemble module an replace seals
Too much grease in the mechanical motion
spaces of the module
Clean the module and relubricate it
( 9, Page 34)
Pressure drops below minimum.
Check the air supply.
( 7.3, Page 16)
32
08.01|JGZ 40 - 160|en
Troubleshooting
8.5 Module does not achieve the opening and closing times?
Possible cause
Corrective action
Compressed air lines are not installed optimally
If present: Open the flow control couplings
on the module to the maximum that the
movement of the jaws occurs without
bouncing and hitting.
Check compressed air lines.
Inner diameter of the compressed air lines
are sufficiently large relative to the compressed air consumption
Compressed air lines between module and
control valve shoud be kept as short as possible
Flow rate of valve is sufficiently large relative to the compressed air consumption
If, despite of optimal air connections, the
opening and closing times are not achieved
according to the catalog, we recommend
the use of quick exhaust valves direct at the
module
Load too high
Review permissible weight and length of the
jaws
08.01|JGZ 40 - 160|en
33
Maintenance and Care
9 Maintenance and Care
9.1 Notes
Original spare parts
When replacing damaged parts (wearing parts/spare parts) only
use SCHUNK original spares.
Replacement of housing and base jaws
The base jaws and the guides in the housing are matched to each
other. To have these parts replaced, send the complete module
along with a repair order to SCHUNK.
Maintenance of module with gripping force maintenance "I.D.
gripping" (I.D.) and "A.D. gripping" (A.D.)
The pistons have to be aligned using an assembly device. Therefore we recommend to have the module serviced and the seals replaced by SCHUNK.
If this is not possible, you can carry out the maintenance and replace the seals yourself.
9.2 Maintenance and lubrication intervals
NOTICE
At ambient tempertature above 60°C the lubricans
cure out faster
• Interval decrease accordingly.
Size
Interval [Mio. cycles]
34
08.01|JGZ 40 - 160|en
40 -160
2
Maintenance and Care
9.3 Lubricants/Lubrication points (basic lubrication)
We recommend the lubricants listed.
During maintenance, treat all greased areas with lubricant. Thinly
apply lubricant with a lint-free cloth.
Lubrication point
Lubricant
Metallic sliding surfaces
microGLEIT GP 360
All seals
Renolit HLT 2
Bores on the piston
Renolit HLT 2
In addition to the described maintenance, the guides of the gripper can be re-lubricated as needed by means of lubricating nipples. The lubricating nipples can be used instead of the air purge
connection.
Remove the two set screws for the air purge connection and replace them with two conical grease nipples.
08.01|JGZ 40 - 160|en
35
Maintenance and Care
9.4 Disassembly of the module
9.4.1 Version without gripping force maintenance
Position of the position numbers ( 10, Page 45)
WARNING
Risk of injury when the machine/system moves unexpectedly!
Remove the energy supplies.
Make sure that no residual energy remains in the system.
1 Remove compressed air line.
2 Unfasten the set screws (74) and remove the pressure piece.
3 Remove the cover (5).
4 Mark the installation positions of the piston (3) and the base
jaws (50) on the housing (50).
5 Unscrew and remove the screws (41) and remove the cover (4).
6 Mark the installation position between the cylinder piston (6)
and the housing (50).
7 Unscrew screw (40) and remove cylinder piston (6) from the
housing (50).
8 Push the piston (3) upwards out of the housing (50).
9 Pull the base jaws (50) out of the housing (50).
36
08.01|JGZ 40 - 160|en
Maintenance and Care
9.4.2 Maintencance of module with gripping force maintenance "O.D.
gripping" (O.D.)
Position of the position numbers ( 10, Page 45)
WARNING
Risk of injury when the machine/system moves unexpectedly!
Remove the energy supplies.
Make sure that no residual energy remains in the system.
WARNING
Risk of injury due to spring forces!
The lid is under spring tension.
Carefully disassemble the module.
WARNING
Risk of injury due to spring forces!
The cylinder piston is under spring tension.
Carefully disassemble the module.
1 Remove compressed air lines.
2 Remove the cover (5).
3 Mark the installation positions of the piston (3) and the base
jaws (50) on the housing (50).
4 WARNING! Risk of injury due to spring forces! The lid is under spring tension. Carefully disassemble the module. Clamp
the module between the base jaws (50) and the cover (9) in
the vise so that it is still possible to remove the 8 screws (46).
5 Unscrew screws (46).
6 Open the vise carefully and remove the cover (9).
7 Remove the centering pins (55).
08.01|JGZ 40 - 160|en
37
Maintenance and Care
8 WARNING! Risk of injury due to spring forces! The cylinder
piston is under spring tension. Carefully disassemble the
module. Mark the installation position between the cylinder
piston (6) and the housing (50).
9 Clamp the module between base jaws (50) and the cylinder
piston (10).
10 Unfasten and remove the screws (45).
11 Carefully open the vise until the compression spring (25) has
no more tension.
