ba tmf 1-4 - Сервотехника Нева20tmf$201-4$20english.pdf · tmf size 1-4 project:...
TRANSCRIPT
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MODULES ROBOTICS SYSTEMSCOMPONENTS
OPERATING MANUAL
TMF Size 1-4
Project: Bill of materials:Year of manufacture:
Axxxxxxx09xxxxx2012
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OPERATING MANUAL TMF
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© by GÜDEL 2012
Translation of the original operating manual
This operating manual contains standard illustrations that may deviate from the original. In the case of special models, options, or technical changes, the scope of delivery may differ from the descriptions here. Any reproduction of this operating manual, in whole or in part, requires our express permission. Subject to change in the course of technical improvements.
Version a
Author chrgal
GÜDEL AG
Industrie Nord
CH-4900 Langenthal
Switzerland
phone +41 (0)62 916 91 91
fax +41 (0)62 916 91 50
e-mail [email protected]
www.gudel.com
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Tab. 0-1 Revision history
Version Date Specification / Description
a 21.05.2012 Basic version
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Table of contents
Table of contents
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Further applicable documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Purpose of the document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Target readership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Characters / Explanation of abbreviations . . . . . . . . . . . . . . . . . . . . 10
1.5 Torque tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5.1 Tightening torques for screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111.5.2 Tightening torques for HV sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131.5.3 Tightening torques for roller holder . . . . . . . . . . . . . . . . . . . . . . . . 141.5.4 Tightening torques for roller support . . . . . . . . . . . . . . . . . . . . . . . 15
1.6 Thread rolling screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172.1.2 Non-intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Product designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1.1 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.1.2 Operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.1.3 Failure to comply with safety regulations . . . . . . . . . . . . . . . . . . . . . 213.1.4 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2 Declaration of incorporation in acc. with Machinery Directive 2006/42/EC22
3.3 Hazard symbols and instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3.1 Hazard symbols in the operating manual . . . . . . . . . . . . . . . . . . . . . 23Hazard warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Warning symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Special symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3.2 Hazard symbols on the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.4 Fundamentals of safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.4.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273.4.2 Safety and monitoring equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 273.4.3 Product-specific hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Danger from electric current . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Danger from falling axles/workpieces . . . . . . . . . . . . . . . . . . . . . . 28
3.4.4 Safety data sheets (MSDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4 Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1.1 Standard configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294.1.2 Option FullCover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304.1.3 Planetary gear option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314.1.4 Double roller support option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345.1.2 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.3 Positioning, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.3.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365.3.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365.3.3 Positioning, fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Base fixing with adhesive anchor . . . . . . . . . . . . . . . . . . . . . . . . . 42Base fixing with welded joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.3.4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455.3.5 Transport securing devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.4 Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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6 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597.1.2 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.2 Consumables and auxiliary agents . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.2.1 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607.2.2 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Markings at the lubricating points. . . . . . . . . . . . . . . . . . . . . . . . . 60Oils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.3 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.4 Maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.4.1 General prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657.4.2 Maintenance tasks 100 hours after commissioning . . . . . . . . . . . . . 657.4.3 Maintenance tasks every 150 hours . . . . . . . . . . . . . . . . . . . . . . . . . 66
Lubricating guideways, racks and pinions . . . . . . . . . . . . . . . . . . 667.4.4 Maintenance tasks every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . 67
General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677.4.5 Maintenance tasks every 2000 hours . . . . . . . . . . . . . . . . . . . . . . . . 69
Replacing the lubricating pinion . . . . . . . . . . . . . . . . . . . . . . . . . . 697.4.6 Maintenance tasks every 10000 hours . . . . . . . . . . . . . . . . . . . . . . . 71
Oil change in type NA / NH / FA / FH / AE gearboxes . . . . . . . 71
8 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 768.1.2 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.2 Special tools, testing and measuring instruments . . . . . . . . . . . . . . . 77
8.3 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.3.1 General prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 798.3.2 Replacing the bumper unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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8.3.3 Replacing the wiper and felt insert . . . . . . . . . . . . . . . . . . . . . . . . . . 808.3.4 Replacing the rollers and guideways . . . . . . . . . . . . . . . . . . . . . . . . . 83
Replacing guideways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 868.3.5 Setting rollers and tooth flank backlash . . . . . . . . . . . . . . . . . . . . . . 908.3.6 Replacing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 968.3.7 Setting the gear backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 998.3.8 Replacing motor and coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
8.4 Other documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8.5 Service departments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9 Decommissioning, storage . . . . . . . . . . . . . . . . . . . . . . . . . 104
9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1049.1.2 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9.2 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9.3 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
9.3.1 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1059.3.2 Cleaning / rust-proofing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1069.3.3 Transport securing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1069.3.4 Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
9.4 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10810.1.2 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10.3 Waste management compliant assemblies . . . . . . . . . . . . . . . . . . . 109
10.3.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10910.3.2 Material groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
10.4 Disposal facilities, authorities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
11 Spare part supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
11.1 Explanations regarding the spare parts list . . . . . . . . . . . . . . . . . . . 111
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11.1.1 Positioning drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11111.1.2 Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
11.2 Service departments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
12 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
13 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
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1 General
1.1 Further applicable documentation
All documents in the appendix of this operating manual are further applicable documentation. They must be observed in addition to this operating manual for the safe handling of the product.
1.2 Purpose of the document
This operating manual describes all product life phases of the product TMF:
• Transport• Repairs• Commissioning• Operation• Maintenance• Disposal
The operating manual contains the required information on how to operate the product in the intended manner. It is an important component of the product TMF. The operating manual must be available at the product site throughout its entire service life. If the product is sold, it has to be transferred to the new owner with the machine.
Assembly instruc-tions for partly
completedmachinery
This document serves as the "Assembly instructions for partly completed machinery" in acc. with the Machinery Directive 2006/42/EC, and is in this respect an "Operating Manual".
NOTERead the entire operating manual before working with the prod-uct! It contains important information for your personal safety. The operating manual must be read and understood by all per-sons who work on the product in any of the product life phases.
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1.3 Target readership
This operating manual is aimed at the following target readership:
• Construction
• Specialists• Technicians• Forwarding agents
• Operating companies
• Operating personnel
• Service personnel
1.4 Characters / Explanation of abbreviations
The following symbols and abbreviations are used in this operating manual:
Tab. 1-1 Explanation of symbols/abbreviations
Symbol/Abbreviation Use Explanation
For cross-reference Page
Fig. Designates drawings Figure
Tab. Designates tables Table
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1.5 Torque tables
1.5.1 Tightening torques for screws
If no other specifications have been made, the following tightening torques apply for zinced screws lubricated with Molykote(MoS2) grease or secured with Loc-tite 242:
Tab. 1-2 Torque table for zinced screws lubricated with Molykote(MoS2) grease
NOTEScrew connections on moving parts have to be secured with Loctite medium strength 242. The adhesive has to be applied onto the nut thread, not onto the screw!
Thread size
Tightening torque [Nm]
8.8 10.9 12.9
M3 1.1 1.7 2.0
M4 2.6 3.9 4.5
M5 5.2 7.6 8.9
M6 9 13 15
M8 22 32 37
M10 42 62 72
M12 74 108 126
M14 117 172 201
M16 180 264 309
M20 363 517 605
M22 495 704 824
M24 625 890 1041
M27 915 1304 1526
M30 1246 1775 2077
M36 2164 3082 3607
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General
If no other specifications have been made, the following tightening torques apply for black oiled and unlubricated screws, or screws secured with Loctite 242:
Tab. 1-3 Torque table for black oiled and unlubricated screws
Thread size
Tightening torque [Nm]
8.8 10.9 12.9
M4 3 4.6 5.1
M5 5.9 8.6 10
M6 10.1 14.9 17.4
M8 24.6 36.1 42.2
M10 48 71 83
M12 84 123 144
M14 133 195 229
M16 206 302 354
M20 415 592 692
M22 567 804 945
M24 714 1017 1190
M27 1050 1496 1750
M30 1420 2033 2380
M36 2482 3535 4136
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General
1.5.2 Tightening torques for HV sets
The following tightening torques apply to DIN6914/15/16-10.9 HV sets:
Tab. 1-4 Tightening torques: HV sets
Thread size
Tightening torque [Nm]
Lubricated with moly grease Slightly oiled
M12 100 120
M16 250 350
M20 450 600
M22 650 900
M24 800 1100
M27 1250 1650
M30 1650 2200
M36 2800 3800
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General
1.5.3 Tightening torques for roller holder
Fig. 1-1 Tightening torques for roller holders
A Move roller with hexagonal socket wrench (tightening torque A1)B Roller holderC Tighten screw with hexagonal socket wrench (tightening torque A2)
The following tightening torques apply to roller holders:
Tab. 1-5 Tightening torques: Roller holders
D00
0772
A2
A1
A B C
SizeTightening torque [Nm]
A1 A2
40 1.5 4
52 2 4
62 3 15
72 4.5 15
90 7 15
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1.5.4 Tightening torques for roller support
Fig. 1-2 Tightening torques for roller supports
A Roller supports size 72 and 90B Move roller with hexagonal socket wrench (tightening torque A1)C Roller supports size 40 and 52D Tighten nut and locknut with hexagonal key (tightening torque A2)
The following tightening torques apply to roller supports:
Tab. 1-6 Tightening torques: Roller supports
D00
0941
A1
A2A2
A1
A B C B
D D
SizeTightening torque [Nm]
A1 A2
40 1 87
52 2 120
72 3 220
90 5.5 450
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General
1.6 Thread rolling screws
Thread rolling screws are mainly used for guideways, mounting plates, as well as for cable tray brackets.
