SERVICE MANUAL Contents

EC manufacturers declaration General safety instructions Technical details BB-N Technical details BB-N-ES Description of function Installation Operation Maintenance Top jaws Disassembling Assembling Trouble shooting Spare parts Control units 2 3 4-63 7-9 10-11 12 13 14 14 14 15 15 15 16-21

Service manual BIG BORE

Thank you for purchasing an original SMW self-contained frontend power chuck type Big Bore. This service manual contains the installation, the use and the maintenance of the self-contained frontend power chuck type Big Bore. SMW-AUTOBLOK reserves the right to make changes without notice. This service manual may not be, in whole or in part, copied without our written agreement.
2001-09-E

Please read the service manual carefully before installation and use and always follow the regulations.

Please note especially the sections which are marked with the following signs: Danger of injury or danger to life if instructions are not followed.
WARNING!

The service manual is a part of the self-contained frontend power chuck type Big Bore and must be passed to the new owner in case of sale.

Danger of damage to the machine, the power chuck or the components.

ATTENTION!

SMW-AUTOBLOK

MANUFACTURERS DECLARATON

Manufacturers declaration
according to machine specification 89/392/EC appendix II paragraph B

SMW-AUTOBLOK Spannsysteme GmbH declares that the component described following is designed for the use on a machine. It is prohibited to operated the component until it is certain that the machine in which the component is installed is in accordance with the regulations of the EC-rule i.d.F. 91/368/EWG. Important: The operation of the self-contained frontend power chuck type Big Bore is allowed only if suitable safety control units with airflow sensors, pressure gauges as well as pressure control during rotation are installed. Different from standard power chucks the jaw stroke of Big Bore air chucks is not controlled by proximity switches. The resulting remaining risks must be covered by suitable protections and covers on the machine.

Component: Application: Type: Applied harmonized norms:

Self-contained frontend power chuck Installation in machine tool Big Bore DIN EN 1550

Signature of responsible person

SMW-AUTOBLOK

GENERAL SAFETY INSTRUCTIONS General safety instructions

1. Correct use SMW-AUTOBLOK self-contained frontend power chucks work safely and troublefree if WARNING! they are used according to their specification, i.e. to clamp components on the outside diameter on turning machines. Any other use can cause hazards. 2. Personnel Self-contained frontend power chucks must be installed, operated and maintained by qualified and regularly trained personnel only. 7. Top jaws Always use original-SMW-AUTOBLOK-top jaws only. Jaws of other manufacturers can ATTENTION! cause damage to the chuck or accidents. Top jaws must be mounted with head socket screws of quality class 12.9 only! Tighten all mounting bolts with a specified torque. Always ensure sufficient length of the engagement (min. 1,25 x thread diameter)! If the jaw height of special jaws exceeds the height of the standard jaws the max. actuating force of the chuck must be reduced in order to avoid an excessive lever action and thus damage to the power chuck. At reduced actuating force the max. speed must also be reduced accordingly!

WARNING!

3. Safety precautions During the machining process the self-contained frontend power chuck and the clamped WARNING! component must be protected by suitable safety guards mounted to the machine. The machine door must be locked closed until the machine spindle arrives to its full stop. Actuation of the power chuck must be possible at stopped spindle only! Set-up works, maintenance and all other mechanical work must be done at safe spindle stop only! 4. Technical details The max. data as max. pressure p and max. spindle speed n are engraved on the chuck body. They must not be exceeded in any case.

8. Maintenance The self-contained frontend power chuck must be maintained in regular intervals according to WARNING! the specification. Check the sealness and the clamping force of both cylinder chambers with a static gripforce meter regularly. Replace damage parts with original SMW-AUTOBLOK spare parts only! Maintenance must only be carried out at safe spindle stop of the machine! The actuation of the self-contained frontend power chuck must be only be carried out by suitable safety control units with airflow senWARNING! sors, pressure gauges and pressure control which are in accordance with all valid safety regulations. Important: On chucks type BB-N and BB-N-ES the jaw stroke and the clamping pressure is monitored indirectly when the machine spindle is stopped and the airflow to actuate the chucks is monitored by airflow sensors and pressure gauges. After that the clamping pressure remains trapped in the cylinder chamber. During rotation of the spindle the air pressure is switched off and disconnected from the chuck! When using the safety control unit ACU-NT with the option pressure control on chuck o.d. clamping the clamping pressure in the chuck chamber for o.d. clamping can be monitored. Herefore the pressure control on the chuck must be adjusted according to the present clamping pressure used on the chuck (valid for chucks type BB-N and BBN-ES). On the chuck type BB-N-ES the safety control unit ACU-NT with the option rapid stroke control allows to monitor that the chuck does not clamp the component on the rapid stroke (it is not allowed to clamp components on the rapid stroke!) Remaining risks must be covered by suitable actions and suitable safety guards on the machine. In case of doubts or questions please ask SMW-AUTOBLOK or one of our authorized offices.

WARNING!

5. Maximum speed The max. speed is only allowed at an actuating force of min. 6 bar. The jaws that are used ATTENTION! must be the corresponding hard reversible stepped jaws that radially do not exceed the chuck outside diameter. If, for special applications, special top jaws are used the clamping force and the max. speed must be calculated according to VDI 3106, but not exceeding the max. permitted speed of the chuck. Especially heavy special top jaws have a big influence on the max. speed. During the machining process the centrifugal force increases or decreases the gripping force. O.d. clamping = decreasing, i.d. clamping = increasing. All theoretically calculated values must be double checked with a suitable dynamic gripmeter. We recommend to use our dynamic gripmeter type DGM 270.

6. Remaining risks The type of component (shape, weight, unbalance, material etc.) has a big influence on the ATTENTION! system machine tool - power chuck - component. For that reason there is always a residual risk. These residual risks must be calculated by the user and must be eliminated by suitable actions.