12 Remove the cylinder piston (10) and compression spring (25)
from the housing (50).
13 Push the piston (3) upwards out of the housing (1).
14 Pull the base jaws (50) out of the housing (50).
38
08.01|JGZ 40 - 160|en
Maintenance and Care
9.4.3 Version with gripping force maintenance I.D.
Position of the position numbers ( 10, Page 45)
WARNING
Risk of injury when the machine/system moves unexpectedly!
Remove the energy supplies.
Make sure that no residual energy remains in the system.
WARNING
Risk of injury due to spring forces!
The lid is under spring tension.
Carefully disassemble the module.
1 Remove compressed air lines.
2 Remove the cover (5).
3 Mark the installation positions of the piston (3) and the base
jaws (50) on the housing (50).
4 WARNING! Risk of injury due to spring forces! The lid is under spring tension. Carefully disassemble the module. Clamp
the module between the base jaws (50) and the cover (9) in
the vise so that it is still possible to remove the 8 screws (46).
5 Unfasten and remove the screws (46).
6 Carefully open the vise until the compression spring (25) has
no more tension.
7 Remove the cover (9) and the compression spring (25).
8 Remove the centering pins (55).
9 Mark the installation position between the cylinder piston (6)
and the housing (50).
10 Unscrew screw (40) and remove cylinder piston (6) from the
housing (50).
11 Push the piston (3) upwards out of the housing (50).
12 Pull the base jaws (50) out of the housing (50).
08.01|JGZ 40 - 160|en
39
Maintenance and Care
9.5 Servicing and assembling the module
Maintenance
• Clean all parts thoroughly and check for damage and wear.
• Treat all grease areas with lubricant.
( 9.3, Page 35)
• Oil or grease bare outside steel parts.
• Replace all wearing parts / seals.
– Position of the wearing parts ( 10, Page 45)
– Sealing kit ( 11, Page 46)
Assembly Assembly takes place in the opposite order to disassembly. Observe the following:
• Unless otherwise specified, secure all screws and nuts with Loctite no. 243 and tighten with the appropriate tightening
torque.( 9.5.2, Page 44)
• In the variant with gripping force maintenance "O.D. gripping"
(AS), sizes 40-100, mount the cylinder piston by means of a
mounting device; for frame sizes 125-160, mount the cylinder
piston by means of two mounting devices ( 9.5.1, Page 41).
40
08.01|JGZ 40 - 160|en
Maintenance and Care
9.5.1 Assembly device
Position of the position numbers ( 10, Page 45)
Assembly of sizes 40100 with one assembly device
Fig. 14 Installing cylinder pistons with a assembly device 1
Item Type
70
Device 1
72
73
JGZ 40
JGZ 50 JGZ 64 JGZ 80 JGZ 100
x
x
x
x
x
Cylindrical pin
Ø2H7
(2x)
Ø3H7
(2x)
Ø4H7
(2x)
Ø5H7
(2x)
Ø5H7
(2x)
Screw
ISO 4762
M3x20 M3x25 M5x30 M6x35 M6x40
Drawings and dimensions of the assembly device ( 9.5.1.1, Page 43).
1 Insert the cylindrical pin (72) into the drill hole provided.
2 Install assembly device 1 (70) with the screws (73) and grease
the centering bore with Renolit HTL 2.
3
CAUTION, do not tilt: Place the cylinder piston (10) on the
centering bore and evenly push it into the bore hole by hand
so that the cylinder piston (10) pushes the spring.
4 Insert the screw (45) and screw it into the piston (3) with light
pressure ( 9.5.2, Page 44).
5 Remove the assembly device (70).
6 Insert the seal (32) and install the cover (9).
08.01|JGZ 40 - 160|en
41
Maintenance and Care
Assembly of sizes
125-160 with two
assembly devices
Fig. 15 Installing cylinder pistons with a assembly devices 1 and 2
Item
Type
JGZ 125
JGZ 160
70
Device 1
x
x
71
Device 2
x
x
72
Cylindrical pin
Ø6H7 (2x)
Ø6H7 (2x)
73
Screw, ISO 4762
M8x50
M8x60
74
Screw, ISO 4762
M8x40
M8x45
Drawings and dimensions of the assembly device ( 9.5.1.1, Page 43).
1 Insert the cylindrical pin (72) into the drill hole provided.
2 Install assembly device 1 (70) with the screws (73) and grease
the centering bore with Renolit HTL 2.
3 Insert the compression spring (25) in the housing.
4
CAUTION, do not tilt: Place the cylinder piston (10) on the
centering bore and evenly push it into the bore hole by hand
so that the cylinder piston (10) pushes the spring.
5 Insert the screw (45) into the cylinder piston (10).
6 Apply assembly device 2 (71) and evenly screw it to device 1
(70) with the screws (74).