Fig. 1-3 Use of thread rolling screws
A LabelB Thread rolling screwsC Mounting plateD Cable tray bracketE Guideways
Thread rolling screws, recognizable with Güdel by a Torx drive, can be screwed in directly in the core hole. It is not necessary to cut the thread in advance. After the first use of a thread-cutting screw, a metric screw can also be employed.Drill holes without thread need to be furrowed. No thread may be cut in. This can also be read on the label.
The following tightening torques apply to thread rolling screws when turned in the first time:
Tab. 1-7 Tightening torques for thread rolling screws
3
2
1
0181
843
MA max
M8 30NmM10 60NmM12 100Nm
Nicht GewindeschneidenNo tapping!
GewindefurchendeSchraubenThread grooving screw
MA
.
.
.
.
.
.
.
3
21
0181
843
D
A
B
C
BBE
SizeTightening torque [Nm]
Steel S355J2 Aluminum
M8x30 30 35
M10x45 63 71
M12x40 108 123
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Product description
2 Product description
2.1 Purpose
2.1.1 Intended use
The TMF product is intended exclusively for moving and positioning of robots.
Other use or use that goes beyond the described purpose does not fall under the intended use. The manufacturer assumes no liability for any resulting dam-ages. All risks are carried solely by the user!
2.1.2 Non-intended use
The TMF product is not intended for:
• Movement of poisonous goods• Movement of explosive goods• Operation in explosive areas
Any other use shall be considered improper use and is forbidden!
Do not modify the product in any way.
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Product description
2.2 Product designation
Each product has a type plate. It contains the following information:
Fig. 2-1 Type plate
A Product, typeB Project, sales orderC Serial number (parts list)D Year of manufacture
In the declaration of conformity and declaration of incorporation, the terms are used in acc. with the legend above.
Position of the typeplate
The type plate is attached in accordance with the following illustration:
Fig. 2-2 Position of the type plate
A Type plate
D00
1120
A C DB
D00
1453
A
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Product description
2.3 Technical Data
The technical data is valid for temperatures between +25 and +30 °C.
The emitted sound pressure level depends on how the product is used.
For the following data, refer to the layout(s) in chapter 13 ’Appendix’, 117:
• Dimensions• Weight• Strokes of the individual axes• Gearbox type• Gearbox ratios• Motors
Temperature ranges The following temperature and air humidity ranges apply:
2.4 Options
The following options are available for the product TMF:
• Automatic lubrication system• Planetary gear• Double roller support• FullCover
In general, in these operating instructions the complete covering option is called FullCover.
Information on any available options can be found in the spare parts lists and the layout in chapter 13 ’Appendix’, 117. You may also find relevant docu-mentation in the same chapter under "Options".
Transport -10 to +60°C
Operation +5 to +40°C Up to and with 85%, condensation formation not permissible
Storage -10 to +40°C up to 75%
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Safety
3 Safety
3.1 General
3.1.1 Product safety
Residual danger The TMF product corresponds to the state of the art. It was designed and con-structed according to the recognized safety regulations. However, some resid-ual danger remains during its operation.
There is danger to the personal safety of the operator, as well as to the TMF product and other property.
Operation Always adhere to the instructions in this manual when operating the TMF prod-uct, and ensure that it is always in perfect working order.
3.1.2 Operating personnel
Persons who work with the TMF product must be technically qualified and trained. They must be familiar with all hazards associated with using the TMF product.
NOTERead this chapter prior to working with the product! It contains important information for your personal safety. This chapter must be read and understood by all persons who work on the product in any of the product life phases.
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Safety
3.1.3 Failure to comply with safety regulations
Liability Güdel shall not be held liable under any of the following circumstances:
• The installation regulations were disregarded• Included protective equipment was not installed• Included protective equipment was modified
3.1.4 Installation instructions
Protective measures The operator is responsible for ensuring safe conditions in the vicinity of the product TMF, in particular, for complying with all general safety regulations, guidelines and standards . This includes implementing all of the safety measures before commissioning the system. These must cover all hazards. This is the only way to ensure that operation of the product conforms with CE regulations.
As stipulated by the machinery directive, the protective measures must:
• Correspond to best practices• Comply with the required safety category
Changes The product must never be modified or used in a manner contrary to its intended use. Intended use and non-intended use is described in Chapter 2 ’Product description’, 17.
General rules foroccupational safety
The generally accepted occupational safety rules have to be observed and fol-lowed.
DANGERDisregarding safety regulations
Disregarding the safety regulations can be very hazardous for personnel and the surroundings!
Always comply with the safety regulations!
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3.2 Declaration of incorporation in acc. with Machinery Directive 2006/42/EC
The manufacturer: GÜDEL AG, Industrie Nord, CH-4900 Langenthal
herewith declares that the partly completed machinery:
Product, type / serial number (parts list) / year of manufacture
TMF Size 1-4 / 09xxxxx / 2012
corresponds to the fundamental requirements of the Machinery Directive (2006/42/EC), Annex 1.
The special technical documents as per Annex VII Part B have been drawn up.
The partly completed machinery complies with the following other EC direc-tives:
• Low Voltage Directive 2006/95/EC• EMC Directive 2004/108/EC
The following harmonized standards have been applied:EN ISO12100; EN ISO 13850; EN 60204-1; EN 1088; EN ISO 4413; EN ISO 4414; EN ISO 13849-1
Authorized representative responsible for compiling the technical documents: Martin Knuchel Tel. +41 (0)62 916 92 40
The special technical documents are submitted in electronic form, depending on the respective regulations of the national bodies.
The partly completed machinery may only be commissioned after it has been determined that the machinery into which the partly completed machinery is to be incorporated complies with the stipulations of the Machinery Directive (2006/42/EC).
Langenthal, 01/01/2012 Walter Zulauf Martin Knuchel
Director of Development Director of Systems / Robotics
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Safety
3.3 Hazard symbols and instructions
3.3.1 Hazard symbols in the operating manual
Hazard warnings
The hazard warnings are defined for the following four types of danger levels:
DANGERDANGER
DANGER refers to hazards with a high risk of severe physical injury or im-mediate fatality.
WARNINGWARNING
WARNING refers to hazards with a moderate risk of severe physical injury or potential fatality.
CAUTIONCAUTION
CAUTION refers to hazards with a slight risk of moderate physical injury.
NOTENOTE
NOTE refers to a hazard that can lead to property damage.
NOTENote refers to helpful information and tips for users.
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Warning symbols
Symbol Use
Danger, warning, caution, note
Refers to hazards resulting from automatic operation of the plant
Danger, note
Refers to electrical hazards
Danger, warning
Refers to hazards from falling beams
Warning, caution
Refers to crushing hazards from gears
Danger, warning, caution, note
Refers to hazards from industrial trucks
Warning, caution
Refers to hand injury hazards
Warning, caution
Refers to hazards from heavy components
Danger, warning, caution, note
Refers to environmental pollution hazards
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Safety
Tab. 3-1 Warning symbols
Special symbols
Tab. 3-2 Special symbols
Danger, warning, caution, note
Refers to hazards from suspended loads
Danger, note
Refers to hazards from electromagnetic fields
Danger, warning, caution, note
Refers to hazards from crushing
Danger
Refers to hazards from explosion
Danger, warning, caution, note
Refers to hazardous locations
Warning, caution, note
Refers to hazards from heat
Symbol Use
Symbol Use
Note
Helpful information and other tips
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Safety
3.3.2 Hazard symbols on the product
The following labels are attached to the product:
The "Danger sign" label warns against:
• Axles falling after the transport securing device is removed• Moving the axles before the transport securing device is removed
Fig. 3-1 Danger sign label
The "Transport information" label provides information on correctly attaching transport equipment.
Fig. 3-2 Transport information label
DANGER! GEFAHR!The vertical axis mustbe secured from motionbefore removing therack lock or otherlocking device used fortransportation!
Vor dem Entfernen derTransportsicherungZ-Achse(n) gegenherunterfallen Sichern!
WARNING! ACHTUNG!Remove all rack locks orother locking devicesused for transportationon all axes beforeattempting to move anyaxis!
Vor dem Bewegen derAchsen sämtlicheTransportsicherungenentfernen!
0156
538
D00
0095
0156
539
2X
X
X
D00
1401
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Safety
3.4 Fundamentals of safety
3.4.1 Intended use
The intended use is described in chapter 2.1.1 ’Intended use’, 17.
3.4.2 Safety and monitoring equipment
For information on the safety and monitoring equipment, refer to the docu-mentation on the complete system. More details can be found in the supplied risk analysis.
3.4.3 Product-specific hazards
Danger from electric current
NOTENever remove or modify any of the safety and monitoring equip-ment! Be sure to close all of the protective equipment during op-eration!
DANGERHazardous voltage
The product contains components that are energized with hazardous volt-ages. Touching these components will cause an electric shock. Electric shocks can be fatal.
Before working in the danger area:• Switch off the main power supply and secure it against being switched on
again (main switch of complete plant)• Ground the equipment• Before switching on the product again, make sure that no one is located
in the danger area
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Safety
Danger from falling axles/workpieces
3.4.4 Safety data sheets (MSDS)
Safety data sheets contain safety information about the materials. The operator is responsible for obtaining safety data sheets for all materials used, such as oils, greases, cleaning agents etc.
Safety data sheets can be obtained as follows:
• Chemical vendors usually deliver their substances with safety data sheets.
• Safety data sheets are available on the InternetExample: Enter "msds" plus the name of the material to find safety informa-tion for the material.