SMW-AUTOBLOK

TECHNICAL DETAILS

Subject to technical changes

NEW
SMW-AUTOBLOK BIG BORE Id.No. Mounting A B C D H6 E Fixing bolts circle F G G1 H H1 J Thread circle 6x M8 / 6x UNC K L M Pneumatic connection N O P R S a b Serration c Bolt DIN 912 12.9 d min. e T-nuts distance min./max. f Serration length g min./max. h mm mm mm mm mm mm mm mm mm mm mm mm mm mm inch mm mm mm mm mm mm inch mm mm mm mm mm BB-N 400-140 BB-N 460-181 052300 052887 Z 310 Z 310 422 467 140 181 467 467 310 310 400 400 374 374 M12 M12 26 26 196 196 194 194 8 8 448 448 20 20 70 R 3/8" R 3/8" 37 37 26 26 35 35 374 374 57 57 25,5 25,5 3/32" x 90 3/32" x 90 M20 M20 13 13 38/85 38/85 117,5 117 94,5/101,5 112/119 20 20 9 x 40 9 x 40 37 83 BB-N 500-205 052318 Z 415 540 205 570 415 500 474 M12 26 225 223 8 550 20 98 R 3/8" 37 26 35 474 57 25,5 3/32" x 90 M20 14 38/102 138 133,5/142 15 12 x 30 60 BB-N 500-230 052340 Z 415 570 230 570 415 500 474 M12 26 225 223 8 550 20 98 R 3/8" 37 26 35 475 57 25,5 3/32" x 90 M20 14 38/102 138 143,5/152 15 12 x 30 60 BB-N 630-310 052534 Z 510 662 310 685 510 610 580 M16 30 263 261 8 666 20 115 R 3/8" 39,5 33 42 575 75 30 3/32" x 90 M24 16 47/103 142 190,5/200,5 15 12 x 30 60 BB-N 800-410 BB-N 1000-534 052347 052650 Z 700 Z 700 800 1000 410 534 850 925 700 700 775 850 745 815 M16 M16 30 30 305 332 303 330 8 10 830 910 25 33 154 224 R 3/8" R 3/8" 44,5 52,5 33 33 35 42 745 815 75 75 30 30 3/32" x 90 3/32" x 90 M24 M24 16 16 47/130 47/148 171,5 188 243/255 311/323,5 15 15 12 x 30 12 x 30 60 60

SMW-AUTOBLOK

TECHNICAL DETAILS

GUB Hard reversible top jaws

Gripping ranges

Chuck Jaw type Id.No. B H L T N Serration a b c kg/set A1 A2 A3 S

BB-N 400-140 BB-N 460-181 BB-N 500-205 BB-N 500-230 BB-N 630-310 BB-N 800-410 BB-N 1000-534 GUB 500 GUB 500 GUB 500 GUB 500 GUB 630 GUB 800 GUB 800 12085046 12085046 12085046 12085046 12086446 12088046 12088046 55 55 55 55 75 75 75 73 73 73 73 85 85 85 145 145 145 145 160 220 220 32 32 32 32 30 30 30 25,5 25,5 25,5 25,5 30 30 30 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 46 46 46 46 30 51 51 38 38 38 38 50 62 62 38 38 38 38 50 62 62 6,6 6,6 6,6 6,6 13,5 19,5 19,5 65-238 110-284 294-470 585 100-273 145-320 330-505 620 150-358 200-405 385-590 705 175-378 225-425 410-610 725 275-485 275-485 475-685 820 320-590 330-600 590-865 1050 450-760 460-770 725-1030 1225

GAB Hard top jaws

Gripping ranges

Chuck Jaw type Id.No. B H L N Serration a b c kg/set A1 S

BB-N 400-140 BB-N 460-181 BB-N 500-205 BB-N 500-230 BB-N 630-310 BB-N 800-410 BB-N 1000-534 GAB 500 GAB 500 GAB 500 GAB 500 GAB 630 GAB 800 GAB 800 12085146 12085146 12085146 12085146 12086546 12089046 12089046 55 55 55 55 75 75 75 73 73 73 73 82 82 82 195 195 195 195 245 320 320 25,5 25,5 25,5 25,5 30 30 30 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 96 96 96 96 113 165 165 38 38 38 38 50 60 60 38 38 38 38 50 60 60 16,5 16,5 16,5 16,5 31,5 40,5 40,5 25-140 585 60-175 620 50-260 705 70-280 725 105-320 820 95-365 1010 225-535 1180

WBC Soft top jaws

Chuck Jaw type Id.No. B H L N Serration a b kg/pc. A1 S

BB-N 400-140 BB-N 460-181 BB-N 500-205 BB-N 500-230 BB-N 630-310 BB-N 800-410 BB-N 1000-534 WBC 500 WBC 500 WBC 500 WBC 500 WBC 630 WBC 800 WBC 800 12075050 12075050 12075050 12075050 12076440 12078040 12078040 60 60 60 60 80 80 80 60 60 60 60 80 80 80 170 170 170 170 240 320 320 25,5 25,5 25,5 25,5 30 30 30 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 69 69 69 69 110 165 165 38 38 38 38 50 60 60 4,5 4,5 4,5 4,5 11 15 15 25-195 545 60-230 580 105-315 660 125-325 680 110-325 815 95-365 1010 225-535 1180

Gripping ranges

SMW-AUTOBLOK

TECHNICAL DETAILS

WBCL Soft top jaws long version

N

c b a H

L B

Gripping ranges

Chuck Jaw type Id.No. B H L N Serration a b c kg/pc. A1 S

BB-N 400-140 BB-N 460-181 BB-N 500-205 BB-N 500-230 BB-N 630-310 BB-N 800-410 BB-N 1000-534 WBCL 500 WBCL 500 WBCL 500 WBCL 500 WBCL 630 WBCL 800 WBCL 800 12075140 12075140 12075140 12075140 12078040 12079040 12079040 60 60 60 60 80 80 80 60 60 60 60 80 80 80 205 205 205 205 320 390 390 25,5 25,5 25,5 25,5 30 30 30 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 104 104 104 104 165 230 230 38 38 38 38 60 60 60 38 38 38 38 60 60 60 5,5 5,5 5,5 5,5 15 18 18 0-155 575 35-245 660 55-265 680 25-195 845 25-235 1020 95-405 1190