7 Screw the screw (45) into the piston (3) ( 9.5.2, Page 44).
8 Remove the assembly devices (70 and 71).
9 Insert the seals (32 and 34) and install the cover (9).
42
08.01|JGZ 40 - 160|en
Maintenance and Care
9.5.1.1 Assembly device
Fig. 16 Assembly devices
1
Assembly device 1
2
Assembly device 2
Assembly device 1 - dimensions in mm
Size
40
50
64
80
100
ØA
40
50
64
80
100
B
15
20
20
20
30
Ø d2 H7
27.5
34
45
58
78
Ø d3 H7
2
3
4
5
5
d4
M3
M3
M5
M6
M6
l1 ±0.02
36.0
45.0
56.0
70.0
90.0
l2
29.9
41.2
48.5
60.6
78.0
l4
17.25
22.0
28.0
35.0
45.0
l6
8.6
11.0
14.0
17.5
22.5
l7
10.0
10.0
20.0
20.0
20.0
08.01|JGZ 40 - 160|en
43
Maintenance and Care
Assembly device 2 (with assembly device 1) - dimensions in mm
Size
125
160
ØA
125
160
B
60
75
ØC
125
160
D
40
40
Ø d1 f7
94.5
127.5
Ø d2 H7
94.5
127.5
Ø d3 H7
6
6
d4
M8
M8
d5
M8
M8
Ø d6
9
9
Ø d7
18
20
l1 ±0.02
112.0
146.0
l2
97.0
126.4
l3
56.0
73.0
l4
56.0
73.0
l5
97.0
126.4
l6
28.0
36.5
l7
20.0
20.0
l8
112.0
146.0
l9
30.0
30.0
l10
45.0
55.0
9.5.2 Screw tightening torques
Position of the position numbers ( 10, Page 45)
Item
JGZ 40
JGZ 50
JGZ 64
JGZ 80
JGZ 100
JGZ 125
JGZ 160
40
2.2 Nm
5.9 Nm
12 Nm
12 Nm
20 Nm
49.0 Nm
96.0 Nm
41
0.45 Nm
1.2 Nm
1.2 Nm
1.3 Nm
1.3 Nm
2.9 Nm
8.5 Nm
45
4.9 Nm
10.0 Nm
14 Nm
14 Nm
29 Nm
57.5 Nm
96.0 Nm
46
0.45 Nm
1.2 Nm
1.2 Nm
1.3 Nm
2.9 Nm
6.0 Nm
10.0 Nm
44
08.01|JGZ 40 - 160|en
Accessory pack
10 Assembly drawing
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.
Fig. 17 Assembly of the variants O.D. gripping (AS) / I.D. gripping (IS) / without maintenance of gripping force unit
*
Wearing part, replace during maintenance.
Included in the seal kit. Seal kit can only be ordered completely.
**
Positionen sind aufeinander abgestimmt und können nur zusammen bestellt
werden.
***
from size 125
****
from size 160
08.01|JGZ 40 - 160|en
45
Accessory pack
11 Seal kit
ID.-No. of the seal kit
Sealing kit for
ID number
JGZ 40
5516815
JGZ 50
5516816
JGZ 64
0303450
JGZ 80
0303451
JGZ 100
0303452
JGZ 125
0303453
JGZ 160
0303454
Contents of the seal kit ( 10, Page 45).
12 Accessory pack
Content of the accessories pack:
• 6 x Centering sleeves for mounting
• 2 x O-ring for hose-free direct connection
• 2 x screw plug for hose connection
• 2 x cylindrical pin for mounting
ID.-No. of the accessory pack
Accessory pack for
46
ID number
JGZ 40
5521694
JGZ 50
5520796
JGZ 64
5512728
JGZ 80
5512729
JGZ 100
5512730
JGZ 125
5512731
JGZ 160
5512732
08.01|JGZ 40 - 160|en
Translation of original declaration of incorporation
13 Translation of original declaration of incorporation
In terms of the EC Machinery Directive 2006/42/EG, Annex II, Part B
Manufacturer/
Distributor
SCHUNK GmbH & Co. KG
Spann- und Greiftechnik
Bahnhofstr. 106 – 134
D-74348 Lauffen/Neckar
We hereby declare that the following product:
Product designation:
3-finger centric gripper / JGZ 40 - 160 / pneumatic
ID number
0308901... 03089901
meets the applicable basic requirements of the Machinery Directive (2006/42/EC).
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.
Applied harmonized standards, especially:
EN ISO
12100:2011-03
Safety of machinery - General principles for design - Risk assessment
and risk reduction
EN 62079:2001
Preparation of instructions - Structuring, content and presentation
The manufacturer agrees to forward on demand the special technical documents for the
incomplete machine to state offices.
The special technical documents according to Annex VII, Part B, belonging to the incomplete machine have been created.
Person responsible for documentation: Mr. Robert Leuthner, Address:
see address of the manufacturer
Lauffen/Neckar, May 2013
Ralf Winkler;
Business Unit Manager
R & D Mechanical Gripping Systems
08.01|JGZ 40 - 160|en
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48
08.01|JGZ 40 - 160|en