Read the safety data sheets closely and follow all instructions. We recommend that you store the safety data sheets for future reference.
WARNINGFalling axles/workpieces
Falling axles or workpieces can cause severe or fatal injuries!
Observe the following:• Secure suspended axles using the stipulated equipment and deposit any
workpieces before working in the danger area• Never enter the area below suspended axles and workpieces• Check the belts of the telescope axes for signs of breakage and tears
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Design and function
4 Design and function
4.1 Design
4.1.1 Standard configuration
In the standard configuration, the TMF product consists of the following assem-blies:
Fig. 4-1 Design
A Energy chainB Y-carriageC Y-drive (gearbox)D Lubricating pinion unitE Roller supportF Y-axisG Bumper unit
D00
3145
CA B
DG F E
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Design and function
4.1.2 Option FullCover
The TMF product with the FullCover option consists of the following assem-blies:
Fig. 4-2 FullCover option design
A Complete coveringB Y-axisC Y-drive (gearbox or planetary gear)D Y-carriage
D00
3145
DB CA
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Design and function
4.1.3 Planetary gear option
The TMF product with the planetary gear option consists of the following assemblies:
Fig. 4-3 Planetary gear option design
A Y-axisB Y-carriageC Y-drive (planetary gear)
D00
3236
CA B
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Design and function
4.1.4 Double roller support option
The TMF product with the double roller support option consists of the follow-ing assemblies:
Fig. 4-4 Double roller support design
A Y-axisB Y-carriage with double roller supportC Y-drive (gearbox)D Double roller support
D00
3235
DA B C
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Design and function
4.2 Functional description
The TMF product can move along the following axes:
Fig. 4-5 Axis names
D00
1459
Y
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Commissioning
5 Commissioning
5.1 Introduction
Various options are available for your product. This chapter provides informa-tion on several available options. It therefore describes components with which your product is not equipped.
5.1.1 Safety
Only perform the tasks described in this chapter after you have read and under-stood chapter 3 ’Safety’, 20. It concerns your personal safety!
5.1.2 Personnel qualifications
Only appropriately trained and authorized personnel are allowed to commis-sion the TMF product.
WARNINGSuspended loads
Improper handling of suspended loads can lead to severe injuries or death!
Observe the following:• Use appropriate lifting units• Wear appropriate protective clothing• Always keep sufficient distance to suspended loads• Never enter the area below a suspended load
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Commissioning
5.2 Transport
The product is transported by air, land or water. The packaging depends on the means of transport.
Packaging symbols Depending on the contents, the packaging units are marked with the symbols shown below. Observe these at all times.
Fig. 5-1 Packaging symbols
A FragileB This side upC Keep dryD Handle with care
Remove the packaging only to the degree necessary for company-internal trans-port.
Transport the pallet, crate or case to the planned installation location. Use appropriate transport devices.
Truck = Shipped on a transport pallet
Aircraft = Shipped in a crate
Ship = Shipped in a case or container
NOTEImproper transport
Improper handling of the package can lead to transport damage!
Do not tip over the package. Avoid heavy vibrations and shocks. Observe the symbols on the packaging.
FRAGILE
D00
0098
D00
0099
CRAINT L'HUMIDITE
D00
0100
HANDLEWITH CARE
D00
0101
A B C D
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Commissioning
5.3 Positioning, assembly
5.3.1 Prerequisites
Base The base has to fulfill the requirements of the application. For information on the load per surface and the surface properties, please refer to the layout or the documentation of the complete system.
Lines The supply lines have to meet the requirements of the application. For informa-tion on the required capacities, please consult the documentation of the com-plete system.
Lifting unit Lifting units are required for positioning and installing the product or plant. Make sure that appropriately dimensioned devices (crane etc.) are available.
5.3.2 Unpacking
Accessories and small parts are packaged in a separate case or directly with the product itself.
The components have been treated with anti-rust oil (spray) and wrapped in oil paper. Remove packaging carefully.
Dispose of the packaging in accordance with the local disposal regulations.For more information on disposal, refer to chapter 10 ’Disposal’, 108.
DeliveryChecking Check the content of the delivery by comparing it with the accompanying papers.Check the product for damage. Report transport damage immediately.
NOTEThe anti-rust oil protects the components. We recommend not removing the oil.
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5.3.3 Positioning, fastening
This chapter describes the steps for setting up and fastening the TMF product.If no other specifications have been made, the tightening torques as per chapter 1.5.1 ’Tightening torques for screws’, 11 apply.
Before you position the product at the installation site, the requirements listed in chapter 5.3.1 ’Prerequisites’, 36 have to be fulfilled.
WARNINGHeavy components
Components can be very heavy. Improper handling can cause severe or fatal injuries!
Use suitable means to secure the components against tipping over. Only re-move the tip-over protection after the product has been completely assem-bled.
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Attaching slings This section describes the steps for attaching the slings.
Fig. 5-2 Attaching the slings
A Transportation cradleB HookC Lifting belts
Attach the slings as follows:
1 Position the lifting belts as shown in the drawing(Symmetric arrangement according to the figure)
2 Hang the ends of the lifting belts into the hooks of the transportation cra-dle
The slings are in place.
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X
X
2X
A
B
C
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Positioning theproduct
This section describes the steps for positioning and aligning the product.
Fig. 5-3 Positioning the product
A Floor leveling screwsB Locknuts
Position the product as follows:
1 Set floor levelling screws to the specified mass
2 Position the product as shown in the layout
3 Align the product horizontally and vertically by means of floor leveling screws (use guideways as reference)Flatness along overall length of the axis: up to 10 meters = 0.5 mm, up to 20 meters = 0.6 mm,up to 30 meters = 0.7 mm, etc.(max 0.1 mm tolerance for every 10 m extension)
4 Lock the floor leveling screws
The product has been completely positioned and aligned.
25
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Connecting theprofiles
This section describes the steps for connecting and aligning the profiles.
Fig. 5-4 Connecting the profiles
A Cover plateB RacksC Profile CD ScrewsE Profile EF Guideways
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A B C
D
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Connect the profiles as follows:
1 Align profile E with profile C. Distance between: 5 mmAlignment on the overall length of the axis: up to 10 meters = 0.5 mm, up to 20 meters = 0.6 mm,up to 30 meters = 0.7 mm, etc.(max 0.1 mm tolerance for every 10 m extension)
2 Connect the profiles
2.1 Mount the guideway and rack as per Section ’Installing the guide-way’, 45
2.2 Mount the cover plates
3 Realign the product horizontally and vertically, by means of the floor lev-eling screws (use as reference guideways)Flatness along overall length of the axis: up to 10 meters = 0.5 mm, up to 20 meters = 0.6 mm,up to 30 meters = 0.7 mm, etc.(max 0.1 mm tolerance for every 10 m extension)
The profiles are connected and aligned.
Base fixing The base can be fastened either with adhesive anchors or with a welded joint.
You can find the corresponding anchor type in the layout in chapter 13 ’Appen-dix’, 117.
NOTEOnly anchor the product after it has been correctly positioned and aligned!
Only use anchors approved by Güdel!
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Base fixing with adhesive anchor
This section describes the base fixing with adhesive anchor.
This fastening requires uncracked concrete with a quality of at least C20/25 (ENV 206) with ideal stiffness. Deviations can be found in the layout in the appendix. The minimum concrete thickness, edge distance and maximum per-missible tensile and compressive loads can be found in the table below.
Fig. 5-5 Anchored base fixing
A Floor levelling screwB Column/frameC AnchorD Adhesive capsule
Tab. 5-1 Anchored base fixing
D00
0106
d
h
m
b
r
A
B
C
D
m (anchor size) M12 M20 M27 M30
b (concrete thickness) [mm] 140 220 300 340
r (edge distance) [mm] 110 180 240 270
d (drill diameter) [mm] ø14 ø24 ø30 ø35
h (drilling depth) [mm] 110 170 240 270
Tightening torque [Nm] 50 160 270 300
Permissible tensile load [kN] 12.8 36.5 78 101.6
Permissible compressive load [kN]
34 60 80 135
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Anchor the column as follows:
1 Make a bore hole as per the table above
2 Clean the bore hole
3 Insert the adhesive capsule
4 Screw in the anchor rod with the hammer drill
5 Wait until the hardening period specified by the manufacturer has passed
6 Screw the column tight(For the tightening torque, refer to the table above.)
7 Remove the safety devices
The column is anchored.
Base fixing with welded joint
This section describes the base fixing with welded joint.
Prior to welding the joint, you have to fasten the base plate to the floor.This fastening requires cracked or uncracked concrete with a quality of at least C20/25 (ENV 206) with ideal stiffness. Deviations can be found in the layout in the appendix. The minimum concrete thickness, edge distance and maximum permissible tensile and compressive loads can be found in the table below.
NOTEThe welding work described below may only be performed by certified personnel!
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Fig. 5-6 Welded base fixing
A ScrewB Floor levelling screwC Column/frameD Bottom plateE Base plate
Tab. 5-2 Welded base fixing
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k n
m
br
A
B
C
D
E
m (floor levelling screw) M24x2 M36x2 M48x3 M56x3
b (concrete thickness) [mm] 120 160 250 340
r (edge distance) [mm] 90 130 185 255
k (throat dimension) [mm] a 4 a 4 a 5 a 5
n (joint length) [mm] 140 190 190 330
Permissible tensile load [kN] 12.8 36.5 78 101.6
Permissible compressive load [kN]
34 60 80 135
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Perform the weld joint as follows:
1 Connect the floor levelling screw and bottom plate by means of the screw
2 Weld the bottom plate to the base plate(weld joint in acc. with the table above)
3 Tighten the screw
4 Remove the safety devices
The weld joint has been applied.