NST T-nuts

Chuck Type Id.No. N H h G

Bolt DIN 912 12.9

BB-N 400-140 BB-N 460-181 BB-N 500-205 BB-N 500-230 BB-N 630-310 BB-N 800-410 BB-N 1000-534 NST NST NST NST NST NST NST 12065020 12065020 12065020 12065020 13063900 13063900 13063900 25,5 25,5 25,5 25,5 30 30 30 34 34 34 34 44 44 44 15 15 15 15 18 18 18 M20 M20 M20 M20 M24 M24 M24 M20 x 40 300 M20 x 40 300 M20 x 40 300 M20 x 40 300 M24 x 60 450 M24 x 60 450 M24 x 60 450

Tighten torque
Md max (Nm)

Adapters for BIG BORE chucks

ISO-A DIN 55026 mounting adapters BB-N 400-140/460-181 500-205/500-230 630-310 800-410 1000-534
Spindle nose A8 A11 A15 A11 A15 A20 A11 A15 A20 A15 A20 A15 A20 Id.No. 24184020 24114020 24124020 24115030 24125020 24175020 24116320 24126320 24176320 24128020 24178020 24128020 24178020 A mm 46 46 46 46 46 46 56 56 56 56 56 56 56 B mm 139,719 196,869 285,775 196,869 285,775 412,775 196,869 285,775 412,775 285,775 412,775 265,775 412,775 C mm 171,4 235 330,2 235 330,2 463,6 235 330,2 463,6 330,2 463,6 330,2 463

Bayonet and camlock flanges are available on request

SMW-AUTOBLOK

TECHNICAL DETAILS

Subject to technical changes

NEW
BB-N ES 400-140 BB-N ES 460-181 BB-N ES 500-205 BB-N ES 500-230 BB-N ES 630-325 BB-N ES 850-375 BB-N ES 1000-560 SMW-AUTOBLOK BIG BORE ES Type Id.No. 052330 052838 052651 052652 052653 052654 052655 Mounting Z 310 Z 310 Z 415 Z 415 Z 510 Z 700 Z 700 A mm 467 467 570 570 685 850 1000 B mm 140 181 205 230 325 375 560 C mm 467 467 570 570 685 850 925 D H6 mm 310 310 415 415 510 700 700 E mm 400 400 500 500 610 775 850 Fixing bolts circle F mm 374 374 474 474 580 745 815 G mm M12 M12 M12 M12 M16 M16 M16 G1 mm 26 26 26 26 30 30 30 H mm 240 240 282 282 307,5 354 332 H1 mm 238 238 280 280 305,5 352 330 J mm 8 8 8 8 8 8 10 Thread circle 6x M8 / 6x UNC K mm 448 448 550 550 666 830 910 L mm 20 20 20 20 20 25 33 M mm 224 Pneumatic connection N inch R 3/8" R 3/8" R 3/8" R 3/8" R 3/8" R 3/8" R 3/8" O mm 37 37 37 37 39,5 44,5 52,5 P mm 26 26 26 26 33 33 33 R mm 35 35 35 35 42 35 42 S mm 374 374 474 474 575 745 815 T mm 35 35 35 35 35 35 35 U mm 374 374 474 474 580 745 905 a mm 57 57 57 57 75 75 75 b mm 25,5 25,5 25,5 25,5 30 30 30 Serration c inch 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 Bolt DIN 912 12.9 d mm M20 M20 M20 M20 M24 M24 M24 min. e mm 14 14 14 14 16 16 16 T-nuts distance min./max. f mm 38/90 38/75 38/104 38/92 47/100 47/140 47/125 Serration length g mm 121 106 140 127,5 138 182 166 min./max. h mm 124 141,5 170 182,5 230 268 360 20 20 15 15 15 15 15 9 x 40 9 x 40 12 x 30 12 x 30 12 x 30 12 x 30 12 x 30 83 83 60 60 60 60 60

SMW-AUTOBLOK

TECHNICAL DETAILS

GUB Hard reversible top jaws

Gripping ranges

Chuck Jaw type Id.No. B H L T N Serration a b c kg/set A1 A2 A3 S

BB-N ES 400-140 BB-N ES 460-181 BB-N ES 500-205 BB-N ES 500-230 BB-N ES 630-325 BB-N ES 850-375 BB-N ES1000-560 GUB 500 GUB 500 GUB 500 GUB 500 GUB 630 GUB 800 GUB 800 12085046 12085046 12085046 12085046 12086446 12088046 12088046 55 55 55 55 75 75 75 73 73 73 73 85 85 85 145 145 145 145 160 220 220 32 32 32 32 30 30 30 25,5 25,5 25,5 25,5 30 30 30 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 46 46 46 46 30 51 51 38 38 38 38 50 62 62 38 38 38 38 50 62 62 6,6 6,6 6,6 6,6 13,5 19,5 19,5 78-264 125-310 310-495 635 113-270 160-315 345-500 640 175-388 225-435 410-620 765 200-388 250-435 435-620 765 295-500 295-500 495-700 870 320-610 330-620 590-865 1070 470-760 480-770 745-1030 1250

GAB Hard top jaws

Gripping ranges

Chuck Jaw type Id.No. B H L N Serration a b c kg/set A1 S

BB-N ES 400-140 BB-N ES 460-181 BB-N ES 500-205 BB-N ES 500-230 BB-N ES 630-325 BB-N ES 850-375 BB-N ES1000-560 GAB 500 GAB 500 GAB 500 GAB 500 GAB 630 GAB 800 GAB 800 12085146 12085146 12085146 12085146 12086546 12089046 12089046 55 55 55 55 75 75 75 73 73 73 73 82 82 82 195 195 195 195 245 320 320 25,5 25,5 25,5 25,5 30 30 30 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 96 96 96 96 113 165 165 38 38 38 38 50 60 60 38 38 38 38 50 60 60 16,5 16,5 16,5 16,5 31,5 40,5 40,5 25-160 635 60-165 640 75-290 765 100-290 765 130-335 870 95-385 1060 245-535 1210

WBC Soft top jaws

Chuck Jaw type Id.No. B H L N Serration a b kg/pc. A1 S

BB-N ES 400-140 BB-N ES 460-181 BB-N ES 500-205 BB-N ES 500-230 BB-N ES 630-325 BB-N ES 850-375 BB-N ES1000-560 WBC 500 WBC 500 WBC 500 WBC 500 WBC 630 WBC 800 WBC 800 12075050 12075050 12075050 12075050 12076440 12078040 12078040 60 60 60 60 80 80 80 60 60 60 60 80 80 80 170 170 170 170 240 320 320 25,5 25,5 25,5 25,5 30 30 30 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 69 69 69 69 110 165 165 38 38 38 38 50 60 60 4,5 4,5 4,5 4,5 11 15 15 35-220 590 70-225 595 130-335 720 155-335 720 135-340 865 95-385 1060 245-535 1210