The product is anchored to the floor.
5.3.4 Assembly
Installing theguideway
Proper installation of the guideways in accordance with the regulations is pre-requisite for low-wear use of the product.
Mounting aid The start and end of the rack form a half tooth gap. For precise and low-noise transition, we recommend using a mounting aid geared in the opposite direction (see chapter 8.2 ’Special tools, testing and measuring instruments’, 77).
Fig. 5-7 Mounting aid for rack assembly
A RackB Mounting aid
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This section describes the steps for installing the guideway.
For axes over 20 meters, the assembly of the guideways must be performed from the middle.
Fig. 5-8 Installing the guideway
A Reference surfacesB ScrewsC Screw clampD Mounting aidE RackF Torque wrenchG ScrewsH Guideway
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A B A C D E
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Install the guideway as follows:
1 Clean the reference surfaces and guideways thoroughly and rub an oil stone across them
2 Lay first pair of guideways and racks on the reference surface. Lightly tighten with outermost screws (all holes must be aligned)
3 Mount next pair of guides and rack as in step 2
4 Clamp mounting aid to guides and racks with screw clamp
5 Install the rest of the screws and tighten with all the others
6 Inspect transition:
6.1 For guideways with gears, transition according to section ’Inspect-ing rack transition’, 48
6.2 For guideways without gears(gap dimension < 0.02 mm)
7 Use a suitable measuring instrument to check that the guideways are par-allel(tolerance: ±0.04 mm)
8 If deviations occur (transition/parallelism):
8.1 Remove screws and guideway
8.2 Repeat the procedure
The guideway has been installed.
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Inspecting racktransition
This section describes the inspection of the rack transition.
The racks correspond to the qualities in the following table:
Tab. 5-3 Rack quality
Hardened racks can be recognized by the engraved Güdel logo.
Fig. 5-9 Inspect rack transition with micrometer
A Rack transitionB Measurement boltC Micrometer position CD Micrometer position DE Micrometer position E
Rack quality
Standard configura-tion Planetary gear option
Q9 Q6
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A B
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Tab. 5-4 Deviation method 1
Inspect the rack transition as follows:
1 Position the measurement bolt as shown in the illustration
2 Inspect the deviations in the height of positions C and E to position D via micrometer(Permissible deviation of position C and E to D, refer to table above)
The rack transition has been inspected.
Mounting motor andcoupling
This section describes the steps for assembly of the coupling and the motor.
Depending on the type of transport securing device used, you have to remove the device before installing the motor for the first time (see Section ’Transport securing device at the gearbox’, 55).
Permissible deviation [mm]
Rack quality Modulem ≤ 3
Module3 < m ≤ 8
Module8 < m ≤ 12
Q4 h21 0.014 0.016 0.022
Q5 h22 0.022 0.027 0.034
Q6 h23 0.034 0.041 0.055
Q7 h25 0.082 0.110 0.137
Q8 h27 0.220 0.275 0.343
Q9 h27 0.220 0.275 0.343
WARNINGDanger of being crushed
Incorrect tightening torques can lead to suddenly moving axes or workpiec-es. This can cause severe or fatal injuries!
Observe the following:• Calibrate and check the torque wrench periodically• Tighten all screws with a torque wrench to the specified tightening tor-
ques
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Fig. 5-10 Installing the motor and coupling
A GearboxB Motor flangeC Measuring instrumentD CouplingE Coupling screwsF Motor screwsG Motor
Install the motor and the coupling as follows:
1 Clean the coupling and motor shaft to ensure that they are free of grease
2 Measure distance X
3 Push the coupling onto the motor shaft(Dimension Y has to match dimension X, tolerance -0.2 to -0.4 mm)
4 Tighten the coupling screws For the tightening torque, refer to tab. 1-2, 11
5 Grease the gear rim of the coupling(For grease types, see 7.2.2 ’Lubricants’, 60)
6 Push the motor, with the mounted coupling, onto the gearbox
7 Tighten the motor screws
The motor and the coupling have been installed.
X
Y
D00
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A B C D GFE
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Attaching optionalcomponents
If equipped, attach the following optional components as per the separate doc-umentation:
• Automatic lubrication system• Manual lifting and safety unit: vertical axis• Safety brake system to vertical axle• Rotary axis• Telescope axis• Pneumatic load balance
Attaching the load Attach the load (gripper, robot, etc.) to the TMF product. Set the roller and tooth flank backlash again. This procedure is described in chapter 8.3.5 ’Setting rollers and tooth flank backlash’, 90.
NOTEWear on the guideways!
Incorrectly adjusted roller and tooth flank backlash increase the wear on the guideways.
After attaching the load, set the roller backlash and tooth flank backlash again!
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Mounting the robot This section describes the steps for mounting the robot.
Fig. 5-11 Mounting the robot
A RobotB ScrewC PlateD Carriage
Mount the robot as follows:
1 With a lifting unit, place the robot on the carriage and align it
2 Screw robot tight(The screws have to go at least 1xd into the plate)
3 Remove the lifting unit
The robot has been mounted.
Integrating product Integrate the TMF product into the complete plant. Connect the product with the supply lines for energy and consumables. For this procedure, refer to the documentation of the complete system.
NOTEWhen installing the robot, use sufficiently long screws. The screws have to go at least 1xd into the plate.
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d
A
B
C
D
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Cables and Lines This section provides information on the proper handling of cables and lines.
Fig. 5-12 Cables and lines
A Strain relief version cable fittingB Energy chainC Strain relief version ChainFixD Cable descriptionE Reel with dispenserF Vertical dividerG Fixed sideH Driver
NOTEImproper handling of cables
The improper handling of cables leads to cable damage, unnecessary maintenance work and stopped operation.
Observe the instructions for use of cables and lines.
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A B C D
H G F E
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Observe the following when handling cables and lines:
• Use only highly flexible, energy chain capable lines! The maximum permissible bending radius of the line must not be larger than the minimum radius of the energy chain.
• Roll the cable off evenly, never take off in loops
• Layout cables without twisting for at least 24 hours before putting them into energy chains! The cable description will aid you in doing so.
• Prepare vertical dividers:• Cables are separated by vertical dividers, cables are not permitted to
be layed next to each other• Piled up cables with variant sheath materials must be separated from
each other (danger of sticking)• The vertical dividers are not allowed to be positioned in an offset man-
ner in the roll-off direction
• The cable must have play on all sides of the cable divider. At its mini-mum, it should be 10% of the cable diameter. However, it should not be less than one millimeter.
• Lay cables in, never pull them in!
• If the process paths of the energy chain are less than 50m:• Relieve cable strain at the driver and the fixed side
• The distance between the end of bend movement and strain re-lief is 10-30 times the diameter of the cable
• Strain relief version cable fitting: Two pieces 4.5mm wide on the appropriate holders, Do not damage the sheaths of the cables!
• Strain relief version ChainFix (IGUS energy chains): Do not exceed a tightening torque of 1 Nm!
• Run cable straight at least 20cm after the strain relief on the fixed side (length L)
• For process paths of the energy chain larger than 50m:• Relieve cable strain at the drive
• The distance between the end of bend movement and strain re-lief is 10-30 times the diameter of the cable
• Strain relief version cable fitting: Two pieces 4.5mm wide on the appropriate holders, Do not damage the sheaths of the cables!
• Strain relief version ChainFix (IGUS energy chains): Do not exceed a tightening torque of 1 Nm!
• Run cable straight at least 50cm after the strain relief on the fixed side (length L)
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• Pressure hoses from the hydraulic system and pneumatics have to be strain relieved at the driver and at the fixed side. Except if they expand under pres-sure (only fabric hoses).
• Before commissioning, label cables during strain relief so they can be read-justed during maintenance work
5.3.5 Transport securing devices
At delivery, a transport securing device is in effect at the gearbox. This has to be removed prior to assembling the motor.
Transport securingdevice at the
gearbox
This section describes the removal of the transport securing device at the gear-box.
Fig. 5-13 Transport securing device at the gearbox
A ScrewsB Transport securing device
WARNINGDanger of being crushed
After removing the transport securing device or the motor, the carriage may run off to the side. This can cause severe or fatal injuries!
Secure the carriage before removing the transport securing device or the motor!
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A
B
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Remove the transport securing device at the gearbox as follows:
1 Fixate the carriage
2 Loosen the screw
3 Remove the transport securing device
Transport securing device has been removed.
5.4 Functional check
Prior to the functional check, ensure that:
• The Installation instructions were observed.
• The product is anchored to the floor.
• The safety equipment has been attached and closed.
• No persons are present in the danger area.
The procedure for the functional check is described in the documentation of the complete system.
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6 Operation
6.1 General
Operate the product only after the Installation instructions has been observed!
For information on how to operate the product TMF refer to the respective chapters of the documentation of the complete plant.
6.2 Personnel
WARNINGTraining of operating personnel
Wrong behavior of untrained or insufficiently trained operating personnel can lead to severe personal or material damage.
Before the operating personnel begins working with the product:• Train and instruct the operating personnel• Point out dangers in the work area to the operating personnel• Assess qualification of operating personnel before approving them• Keep the operating personnel trained in best practices. Inform them also
about technical progress, changes, etc.
If these measures are not complied with, you alone as operating company are liable for damages that may result!
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7 Maintenance
7.1 Introduction
This chapter describes all maintenance tasks.
Work sequences Perform the work sequences in the order described. Perform the described tasks at the specified times. This ensures a long service life for your product.