Gripping ranges

SMW-AUTOBLOK

TECHNICAL DETAILS

WBCL Soft top jaws long version

N

c b a H

L B

Gripping range

Chuck Jaw type Id.No. B H L N Serration a b c kg/pc. A1 S

BB-N ES 400-140 BB-N ES 460-181 BB-N ES 500-205 BB-N ES 500-230 BB-N ES 630-325 BB-N ES 850-375 BB-N ES1000-560 WBCL 500 WBCL 500 WBCL 500 WBCL 500 WBCL 630 WBCL 800 WBCL 800 12075140 12075140 12075140 12075140 12078040 12079040 12079040 60 60 60 60 80 80 80 60 60 60 60 80 80 80 205 205 205 205 320 390 390 25,5 25,5 25,5 25,5 30 30 30 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 3/32" x 90 104 104 104 104 165 230 230 38 38 38 38 60 60 60 38 38 38 38 60 60 60 5,5 5,5 5,5 5,5 15 18 18 0-150 595 60-275 720 85-275 720 25-210 895 25-255 1070 115-405 1220

NST T-nuts

Chuck Type Id.No. N H h G

Bolt DIN 912 12.9

BB-N ES 400-140 BB-N ES 460-181 BB-N ES 500-205 BB-N ES 500-230 BB-N ES 630-325 BB-N ES 850-375 BB-N ES1000-560 NST NST NST NST NST NST NST 12065020 12065020 12065020 12065020 13063900 13063900 13063900 25,5 25,5 25,5 25,5 30 30 30 34 34 34 34 44 44 44 15 15 15 15 18 18 18 M 20 M 20 M 20 M 20 M 24 M24 M 24 M20 x 40 300 M20 x 40 300 M20 x 40 300 M20 x 40 300 M24 x 60 450 M24 x 60 450 M24 x 60 450

Tighten torque
Md max (Nm)

Adapters for BB-N-ES chucks

ISO-A DIN 55026 mounting adapters BB-N ES 400-140/460-181 500-205/500-230 630-310 850-375 1000-534
Spindle nose A8 A11 A15 A11 A15 A20 A11 A15 A20 A15 A20 A15 A20 Id.No. 24184020 24114020 24124020 24115030 24125020 24175020 24116320 24126320 24176320 24128020 24178020 24128020 24178020 A mm 46 46 46 46 46 46 56 56 56 56 56 56 56 B mm 139,719 196,869 285,775 196,869 285,775 412,775 196,869 285,775 412,775 285,775 412,775 265,775 412,775 C mm 171,4 235 330,2 235 330,2 463,6 235 330,2 463,6 330,2 463,6 330,2 463,6

Bayonet and camlock flanges are available on request

SMW-AUTOBLOK

DESCRIPTION OF FUNCTION 1. Description of function

1.1 General function
Self-contained frontend power chucks type BIG BORE are wedge hook chucks with large through hole with an integrated pneumatic actuating cylinder. The main use is clamping of tubes. The clamping/unclamping is done at stopped spindle by filling/exhausting the cylinder chambers with compressed air. The air must be cleaned and lubricated with a suitable air service unit with a filter, dryer and oiler. Actuation is done by an air distribution system which is mounted stationary on the headstock of the machine. When the correct clamping pressure in the cylinder chamber is reached the mounted safety control unit stops the airflow and disconnects the air distributor from the chuck. The clamping pressure is trapped in the cylinder chamber by a non-return valve.

1.3 Safety non-return valve (pic. 2)

The safety non-return valve is a brass valve body including 2 steel sealing pistons. It is easily accessible through a plug on the face of the chuck. It guides the airflow from the profile seals through the channels to the corresponding chuck chamber. By pressurizing the different profile seals the clamping pressure is guided to the corresponding clamping chamber and in the same movement the other chamber can exhausts the air through the other side of the safety valve. As the safety valve acts like a shuttle valve any actuation causes a movement of the entire assembly in the ball of the chuck body. This allows to have the function for pressurizing the clamping chamber and exhausting the other chamber in one motion (see also page 11, pic. 2).

1.2 Air distribution system (pic. 1)

The air for actuation is transmitted through the air distributor ring and the mounted profile seals to the chuck at stopped spindle only. The profile seals are designed so that the outside surface is bigger than the inside surface. When the profile seal is pressurized the bigger outside surface causes a radial deformation of the profile seals inwards until they are in full contact with the outside diameter of the chuck body. Now the profile seals seal all around the outside dia. of the chuck body and the air flows through the small holes of the profile seals into the corresponding chuck chamber.
pic. 1

When the airflow is stopped the elasticly free loaded profile seals lift completely off the chuck body and thus cannot wear out during rotation of the chuck. The air of the non-pressurized chamber exhausts mainly directly through the gap between the air distributor ring/profile seal and the chuck body.

10

SMW-AUTOBLOK

DESCRIPTION OF FUNCTION

to cylinder chamber I from distributor ring

from cylinder chamber II to distributor ring

pic. 2

brass valve body steel sealing piston in exhaust position steel sealing piston in seal position plug

1.4 Jaw drive

The self-centering jaw drive on all 3 master jaws is ensured by a piston with a wedge hook machined into the piston collar. The force transmission is done by the 10 wedge hook from the piston to the master jaws. The clamping forces are taken by the piston collar and are radially supported in the piston guide of the chuck body. The pneumatic actuation is done on to the piston cover that is bolted on to the piston in the pneumatic part of the chuck.

pic. 3

master jaw
pressurized chamber for o.d. clamping axial force

piston guide on guide bush pressurized chamber for unclamping piston with wedge hook

clamping force

force transmission

piston collar piston guide piston cover

self-centering jaw drive of selfcontained frontend power chuck

SMW-AUTOBLOK

11

INSTALLATION 2. INSTALLATION
pic. 4 prox. switch M12x1 bracket

2.1 Distributor ring (see pic. 4)

The distributor ring must be mounted stationary onto the headstock of the spindle without any contact to the chuck. The distributor ring is a separate stationary part which is mounted with the distributor ring mounting bracket (DRMB) to the headstock of the machine and has to be held rigidly in axial and radial position. It can be centred and mounted on the cover of the front spindle bearing. Always reconfirm with the machine manufacturer for the best place for mounting the DRMB.
ATTENTION!