Original spare parts Use only original spare parts. For information on spare parts and wear items, refer to chapter 11 ’Spare part supply’, 111.
Options andThird-party products
For information on maintenance of options and third-party products, read the appropriate documents in the appendix.
Lubrication This chapter describes the steps for manually lubricating the product. If your product has an automatic lubrication system, manual lubrication of guideways, racks and pinions is not necessary. However, perform lubrication work when the first signs of tribocorrosion (reddish discoloration of the track) show.
Tightening torques If no other specifications have been made, the tightening torques as per chapter 1.5.1 ’Tightening torques for screws’, 11 apply.
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7.1.1 Safety
Only perform the tasks described in this chapter after you have read and under-stood chapter 3 ’Safety’, 20. It concerns your personal safety!
7.1.2 Personnel qualifications
Only appropriately trained and authorized personnel are allowed to work on the TMF product.
WARNINGAutomatic startup
When work is being performed on the product, there is danger of the ma-chine starting up automatically. This can cause severe or fatal injuries!
Before working in the danger area:• Secure vertical axles (if equipped) against falling• Switch off the main power supply and secure it against being switched on
again (main switch of complete plant)• Before switching on the plant again, make sure that no one is in the dan-
ger area.
WARNINGFalling axles/workpieces
Falling axles or workpieces can cause severe or fatal injuries!
Observe the following:• Secure suspended axles using the stipulated equipment and deposit any
workpieces before working in the danger area• Never enter the area below suspended axles and workpieces• Check the belts of the telescope axes for signs of breakage and tears
WARNINGHeavy components
Components can be very heavy. Improper handling can cause severe or fatal injuries!
Use appropriate lifting units!
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7.2 Consumables and auxiliary agents
7.2.1 Cleaning agents
For cleaning tasks, have a grease-dissolving cleaning agent (e.g. acetone) at hand.
7.2.2 Lubricants
Markings at the lubricating points
The identification disc below the grease nipple shows the type of lubricant.
Fig. 7-1 Markings at the lubricating points
A Identification discB Grease nipple
NOTEUnsuitable lubricants
Using unsuitable lubricants can lead to machine damage!
Only use the lubricants listed below. If uncertain, please contact our service departments!
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A
B
Yellow identification disc
Grease
Red identification disc Oil
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Oils
If special oils have been delivered from the factory at the request of the cus-tomer, you can find the relevant specifications in the spare parts list. Otherwise, the following lubricants apply:
Oil types The following oil is used ex works by default:
The following types of oil can be used alternatively:
Oil quantities Refer to the table below for the required oil quantities for the gearbox.
Tab. 7-1 Oil quantity for gearbox
Mobil Glygoyle 460
Aral Degol GS 460
BP Enersyn SG-XP-460
Texaco Pinnacle 460
Shell Tivela S 460
Klüber Klübersynth GH6-220
Type Quantity [cm3]
AE030 40
AE045 100
AE060 250
AE090 700
AE120 1400
AE180 as per type plate
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Greases
If special greases have been delivered from the factory at the request of the cus-tomer, you can find the relevant specifications in the spare parts list. Otherwise, the following lubricants apply:
Grease types forrack/pinion teeth
The following grease is used ex works for manual lubrication of the rack and pinion teeth:
The following grease types can be used alternatively:
The following grease is used ex works for automatic lubrication of the rack and pinion teeth:
Grease types forteeth
Gearbox coupling
The following grease is used ex works for the gear teeth of the gearbox cou-pling:
The following grease types can be used alternatively:
Mobil Mobilux EP 2
Aral Aralup HLP 2
BP Energrease LS-EP 2
Texaco Multifak EP 2
Shell Gadus S2 V220 2
Klüber Centoplex EP-2
Castrol Longtime PD2 Lubrication system Memolub
Güdel Güdel H1 Lubrication system FlexxPump
Motorex Grease 218 M
Mobil Mobilith SCH 1000 Special
OtherManufac-turer
Specifications: KPF2K-20
in acc. with DIN 51502 MoS2 content minimum 3%
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Grease type forbearings of the
rollers
For the rollers, you must use a high quality lithium soap greaseDIN 51825-KP2N-20.For rollers the following grease is used from the factory:
The following grease types can be used alternatively:
INA Arcanol LOAD150
Shell Gadus S4V150KP2
ExxonMobil Beacon EP2
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7.3 Maintenance schedule
Fig. 7-2 Maintenance schedule
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500 h
150 h
150 h
500 h
2000 h
10000 h
10000 h
Grease Replace Oil change
Oil Cleaning Visual inspection
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7.4 Maintenance tasks
7.4.1 General prerequisites
Prior to performing repair and maintenance tasks, do the following:
• If vertical axles are present, secure them against falling
• Switch off the plant and padlock it to secure it against being switched on again
• Make sure that all spare parts and wear items are at hand(For information on spare parts and wear items, refer to chapter 11 ’Spare part supply’, 111)
7.4.2 Maintenance tasks 100 hours after commissioning
To ensure smooth operation, certain maintenance tasks have to be performed after commissioning.
Perform the following tasks 100h after commissioning the product:
• General inspection as per chapter ’General inspection’, 67
• Check the base fixing:• Check the tightening torques of the screws and nuts, retighten if re-
quired• Check the anchor connection, place new anchor if required
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7.4.3 Maintenance tasks every 150 hours
For more information on the lubricants, refer to chapter 7.2 ’Consumables and auxiliary agents’, 60.
Lubricating guideways, racks and pinions
Lubricate all guideways, racks and pinions every 150 hours.
Tab. 7-2 Number of shots with the grease gun
Lubricate the guideways, racks and pinions as follows:
1 Switch off the system and padlock it to secure it against being switched on again
2 Use a grease gun to manually inject full shots of lubricant at the lubricating point of all wiper and lubrication units and all lubricating pinions(Number of shots according to table above)
The guideways, racks and pinions are lubricated.
NOTEIncompatible lubricant!
Mixing different lubricants affects their properties.
Never mix different types of lubricant!Before using another type of lubricant, exchange the wiper and lubrication units and the lubricating pinions! Rinse the lines with fresh lubricant!
Product size Roller size Number of shots with the grease gun (1 shot = 1.5 cm3)
TMF-1 40 5-6
TMF-2 52 5-6
TMF-3 72 8-10
TMF-4 90 8-10
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7.4.4 Maintenance tasks every 500 hours
General inspection
During the general inspection, the entire product is subjected to an overall check.
Performing a generalinspection
Perform the general inspection as follows:
1 Switch off the plant and padlock it to secure it against being switched on again
2 Check the inspection points as described in the inspection table
3 Take measures as described in the inspection table
The general inspection has been performed.
Inspection tableInspection cri-terion
Specification / Description Measures
Dirt Check the components for dirt:• Wipers• Rollers• Guideways
Immediately clean away any dirt
Damage Check the plant for dam-age:• Paint damage• Bent attachments (e.g.
cover plates)• Cracks in the cast
parts• Cracks at welding
seams
Immediately remedy all dis-covered damage
Loose compo-nents
Check the seating of the components:• Screws• Nuts • Attachments
• Immediately tighten loose screws to the re-quired torque
• Align and fasten loose attachments
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Tab. 7-3 Inspection table
Loss of oil Check the plant and its surroundings for signs of the following:• Puddles of oil and oil
spills on the floor or in the drip sheets
• Leaks, torn or pinched lines
• Leakage at the gearbox
• Replace defective and pinched lines
• Repair or replace the gearbox
• Remove puddles of oil and oil spills on the floor or in the drip sheets
Components Check the condition of the components:• Carriage• Rollers• Guideways• Racks• Cog belt
Replace worn components
Backlash Check for correct amount of backlash in the components:• Pinions• Rollers
Correct the backlash
Tension Correct cog belts for cor-rect tension
Correct the tension
Energy chain and cable
Check the energy chain:• Mobility• Wear• Damage• Position of the cables
and lines• Condition of the cables
and lines• Tightening torques,
strain relief(e.g. 1Nm at IGUS Chainfix)
• Look for cause• Replace defective or
worn energy chains• Correct the position of
cables and lines• Replace worn or defec-
tive cables• Correct the tightening
torque
Inspection cri-terion
Specification / Description Measures
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7.4.5 Maintenance tasks every 2000 hours
Replacing the lubricating pinion
A pinion soaked in lubrication runs along next to the drive pinion. It ensures a continuous lubrication of the rack and the drive pinions.
Replace the lubricating pinion to ensure uniform lubrication.
This section describes the steps for replacing the lubricating pinion.
Fig. 7-3 Replacing the lubricating pinion
A Lubrication pointB Holder of the axle to the lubricating pinionC Axle to the lubricating pinionD Lubricating pinionE Gasket
Replace the lubricating pinion as follows:
1 Switch off the system and padlock it to secure it against being switched on again
2 If there is an automatic lubrication, disconnect the supply
3 Remove the entire lubricating pinion unit
4 Replace the lubricating pinion: For oil lubrication, submerge the new lubricating pinion in oil for several minutes(Oil quality, see chapter 7.2 ’Consumables and auxiliary agents’, 60)
5 If necessary, replace the gasket
6 To install the entire lubricating pinion unit, reverse the removal steps
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E D C
B
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7 Lubricate the lubricating pinion at the lubrication point
7.1 For manual lubrication:Lubricate the lubricating pinion according to the chapter "Lubricat-ing the rack and pinion"
7.2 For automatic lubrication:Connect supply line, start lubrication procedure(See separate operating manual on automatic lubrication)
The lubricating pinion has been replaced.
This section describes the steps for greasing the roller.
Fig. 7-4 Greasing the roller
A Grease nippleB Covering
Tab. 7-4 Roller relubrication quantity
D00
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A
B
Product size Roller size Relubrication
quantity [g]
TMF-1 40 1.1
TMF-2 52 2.4
TMF-3 72 7.3
TMF-4 90 7.3
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Grease the roller as follows:
1 Switch off the system and padlock it to secure it against being switched on again
2 Remove the covering
3 Use a grease gun to press in the grease(Relubrication quantity according to table above)
The roller has been greased.
7.4.6 Maintenance tasks every 10000 hours
Oil change in type NA / NH / FA / FH / AE gearboxes
Always replace the gearbox oil within the specified intervals.
For more information on the oil qualities, refer to chapter 7.2 ’Consumables and auxiliary agents’, 60.
Perform the oil change as follows:
Disassembling adrive with pinion
This section describes the steps for disassembling the drive.
WARNINGDanger of being crushed
After removing the transport securing device or the motor, the carriage may run off to the side. This can cause severe or fatal injuries!
Secure the carriage before removing the transport securing device or the motor!
NOTEDo not change the position of the coupling on the motor shaft!
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Fig. 7-5 Disassembling the drive
A Gearbox screwsB GearboxC Motor screwsD MotorE Eccentric ringF Headless set screw
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A B C D
F E
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Disassemble the drive as follows:
1 Switch off the system and padlock it to secure it against being switched on again
2 Secure carriage or axle with transport securing device or lifting device
3 Remove coverings if necessary
4 Remove lubricating pinion if necessary
5 Mark eccentric position
6 Remove the motor, together with the coupling
7 Remove headless set screw
8 Remove the gearbox
The drive has been disassembled.
Changing gearbox oil This section describes the steps for changing the gearbox oil.
CAUTIONOils/greases
Oils and greases are harmful to the environment!
The oils and greases may not get into the drinking water supply:• Take appropriate measures.• Observe the country-specific safety data sheets.• Oils and greases must be disposed of as hazardous waste, even if the to-
tal quantity is small.
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Fig. 7-6 Oil change
A Bleed screwB Filler screwC Drain screw
Change the gearbox oil as follows:
1 Position the gearbox: Drain screw at the bottomFiller and bleed screw at the top
2 Position a suitable container below the drain screw
3 Remove the bleed, filler and drain screw
4 Drain the oil
5 Rinse the gearbox with fresh oil(for oil types, see the Oils chapter)
6 Allow the gearbox to drain
7 Screw in the drain screw
8 Fill up the gearbox through the filler screw(for oil types and quantity, see the Oils chapter)
9 Screw in the bleed and filler screws
The gearbox oil has been changed.
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A B
C
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Assembling the drive This section describes the steps for assembling the drive.
Assemble the drive as follows:
1 To assemble the drive, reverse the disassembly steps in section ’Disas-sembling a drive with pinion’, 71
2 Set the tooth flank backlash according to chapter 8.3.5, 90
3 Calibrate the measurement reference plane of the motor (This procedure is described in the documentation of the complete plant or of the motor)
The drive has been assembled.
The oil change has been completed
NOTECalibrate the measurement reference plane after each drive as-sembly.This procedure is described in the documentation of the com-plete system or of the motor!
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8 Repairs
8.1 Introduction
This chapter describes all repair tasks.
Work sequences Perform the work sequences in the order described.
Original spare parts Use only original spare parts. For information on spare parts and wear items, refer to chapter 11 ’Spare part supply’, 111.
Tightening torques If no other specifications have been made, the tightening torques as per chapter 1.5.1 ’Tightening torques for screws’, 11 apply.
8.1.1 Safety
Only perform the tasks described in this chapter after you have read and under-stood chapter 3 ’Safety’, 20. It concerns your personal safety!
WARNINGAutomatic startup
When work is being performed on the product, there is danger of the ma-chine starting up automatically. This can cause severe or fatal injuries!
Before working in the danger area:• Secure vertical axles (if equipped) against falling• Switch off the main power supply and secure it against being switched on
again (main switch of complete plant)• Before switching on the plant again, make sure that no one is in the dan-
ger area.
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8.1.2 Personnel qualifications
Only appropriately trained and authorized personnel are allowed to work on the TMF product.
8.2 Special tools, testing and measuring instruments
For repairs, make sure that you have the following special tools, testing and measuring instruments at hand:
WARNINGFalling axles/workpieces
Falling axles or workpieces can cause severe or fatal injuries!
Observe the following:• Secure suspended axles using the stipulated equipment and deposit any
workpieces before working in the danger area• Never enter the area below suspended axles and workpieces• Check the belts of the telescope axes for signs of breakage and tears
WARNINGHeavy components
Components can be very heavy. Improper handling can cause severe or fatal injuries!
Use appropriate lifting units!
Tool Use Item number
Pin-type face spanner Setting the tooth flank backlash (TMF 1)
999 758
Dial gauge Setting the tooth flank backlash
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Tab. 8-1 Special tools, testing and measuring instruments
Micrometer Checking parallelism at the guideways
Inspecting the rack transition
Screw clamps Assembly of the racks
Mounting aid Assembly of rack mod-ule 2.5helical
902282
Assembly of rack mod-ule 3helical
902283
Assembly of rack mod-ule 4helical
902284
Fastening device Blocking the drive pin-ion AE030
0917452
Blocking the drive pin-ion AE045
0917453
Blocking the drive pin-ion AE060
0917454
Blocking the drive pin-ion AE090
0917447
Blocking the drive pin-ion AE120
0917455
Blocking the drive pin-ion AE180
0917456
Adjusting tool Adjusting the rollersSize 40/52
0919690
Adjusting the rollersSize 72/90
0915289
Tool Use Item number
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8.3 Repairs
8.3.1 General prerequisites
Prior to performing repair and maintenance tasks, do the following:
• If vertical axles are present, secure them against falling
• Switch off the plant and padlock it to secure it against being switched on again
• Make sure that all spare parts and wear items are at hand(For information on spare parts and wear items, refer to chapter 11 ’Spare part supply’, 111)
8.3.2 Replacing the bumper unit
The bumper unit is a safety component.Replace the entire bumper unit after a crash has occurred.
The buffer unit consists of the following components:
• Bumper
• Bumper block or bumper bracket
• Screws
• Sleeves and/or heavy-duty spring tension pins
WARNINGWeak safety component
After a crash, it is not immediately apparent whether bumper unit elements have been weakened or are defective. Another crash can cause severe or fatal injuries.
Always replace the entire bumper unit!
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8.3.3 Replacing the wiper and felt insert
Continuous lubrication of the guideways at operating temperatures under 0 °C or with grease requires a modification to the wiper and felt insert. This proce-dure is described in the sections:
• ’Preparing the wiper’, 81• ’Preparing the felt insert’, 82
This section describes the steps for replacing the wiper and the felt insert.
Fig. 8-1 Wiper and felt insert
A ScrewsB WiperC Felt insert
Replace the wiper and felt insert as follows:
1 Switch off the system and padlock it to secure it against being switched on again
2 If there is an automatic lubrication, disconnect the supply
3 Remove the screws
4 Replace the wiper
5 Replace the felt insert
6 Only for oil lubrication:Submerge new felt insert in oil for several minutes
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A B C
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(Oil quality, see chapter 7.2 ’Consumables and auxiliary agents’, 60)
7 To install the wiper and felt insert, reverse the removal steps
8 Only for manual lubrication: Lubricate guideways (See chapter ’Lubricating guideways, racks and pinions’, 66)
9 Only for automatic lubrication:(See separate operating manual on automatic lubrication)
9.1 Connect lubrication line
9.2 Start lubrication procedure(See separate operating manual on automatic lubrication)
The wiper and felt insert have been replaced.
Preparing the wiper This section describes the steps for preparing the wiper. This applies for oil lubrication, operating temperature under 0 °C or grease lubrication.
Fig. 8-2 Preparing the wiper
A WiperB Recess
Prepare the wiper as follows:
1 Attach recess(Mass according to figure)
The wiper has been prepared.
10...12
2.5.
..3
8...10D00
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A
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Preparing the feltinsert
This section describes the steps for preparing the felt insert. This applies for oil lubrication, operating temperature under 0 °C or grease lubrication.
Fig. 8-3 Preparing the felt insert
A ReductionB Slot
Prepare the felt insert as follows:
1 Shorten the felt insert to the 5 mm dimension
2 Increase dimension S by 1 mm(Only for oil lubrication, operating temperature below 0 °C)
The felt insert has been prepared.
5D
0010
35
S +
1
A
B
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8.3.4 Replacing the rollers and guideways
The rollers, guideways and racks are designed for continuous use. Certain ambi-ent conditions can increase the wear on these components.
Replacing the rollers, guideways and racks involves a considerable amount of work. Always replace these components simultaneously.
Roller holder instal-lation types
The roller holders have installation types for setting the roller backlash and tooth flank backlash.
Fig. 8-4 Roller holder installation types
A Installation type (E1): Eccentric zero position, fixed with positioning screwB Installation type (E2): Eccentric infinitely adjustable, fixed with flangeC Installation type (E3): Eccentric adjustable in increments, fixed with positioning screw
D00
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+
-
+
-
A B C
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Roller holderarrangement
The roller holders are to be arranged according to the following figure:
Fig. 8-5 Roller holder arrangement
A Roller holder E2 unloadedB Roller holder E1 loadedC Roller supportD E1 roller holderE Gearbox sideF Direction of loadG E2 roller holderH Fastening screws and flange
FullCover option:For this option the roller supports are installed rotated by 90°.Roller holder (A) corresponds thus to the installation type E1 loaded and Roller holder (B) to installation type E2.