The DRMB must have a large hole on the bottom in order to allow coolant and exhaust air to escape!

The brackets for the proximity switches for the pressure control and for the rapid stroke control can also be mounted onto the DRMB. DRMB distributor ring labyrinth gap

2.2 Mounting to the machine spindle

2.2.1 Mount chuck adapter plate with mounting bolts onto the machine spindle, and finish machine if necessary. Always apply correct torque to the machine mounting bolts. 2.2.2 Bolt DRMB and distributor ring together, and mount onto the machine (see pic. 4). 2.2.3 Lift the chuck with suitable lifting equipment (eyebolt) and mount carefully onto the machine. Be sure not to damage the distributor ring and the profile seals. 2.2.4 Insert chuck mounting bolts, mount the chuck to the chuck adapter plate and check concentricity. Adjust labyrinth gap (1,5 mm = 0,059) with thickness gage, 2.2.5 and adjust concentricity of the distributor ring with dial indicator. 2.2.6 Tighten all bolts with correct torque. 2.2.7 Connect hoses for clamp and unclamp and check function and sealness. 2.2.8 Insert gripmeter into the chuck and check grip force. Leave the grip force meter clamped for at least 1 hour WARNING! to ensure the chuck holds the grip force properly.

(Illustration without pressure control and without rapid stroke control)

distributor ring SMW profile seal labyrinth gap 1,5 mm seal disc grease nipple

pic. 5

2.3 Adjustment of proximity switch for pressure control

2.3.1 Set the air control unit ACU-NT to adjustment mode (see manual ACU-NT page 14, 6.6). 2.3.2 Orientate chuck so that the switch ring of the pressure control is underneath the slot where the proximity switch for the pressure control is mounted. Mount the proximity switch to the bracket and radially adjust to approx. 1 mm (0,039) distance to the switch ring. 2.3.3 Adjust the pressure control of the chuck to the requested min. pressure (see page 13, 3.3 and pic. 6, 7, 8, 9). 2.3.4 Adjust axial position of the proximity switch, so that the proximity switch is actuated at low pressure or at position chuck open. At correct clamping there must be no alarm signal.

bolt T-nut master jaw

guide bush piston safety non-return valve

2.4 Adjustment of proximity switch for rapid stroke control

2.4.1 Set the air control unit ACU-NT to set-up mode for jaw movement (see manual ACU-NT page 14, 6.5). 2.4.2 Orientate the chuck so that the switch ring for rapid stroke control is underneath the slot where the proximity switch for the rapid stroke control is mounted. Mount the proximity switch to the bracket and radially adjust to approx. 1 mm (0,039) distance to the switch ring. 2.4.3 Move the chuck master jaws to the position where the stroke changes from rapid stroke to clamping stroke. 2.4.4 Adjust the axial position of the proximity switch so that at rapid stroke the proximity switch is actuated. At clamping stroke there must be no alarm signal.

cap chuck body

piston cover back plate air connection

12

SMW-AUTOBLOK

OPERATION 3. Operation
3.1 Operation
3.1.1 Ensure that the self-contained frontend power chuck type Big Bore is well lubricated. If necessary relubricate on all grease nipples using original SMW-AUTOBLOK grease K05. Lubrication is done with closed jaws (all 3 jaws are in inward end position). A chuck that is not sufficiently lubricated does not offer full gripping force and causeS hazards! 3.1.2 On the face of the chuck there is a plug with a 6 mm i.d. hex. Behind this plug the safety non return valve is mounted. It is important that the ball for the safety valve is slightly oiled so that the valve body can easily slight in the valve ball.
WARNING!

Too much grease, dirt or chips in the ball of the safety valve can lock the safety valve or cause damage of the o-rings! The air must be cleaned and lubricated with a suitable air service unit. Moisture or dirt can cause rust or contamination which can damage the seals of the chuck and thus can cause loss of clamping force. Danger of loss of gripping force!

As the clamping pressure is correct no alarm signal is created and the machine spindle and the machining process can be started. In case the pressure in the clamping chamber for o.d. clamping drops below the preselected value correspondingly the pressure in chamber (S) is reduced. The lower pressure in chamber (S) causes a lower force against the tension of the spring (1). The spring causes the switch rod and thus the switch ring (2) to move backwards and thus creating an alarm signal by switching on the proximity switch (3). The signal of the proximity switch is detected by the built-in electronics of the ACU-NT and creates an alarm output signal which can be used to stop the machine spindle.

3.3 Changing of the preset minimum pressure

When the chuck is delivered from the factory a pressure control for o.d. clamping is set to a pressure of 3 bar (43 psi). In order to readjust this pressure following procedure is necessary: 1. The chuck is clamped for o.d. clamping with a pressure that lateron is used as a clamping pressure to hold the part. 2. Open counter nut (6) by 8 mm hex key. 3. Readjust set screw (5) by 6 mm hex key until the pneumatic pressure in chamber (S) forces the switch ring to position A 11 mm towards the backface of the chuck (see pic. 6). 4. Tighten counternut (6) again. 5. Open the chuck and reclamp for o.d. clamping with a pressure 2 bar (29 psi) less then the initial pressure. Now switch ring (2) must reach the position 7 mm as shown in picture 7 as a maximum. In this position the switch ring creates an alarm signal as soon as the spindle starts rotating and the switch ring passes by the proximity switch. The built-in electronics in the ACU-NT detect the low pressure and create an alarm output signal. This can be used to stop the machine spindle. To check the function without rotating the spindle (rotating spindle by hand) the ACU-NT must be set to set-up mode (please refer to service and maintenance instruction of ACU-NT). pic. 8
min. pressure set to 2 bar (29 psi)

WARNING!

ATTENTION!

Pressure control Monitoring of the clamping pressure on chuck o.d. clamping is possible with suitable safety control units only! (please refer to power safety control unit ACU-NT).

3.2 Standard conditions

The self-contained frontend power chucks type Big Bore are equipped with a pressure control for chuck o.d. clamping as a standard. This control contains the part 1, 2, 3 and 4 (see illustration below) and works as follows: The air pressure in chamber (S) creates a force on piston (4) that is equal or bigger than the counterforce created by the spring (1). This causes the switch ring (2) to move forward in working position (A). In this position the switch ring (2) can lock the proximity switch (3).
flush with chuck body

pic. 6

standard setting Switch ring in position ok (for o.d. clamping only)

standard setting for 3 bar (43 psi)

Switch ring in alarm position low pressure in chuck chamber or jaws

pic. 7

pic. 9
min. pressure set to 4,5 bar 65 psi)

Switch ring in alarm position low pressure in chuck chamber or jaws

Switch ring in alarm position low pressure in chuck chamber or jaws

assembly of pressure control

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MAINTENANCE / JAWS DISASSEMBLING 4. Maintenance

4.1.1 Cleaning and lubrication of the chuck Constant clamping force, accuracy and service life of the chuck mainly depend on that the chuck is regularly cleaned and maintained. Rust, dust, chips and coolant increase the friction and thus increase wear of the chuck. Regular lubrication with SMW-AUTOBLOK K05 ensure high gripping force, accuracy and service life. 4.1.2 Every 20-30 working hours the 3 grease nipples on the master jaws have to be lubricated with SMW-AUTOBLOK grease K05. After lubricating the chuck should be opened and closed 3 times without a clamped workpiece to spread the grease equally on all surfaces. 4.1.3 Depending on the working conditions the safety valve has to be removed, cleaned and oiled minimum once per week. Also the ball of the safety valve has to be cleaned and checked for damage.

5.1 Disassembling
refer to page 15)

(for reference numbers please

5.1.1 Disconnect both fittings from distributor ring (4). Loose mounting bolts of distributor ring mounting bracket mounted to the machine headstock. Use eyebolt M12 or M16 in radial eyebolt holes and engage suitable lifting equipment into crane. Loosen mounting bolts that hold the chuck on the adapter plate. Now take off the complete chuck assembly with a crane and place safely on a work bench. Please obersve hands and feet because chuck is very heavy. 5.1.2 Disassemble profile seals (5 and 8) from distributor ring (4) and check for wear. If necessary replace by new original SMW-AUTOBLOK profile seals. If the profile seals are not worn out clean and grease slightly. When reassembling the profile seals to the air dsitributor ring ensure that the small holes in the profile seals are as far as possible away from the pneumatic fittings of the distributor ring. 5.1.3 Take out safety non-return valve (10) by opening plug (9) with o-ring (39) carefully. Attention: The chuck is still pressurized! Please use clothrag to cover and protect yourself during disassembling the safety nonreturn valve. It is absolutely necessary to take off the safety non-return valve before continuing any other disassembling! Check all parts and o-rings of the valve system for wear or damage, and replace if necessary! 5.1.4 When the safety valve is disassembled from the chuck the backplate (12) with the o-rings (34, 35) can be disassembled by loosening the head socket screws (11). Before removing the backplate disassemble the switch rings for pressure control and stroke control. 5.1.5 Open head socket screws (13) which hold the piston cover (14) onto the piston (21). 5.1.6 Use 2 of the screws in the 2 tapped holes in the piston cover (14) to lift the piston cover (14) off the piston (21). 5.1.7 Open the head socket screws (15) of the guide bush (16) and disassemble the guide bush (16) by pushing towards the front. 5.1.8 Open head socket screws (17 or 17.1) and remove sealing disc (19 or 19.1) and take out the o-ring (20 or 20.1). Attention: On older chucks there can be washers underneath the heads of the bolts. Please do not loose them! 5.1.9 The piston (21) can now be removed from the chuck body (23). Also the master jaws (22) can be slided out radially towards the center of the chuck. The jaws as well as the piston are marked with 1,2,3. When reassembling please observe correct position in chuck body. 5.1.10 Clean all parts of the chuck with suitable cleaning liquid and dry. Always observe all safety regulations. Please check all parts for wear or damage and replace if necessary. We recommend to use a new seal kit and replace all o-rings before reassembling the chuck. All o-rings and parts in the pneumatic part must be oiled, all parts in the mechanical part (piston and master jaws) must be lubricated with SMW-AUTOBLOK grease K05. Please note that the seal in the sealing disc (part 32) in the chuck is a Teflon seal. Normally this seal does not have to be changed. In case it is damaged, a o-ring in the seal kit replaces the Teflon seal and its o-ring!

WARNING!

4.1.4 The serration of the master jaws and the top jaws must be cleaned when changing all repositioning jaws. 4.1.5 Contamination of rust, dust, fine chips or coolant cannot be avoided, even if all gaps are sealed by very close tolerances. Therefore the chuck has to be disassembled and completely cleaned and relubricated max. every 6 months. In case of big amounts of dust or coolant contaminating the chuck this interval has to be shortened accordingly.

WARNING!

4.2 Top jaws

4.2.1 The fine serration of the master jaws and the top jaws on the Big Bore chucks is 3/32 x 90. The increments from teeth to teeth are approx. 2.4 mm (approx. 3/32). Please observe that the top jaws to clamp the components are positioned on the master jaws so that max. 2/3 of the total jaw stroke are used to clamp the part (1/3 remaining as remaining jaw stroke). Hard top jaws must only be used in sets (marked with 1, 2, 3). Please observe correct position of the top jaws 1, 2, 3 on the corresponding master jaws, to reach best concentricity. 4.2.2 Machining of soft top jaws on the self-contained frontend power chuck type Big Bore must be done in the same clamping position using the same clamping pressure that will be used for the machining process afterwards. Please note that all mounting bolts must be tightened with a correct torque. 4.2.3 When mounting hard or soft top jaws always use a torque wrench. Always tighten the mounting bolts with correct torque. Always use mounting bolts with minimum quality class 10.9!

WARNING!