Double roller support option:The double roller support has two loaded (B) and two unloaded (A) roller hold-ers.
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This chapter describes the steps for replacing the roller.
Fig. 8-6 Replacing the roller
A ScrewB PegC Supporting rollerD Roller holderE CoveringF Positioning screwG FlangeH Fastening screws
Replace the roller as follows:
1 Switch off the system and padlock it to secure it against being switched on again
2 Secure vertical axis, if equipped
3 Support the carriage or secure it to a lifting device
4 Remove fastening screws and flange
5 If there is a positioning screw, remove it
6 Remove the covering
7 Remove the entire roller holder
7.1 Remove screw and peg
7.2 Replace the roller
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7.3 To assemble the roller holder, reverse the disassembly steps(Secure screw with Loctite 242, tightening torque according to tab. 1-5, 14)
8 Install E1 roller holder:(Type and arrangement of installation, see chapter ’Roller holder instal-lation types’, 83)
8.1 Fix roller holder in eccentric zero position with positioning screw
8.2 Mount flange
8.3 Tighten fastening screws
9 Install E2 roller holder:
9.1 Turn roller holder to eccentric minimum setting
9.2 Mount flange
9.3 Move fastening screws slightly
10 If it is present, turn E3 roller holder to eccentric minimum setting
11 Remove the securing element, support or lifting device
12 Set roller and tooth flank backlash as per chapter 8.3.5, 90
The roller has been replaced.
Replacing guideways
Replace the guideways as soon as the surfaces show signs of wear.
The term "guideway" includes:
• Guideway• Rack
Replace the guideways as follows:
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Guidewaydisassembly
The designations refer to fig. 8-8, 88.
Remove the guideway as follows:
1 Switch off the system and padlock it to secure it against being switched on again
2 Attach the carriage or axle to a lifting device
3 Expose guideway:
3.1 Remove coverings if necessary
3.2 Move the carriage off the guideway or axle to be replaced if neces-sary
3.3 Extend the vertical axis, if required
4 Remove all screws(See fig. 8-8, 88)
5 Remove the guideways
The guideway has been removed.
Installing theguideway
Proper installation of the guideways in accordance with the regulations is pre-requisite for low-wear use of the product.
Mounting aid The start and end of the rack form a half tooth gap. For precise and low-noise transition, we recommend using a mounting aid geared in the opposite direction (see chapter 8.2 ’Special tools, testing and measuring instruments’, 77).
Fig. 8-7 Mounting aid for rack assembly
A RackB Mounting aid
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This section describes the steps for installing the guideway.
For axes over 20 meters, the assembly of the guideways must be performed from the middle.
Fig. 8-8 Installing the guideway
A Reference surfacesB ScrewsC Screw clampD Mounting aidE RackF Torque wrenchG ScrewsH Guideway
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Install the guideway as follows:
1 Clean the reference surfaces and guideways thoroughly and rub an oil stone across them
2 Lay first pair of guideways and racks on the reference surface. Lightly tighten with outermost screws (all holes must be aligned)
3 Mount next pair of guides and rack as in step 2
4 Clamp mounting aid to guides and racks with screw clamp
5 Install the rest of the screws and tighten with all the others
6 Inspect transition:
6.1 For guideways with gears, transition according to section ’Inspect-ing rack transition’, 48
6.2 For guideways without gears(gap dimension < 0.02 mm)
7 Use a suitable measuring instrument to check that the guideways are par-allel(tolerance: ±0.04 mm)
8 If deviations occur (transition/parallelism):
8.1 Remove screws and guideway
8.2 Repeat the procedure
The guideway has been installed.
Final tasks The following tasks must be performed after assembly of the guideway.
Perform these final tasks as follows:
1 Move the carriage onto the axle if necessary
2 Retract the vertical axis, if required
3 Remove the lifting device
4 If necessary, adjust the rollers
The final tasks have been performed.
The guideway has been replaced.
The guideways have been replaced.
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8.3.5 Setting rollers and tooth flank backlash
Reset the roller and tooth flank backlash after each roller, guideway or gearbox change.
Blocking the drivepinion
This section describes the steps for blocking the drive pinion. Block the drive pinion in order to check the tooth flank backlash.
Unblock the drive pinion after repair work has been finished. For this purpose, remove the fastening device and place the plug back onto the gearbox.
Fig. 8-9 Blocking the drive pinion
A MotorB CarriageC GearboxD Fastening deviceE Plug
NOTEAlways set the roller backlash and tooth flank backlash with load attached and at operating temperature!
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Block the drive pinion as follows:
1 Switch off the plant and padlock it to secure it against being switched on again
2 Remove the plug
3 Attach fastening device to gearbox
The drive pinion is blocked.
Setting rollers This section describes the steps for setting the roller
The designations refer to section "Roller holder arrangement".
Adjust the rollers as follows:
1 You may need to make the following preparations:
1.1 Slightly loosen the fastening screws of all E2 roller holders
1.2 Loosen flanges of the E2 roller holders
1.3 Remove coverings if necessary
2 Move the E2 roller holders closer by rotating them clockwise uniformly(For the tightening torque, refer to tab. 1-5, 14)
3 Fixate the position with the flange and the securing screws
4 If there are deviations:
4.1 Check zero position of E1 roller holder
4.2 Repeat process from step 2
5 Move the unloaded E2 roller holders closer by rotating them clockwise uniformly(For the tightening torque, refer to tab. 1-5, 14)
6 Fixate the position with the flange and the securing screws
7 Install coverings if necessary
The rollers have been set.
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Setting the toothflank backlash
This section describes the steps for setting the tooth flank backlash.
Inspect the tooth flank backlash according to the section "Checking the tooth flank backlash". Only adjust if a deviation is detected.
Fig. 8-10 Setting the tooth flank backlash
A GearboxB ScrewC Marking boreD Headless set screwE RackF Eccentric ringG Drive pinions
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Set the tooth flank backlash as follows:
1 Remove coverings if necessary
2 Remove lubricating pinion if necessary
3 Loosen headless set screw
4 Slightly loosen the gearbox screws
5 Turn eccentric ring with bolt remover or pin-type face wrench (Marking bore near the rack = minimum play; marking bore far away = maximum play)
6 Tighten the gearbox screws
7 Inspect tooth flank backlash according to section "Checking the tooth flank backlash"
8 If there are deviations:
8.1 Slightly loosen the gearbox screws
8.2 Backlash too large: Turn marking bore closer to the rack
8.3 Backlash too small: Turn marking bore away from the rack
8.4 Repeat process from step 6
The tooth flank backlash has been set.
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Checking the toothflank backlash
This section describes the inspection of the tooth flank backlash.
If the axis is not driven with Güdel gearbox type NA / NH / FA / FH / AE, then use the procedure described in the operating manual of the gearbox!
Fig. 8-11 Checking the tooth flank backlash
A CarriageB AxisC GuidewayD RackE GearboxF Drive pinionsG Dial gauge
NOTEThe inexact measurement method described here can lead to in-correct interpretation and subsequent damage of any kind!
Only use it when the exact method is not possible!
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The rack quality can be found in tab. 5-3, 48, the module from the rack of the spare parts list in the appendix.
Tab. 8-2 Tooth flank backlash
Check the tooth flank backlash as follows:
1 Measurement method 1 (exact measurement method):
1.1 Block the drive pinion according to the section "Blocking the drive pinion"
1.2 Mount the dial gauge to the guideway
1.3 Mount dial gauge in the direction of travel aligned with the center of the drive pinion
1.4 Zero the dial gauge
1.5 Move the carriage or axle in the direction of travel
1.6 Read the tooth flank backlash on the dial gauge
Tooth flank backlash [mm]
Rack quality Modulem ≤ 3
Module3 < m ≤ 8
Module8 < m ≤ 12
Q4 h21 0.010 0.012 0.016
Q5 h22 0.016 0.019 0.025
Q6 h23 0.025 0.03 0.04
Q7 h25 0.059 0.079 0.099
Q8 h27 0.158 0.198 0.247
Q9 h27 0.158 0.198 0.247
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2 Measurement method 2 (inexact measurement method only when necessary due to weight rea-sons):
2.1 Insert paper strip from DIN A4 80 g/cm3 with width b between drive pinion and rack
2.2 Move carriage or axis with auxiliary agents(Paper strip is "turned through")
2.3 Paper strip worn:Tooth flank backlash <0.05 mm
2.4 Paper strip cut, partially disconnected pieces: Tooth flank backlash ~ 0.05 mm
2.5 Paper strips mildly cut, no disconnected pieces: Tooth flank back-lash ~ 0.07 mm
2.6 Paper strip wavy:Tooth flank backlash ~ 0.1 mm
2.7 Paper strip undamaged:Tooth flank backlash >0.1 mm
3 Interpret tooth flank backlash according to previous table
The tooth flank backlash has been checked.
8.3.6 Replacing the gearbox
This section describes the steps for replacing the gearbox.
Disassemble the drive to replace the gearbox.
Disassembling adrive with pinion
This section describes the steps for disassembling the drive.
WARNINGDanger of being crushed
After removing the transport securing device or the motor, the carriage may run off to the side. This can cause severe or fatal injuries!
Secure the carriage before removing the transport securing device or the motor!
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Fig. 8-12 Disassembling the drive
A Gearbox screwsB GearboxC Motor screwsD MotorE Eccentric ringF Headless set screw
NOTEDo not change the position of the coupling on the motor shaft!