14

SMW-AUTOBLOK

REASSEMBLING 5.2 Reassembling

5.2.1 Lubricate master jaws and piston with SMW-AUTOBLOK grease K05. Insert master jaws (22) into the corresponding guideways of the chuck body (23). Mount the o-ring (33) into the piston (21). Slide in the piston with a wedge hook into the wedge hook of the master jaws (22) up to the frontend position. Please observe marking 1, 2, 3 on chuck body (23), piston (21) and master jaws (22). 5.2.2 Reinsert o-ring (20 or 20.1) into sealing disc (19 or 19.1), and mount together with O-ring (32) into the chuck body. Use head socket screws (17) to bolt in the sealing disc (19 or 19.1) into the chuck body (23). On older version chucks do not forget the washers underneath the heads of the screw! 5.2.3 Slide in guide bush (16) from the frontside into the chuck and screw-in 3 screws (15). 5.2.4 Insert piston cover (14) with the o-rings (31, 36) and mount with head socket screws (13) to the piston (21). 5.2.5 Put backplate (12) the o-ring (34, 35) back onto the chuck body and tighten head socket screws (11) in chuck body (23). Reassemble the switch rings for pressure control and stroke control. 5.2.6 Lubricate the safety valve (10) and the safety valve ball in the chuck body (23) slightly with oil and slide in the valve into the body. Please observe that the valve must slide easily in the ball. Now reinsert o-ring (39) and close plug (9). All parts of the SMW-AUTOBLOK self-contained frontend power chuck move easily. When reassembling the chuck never apply force! 5.3.4 Air leakage on the chuck after finishing the clamping cylce. 5.3.3 The chuck is loosing clamping force.

5.3 Trouble shooting

Trouble: 5.3.1 On o.d. or i.d. clamping: The chuck is clamping but reverses the movement immediately. caused by and action: The safety valve does not move in the bore. Remove safety valve (10), clean and oil slightly. Reassemble the safety valve and check for easy movement. Contamination underneath the profile seals (5/8): Remove air distributor ring (4), profile seals (5/8), check for damage and clean and oil slightly. If necessary replace! Disassemble the chuck completely, check all parts for damage, clean, replace all orings and safety valve.

5.3.2 Air leakage inside the air distributor ring during actuation of the jaws.

O-rings or seals in the safety valve damaged or worn out. See also point 5.3.3.

ATTENTION!

5.4 Spare parts

Below drawing shows the most common spare parts for the chuck. Please always state chuck type, size and serial number when ordering spare parts. Seal kits are available in sets only!

(Pressure control and stroke control are not shown)

SMW-AUTOBLOK

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CONTROL UNIT AC-SP / AC-BB General safety instructions

1.1 Correct use SMW-AUTOBLOK control units work safely and troublefree if they are used according to their speWARNING! cification i.e. to actuate and control selfcontained air chucks on turning machines. Any other use can cause hazards. Important: The control units AC-SP/AC-BB do not allow to use the safety features pressure control of clamped chuck in o.d. clamping and the rapid stroke control. All necessary steps to ensure safety must be taken. 1.2 Personnel Control units must be installed, operated and maintained only by qualified and regularly trained personnel. During machining the power chuck and the clamped component must be protected by safety guard. Open machine door only when machine spindle is completely stopped. Maintenance and actuation of the power chuck must only be carried out when machine spindle is stopped. 1.4 Remaining risks The type of components (shape, weight, unbalanWARNING! ce, material etc.) has a big influence on the system machine tool - power chuck - component. For that reason there is always a residual risk. These residual risks must be calculated by the user and have to be eliminated by suitable actions. 1.5 Maintenance The function of the control unit has to be checked once a month due to safety reasons. The level of WARNING! the oil in the air service unit (optional) has to be checked regularly. The function of the air service unit (optional) has to be checked regularly. A air service unit to clean and lubricate the air is mandatory! For any problems or questions please contact SMWAUTOBLOK directly or one of our authorized offices.

WARNING!

1.3 Protections During actuating of the chuck the flow of the air to the chuck is monitored via airflow sensors (air WARNING! flow/pressure). As soon as the actuation cycle of the chuck is finished and the air flow stops the pressure in the supply lines is switched off. The built-in non-return valve in the chuck body closes and traps the air pressure inside of the chuck body during the chuck rotates.

Description of function AC-SP / AC-BB

pressure switch (optional pressure converter)

pressure regulation with pressure gauge for clamping pressure current monitor

relay
3/2 valves

air flow sensor

The AC-SP / AC-BB are designed and manufactured to operate pneumatic front and chucks of the SMW-AUTOBLOK series SP and BIG BORE. The main part is a pneumatic block with pressure regula-tion, pressure switch, two 3/2 valves with quick exhaust and 2 air flow sensors. The 2 current monitors and the 2 relays are intended to be installed in the machine side control unit. They can be plugged on usual 35 mm mounting brackets. The control unit has no own operating devices. The pneumatic block that contents all pneumatic parts should be mounted in a well accessible place at the machine. The installation of a manual switch or foot switch or the connection for automatic operation (machine control) is required.
16 SMW-AUTOBLOK

Function sequence Filtered, dehydrated and lubricated air connected at the pressure regulation. When switching the solenoid valves clamping/unclamping the air flow in the corresponding line to the chuck will be released. The in-built air flow sensors together with the current monitors register the air flow and keep it up (red LED is on). (Attention: Impulse must be current for 1 second to make the unit come to self-holding through the air flow sensors.) After reaching of the clamping position with a pre-adjusted pressure the airflow stops. The air flow sensors register this and give the sign release through the current monitors (red LED goes off). The machining process can be started.

CONTROL UNIT AC-SP / AC-BB

The release of the machine spindle (only possible at full spindle stop) only happens when conditions A + B are given: Condition A Air pressure (clamping pressure) in the chuck reaches during the filling process (clamping) the pre-adjusted value at the pressure switch. Condition B Clamping process is completed, that means in the line for clamping there is no more air flow. Attention: At running spindle the operation of the chuck is not possible.

fixing holes

total depth 110 mm

connection line pressure

chuck connections clamping/unclamping

Optional accessories:
Foot switch F2 incl. 4 m wire Id.-No. 013324 Standard delivery range: like shown without hoses and connectors

Air service unit (must be used to clean and lubricate the air!)

Type AC-SP AC-SP AC-SP AC-BB AC-BB AC-BB

24 V 110 V 220 V 24 V 110 V 220 V

I.D. 1/4 1/4 1/4 1/2 1/2 1/2

Id.-No. 192432 192446 192447 192433 192448 192449

SMW-AUTOBLOK

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CONTROL UNIT AC-SP / AC-BB Installation

Fixing the control unit The control unit has to be mounted well accessible in a dry area, e.g. close to the control panel of the machine Electrical connection Electric parts (current monitors and relays) are to be mounted in the machine side control cabinet or at another suitable place. Please consider general regulations (see wiring diagram page 6). Electric power supply The power supply is either 24 VDC, 110 VAC or 230 VAC, 50/60 Hz. The AC-SP/AC-BB are not equipped with a ON/OFF switch and are connected at the control cabinet of the machine. Pneumatic power supply (See pneumatic plan page 6.). The pneumatic line has to be connected with the pressure regulating valve. Connect control unit and chuck with hoses. Hoses with low elasticity, I.D. min. for AC-SP = 8 mm, for AC-BB = 12 mm, are to be used! The hoses, fittings, aramtures and tubes must ot be smaller in ID than 8 mm (AC-SP) or12 mm (AC-BB) Make sure that the adjustment of the air flow sensor insures a correct clamping force at the chuck. (Check clamping WARNING! force with a suitable grip force meter, see operating manual of the chuck). Unsuitable clamping force can cause accidents at the machine. Adjust lubricator at the maintenance unit (optional). oil amount approx. 1 drop for 2 - 3 clamping cycles.

Operating
Switch on unit together with the machine The unit is ready for operation, when the both green LEDs on the current monitors are on. Adjust required clamping pressure and pressure switch accordingly. Release clamping/unclamping by connected operating device. To get the unit in self-holding position by the air flow sensors, the impulse must be current by approx. 1 second.

6. Maintenance
Every 3 days Check oil volume (maintenance unit optional) Refill oil type HLP 32. Check function and adjustment of the lubricator (optional) Adjustment: one drop per 2 - 3 clamping cycles. Check the function of the control unit. Check the clamping force of the chuck therefore clamp grip force meter in the chuck. The cripping force must not decrease by more than 10 % in one hour (see operating instructions of the chuck).

WARNING!

min. operating pressure = 2 bar max. operating pressure = 10 bar All connections need to be checked for leakage. Recommended oil for air lubrication (air maintenance unit optional) HLP 32. Air service unit to clean and lubricate the air must be installed! Rust or contamination can cause damage of seals and thus loss of clamping force.

Weekly

Monthly Monthly

WARNING!

Putting into operating

Switch on electric power supply Green LED at the current monitors is on and indicates ready for operation. Adjust pressure regulator to min. pressure 2 bar. Switch operating device (foot switch, manual switch or M-function). During the operation/movement of the chuck, additionally the red LED on the corresponding monitor is on and by this indicates the air flow. After reaching of the end-position the air flow stops and the red LED goes off. Repeat this sequence for both operating directions (clamping/unclamping) at min. and max. operating pressure. The sensibility of the air flow sensor is adjusted to a standard value from the manufacturer. It can be readjusted according to the local conditions at the potentiometer sensibility/Empfindlichkeit.

Trouble shooting
Green LED at the current monitors is not on no electric power supply Red LED at the current monitors does not go off a) air flow still existing because of leaking hoses connectors, or chuck b) sensibility of air flow sensors is adjusted wrongly Pneumatic control switches off without movement of the chuck a) pressure too low b) chuck or safety valve blocked mechanically c) time of impulse for clamping/unclamping too short

18

SMW-AUTOBLOK

CONTROL UNIT AC-SP / AC-BB

PNEUMATIC DIAGRAM AC-SP / AC-BB

clamping chuck

air flow sensing pressure reducer

air flow sensing

pressure converter 0-10 bar hoses, fittings, aramtures and tubes must not be smaller in ID than 8 mm (AC-SP) or 12 mm (AC-BB)

option

pneumatic power supply max. pressure 10 bar

valve Y1

valve Y2

WIRING DIAGRAM AC-SP / AC-BB

voltage only at spindle stop

relais

operating voltage ok

pressure control (option)

GREEN

RED

air flow sensor

air flow current

sensibility

air flow sensor

period of impulse for clamping/unclamping 1 s

SMW-AUTOBLOK

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CONTROL UNIT ACU-NT

Universal, electronic micro-processor compact control unit for Big Bore chucks in 1/2 design type ACU-NT
n n n n n

All safety systems integrated Easy installation - no other devices needed Can be connected to all common voltages LCD display in English/German Quick chuck actuation by 1/2 pneumatic parts

1/2 pressure connecting lines to the chuck clamp/unclamp

Line pressure

LCD display English/German Push button close (B) / open (A) Key switch to select manual operation, foot pedal or automatic cycle I.d. / o.d. clamping Reset Hysteresis for pressure switch Protection cover

Standard equipment:
Electric connections (as shown, without cable, without hoses without fittings)

Accessories:
Foot pedal F2 with 4 m cable Id.No. 013324 Proximity switch for pressure and rapid stroke control signals Id.No. 090636 Air service unit 1/2 Id.No. 192074

Options:
Line pressure control Pressure control for chuck o.d. clamping Rapid stroke control (for BB-N ES only) Interface Lubrication unit Second independent ok relay 20 SMW-AUTOBLOK 192437 192435 192436 192439 192438 192440 Pressure is shown in the display, minimum pressure pre-selectable, contact for monitoring the pressure. Pressure control of the chuck chamber via proximity switch, contact for monitoring, self diagnostic of proximity switch (for o.d. clamping only). Control of rapid/clamping stroke via proximity switch, contact for monitoring, self diagnostic of proximity switch. To show data chuck clamped, unclamped, too long clamping cycle, air supply lines leaking, i.d./o.d. clamping, pressure control deactivated on the machine display. Actuation of an external lubrication unit with intervals, oil reservoir control, pressure control. Additional relay to double confirm for spindle run.

CONTROL UNIT ACU-NT

Pneumatic diagram ACU-NT

Electric diagram ACU-NT

SMW-AUTOBLOK

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CONTROL UNIT ACU-NT

Electric connection ACU-NT

For further information please refer to the service manual ACU-NT

22

SMW-AUTOBLOK