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Disassemble the drive as follows:
1 Switch off the system and padlock it to secure it against being switched on again
2 Secure carriage or axle with transport securing device or lifting device
3 Remove coverings if necessary
4 Remove lubricating pinion if necessary
5 Mark eccentric position
6 Remove the motor, together with the coupling
7 Remove headless set screw
8 Remove the gearbox
The drive has been disassembled.
Replacing thegearbox
This section describes the steps for replacing and installing the new gearbox.
Replace and install the gearbox as follows:
1 Replace the gearbox
2 To assemble the drive, reverse the disassembly steps
3 Set the tooth flank backlash according to chapter 8.3.5, 90
4 Calibrate the measurement reference plane of the motor(This procedure is described in the documentation of the complete plant or of the motor)
The gearbox has been replaced and installed.
NOTECalibrate the measurement reference plane after each drive as-sembly.This procedure is described in the documentation of the com-plete system or of the motor!
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8.3.7 Setting the gear backlash
Ex works, the gear backlash is set to a value lower than 6‘. If the backlash increases, it has to be readjusted.
Fig. 8-13 Setting the gear backlash
A Worm shaftB ScrewsC Casing cover
NOTE• Do not remove the casing cover, else the gearbox oil will leak
out!• Always align both casing covers in the identical position!
2
3
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Set the gear backlash as follows:
1 Switch off the plant and padlock it to secure it against being switched on again
2 Disassemble the drive according to section ’Disassembling a drive with pinion’, 96
3 Remove all screws on both sides
4 Rotate both covers to the next higher, cast-in number
5 Tighten two screws on each of the two sides
6 Check the gear backlash:Rotate the worm shaft 360° by hand
6.1 The shaft does not resist rotation:Repeat from step 3
6.2 The shaft resists rotation:Remove the screws, set both gearbox covers one level lower
7 Insert all screws on both sides and tighten crosswise
8 Check the gear backlash:Rotate the worm shaft 360° by hand
8.1 The shaft resists rotation:Repeat from step 3
The gear backlash has been set.
8.3.8 Replacing motor and coupling
This chapter describes the steps for replacing the motor and the coupling.
Replace the motor and coupling as follows (for descriptions, see fig. 8-14, 102):
NOTECalibrate the measurement reference plane after each drive as-sembly.This procedure is described in the documentation of the com-plete system or of the motor!
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Disassemblingmotor and coupling
This section describes the steps for removing the coupling and the motor.
Remove the motor and the coupling as follows:
1 Switch off the system and padlock it to secure it against being switched on again
2 Loosen the motor screws
3 Pull the motor, together with the coupling, off the gearbox
4 Loosen the coupling screws
5 Pull the coupling off the motor shaft
The motor and the coupling have been removed
Assembling theMotor and coupling
This section describes the steps for assembly of the coupling and the motor.
Depending on the type of transport securing device used, you have to remove the device before installing the motor for the first time (see Section ’Transport securing device at the gearbox’, 55).
WARNINGFalling axes / workpieces
Incorrect tightening torques can lead to falling axes or workpieces. This can cause severe or fatal injuries!
Observe the following:• Calibrate and check the torque wrench periodically• Tighten all screws with a torque wrench to the specified tightening tor-
ques
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Fig. 8-14 Installing the motor and coupling
A GearboxB Motor flangeC Measuring instrumentD CouplingE Coupling screwsF Motor screwsG Motor
Install the motor and the coupling as follows:
1 Clean the coupling and motor shaft to ensure that they are free of grease
2 Measure distance X
3 Push the coupling onto the motor shaft(Dimension Y has to match dimension X, tolerance -0.2 to -0.4 mm)
4 Tighten the coupling screws For the tightening torque, refer to tab. 1-2, 11
5 Grease the gear rim of the coupling(For grease types, see 7.2.2 ’Lubricants’, 60)
6 Push the motor, with the mounted coupling, onto the gearbox
7 Tighten the motor screws
The motor and the coupling have been installed.
The motor and the coupling have been replaced.
X
Y
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8.4 Other documents
For information on the available options, read the appropriate documents in the appendix.
8.5 Service departments
If you have questions, please contact the service departments. For a list with their contact information, see chapter 11.2 ’Service departments’, 112.
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9 Decommissioning, storage
9.1 Introduction
9.1.1 Safety
Only perform the tasks described in this chapter after you have read and under-stood chapter 3 ’Safety’, 20. It concerns your personal safety!
9.1.2 Personnel qualifications
Only appropriately trained and authorized personnel are allowed to work on the TMF product.
9.2 Storage conditions
CAUTIONLeaking fluids
During storage, substances that are hazardous to the environment could leak!
Hazardous substances may not get into the drinking water supply:• Take appropriate measures.• Observe the country-specific safety data sheets.• Fluids must be disposed of as hazardous waste, even if the total quantity
is small.
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Room Store the product in a dry location. For information on the required space and the floor capacity, refer to the machine layout or general layout.
Use a covering to protect the product against dust and dirt.
Temperature The ambient storage temperature must remain between -10 and +40°C. Make sure that the product is not subjected to large temperature fluctuations.
Air humidity The air humidity must be below 75%.
9.3 Decommissioning
9.3.1 Shutdown
This chapter provides information on shutting down the product.
WARNINGFalling axles/workpieces
Falling axles or workpieces can cause severe or fatal injuries!
Observe the following:• Secure suspended axles using the stipulated equipment and deposit any
workpieces before working in the danger area• Never enter the area below suspended axles and workpieces• Check the belts of the telescope axes for signs of breakage and tears
NOTEDo not empty the lubrication lines and the gearbox when shut-ting down the product!
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To shut down the product, proceed as follows:
1 Fixate the axles
2 Shut down the plant(main switch of complete system)
3 Disconnect the supply lines for energy and consumables
4 Automatic lubrication system (optional): Unscrew the lubricator and remove the batteries
The product has been decommissioned.
9.3.2 Cleaning / rust-proofing
Prior to performing rust-proofing, clean away any dirt and dust from the prod-uct. Clean the product thoroughly.
Apply corrosion protection to all parts.
9.3.3 Transport securing device
On unbraked motors, mount the transport securing devices.
9.3.4 Labeling
Label the product with the following data:
• Date of decommissioning
• Internal machine number/name
• Further data as per internal guidelines
NOTEDispose of any cloths soaked in oils and/or greases in an environ-mentally friendly manner! For more information on disposal, re-fer to chapter 10 ’Disposal’, 108.
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9.4 Recommissioning
For recommissioning, follow the steps described for commissioning.
Prior to recommissioning, perform the general inspection as set out in chapter 7.4 ’Maintenance tasks’, 65. Perform the required maintenance tasks and repairs.
If the machine has been standing still for more than one year, perform the fol-lowing tasks:
• Change the gearbox oil
• Rinse the lubrication lines with fresh lubricant
• Replace the felt inserts and lubricating pinions
• Check the gaskets and replace if necessary
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10 Disposal
10.1 Introduction
Observe the following during disposal:
• Adhere to the country-specific regulations• Separate the material groups• Dispose of the materials in an environmentally friendly way• Recycle waste if possible
10.1.1 Safety
Only perform the tasks described in this chapter after you have read and under-stood chapter 3 ’Safety’, 20. It concerns your personal safety!
10.1.2 Personnel qualifications
Only appropriately trained and authorized personnel are allowed to work on the TMF product.
10.2 Disposal
Your product consists of the following units:
• Packaging • Contaminated materials /auxiliary agents (oil paper)• Wood• Plastic (film)
• Consumables• Lubricants (oils/greases)• Batteries
• Base unit• Metals (steel/aluminum)• Plastics (thermoplasts/duroplasts)• Contaminated materials/auxiliary agents (felt/cleaning cloths)• Electrical material (cables)
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10.3 Waste management compliant assemblies
10.3.1 Disassembly
This chapter describes how to disassemble the product.
Prior to disassembly, shut down product as described in chapter 9.3.1 ’Shut-down’, 105.
Disassemble the product as follows:
1 Remove connecting elements(cables / energy chains)
2 Dismount mobile axes
3 Remove the gearbox and drain the oil
4 Dismount the carriage
WARNINGSuspended loads
Improper handling of suspended loads can lead to severe injuries or death!
Observe the following:• Use appropriate lifting units• Wear appropriate protective clothing• Always keep sufficient distance to suspended loads• Never enter the area below a suspended load
CAUTIONOils/greases
Oils and greases are harmful to the environment!
The oils and greases may not get into the drinking water supply:• Take appropriate measures.• Observe the country-specific safety data sheets.• Oils and greases must be disposed of as hazardous waste, even if the to-
tal quantity is small.
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5 Dismount fixed assemblies(axes/columns)
6 Take the assemblies apart and separate the different materials.
The product has been disassembled.
10.3.2 Material groups
Dispose of the material groups in accordance with the following table.
Tab. 10-1 Disposal: material groups
10.4 Disposal facilities, authorities
The disposal facilities and authorities differ from country to country. Observe the local laws and regulations on disposal.
Material Disposal route
Contaminated mate-rials/auxiliary agents
Hazardous waste
Wood Municipal waste
Plastic Collecting point or municipal waste
Lubricants Collecting pointDisposal in accordance with the safety data sheets 3.4.4 ’Safety data sheets (MSDS)’, 28
Batteries Battery collection
Metals Scrap metal collection
Electrical material Electrical rubbish
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11 Spare part supply
11.1 Explanations regarding the spare parts list
The spare parts list can be found in chapter 13 ’Appendix’, 117. It contains position drawings and the complete parts list of your product.
11.1.1 Positioning drawings
The positions of the spare parts can be seen on the drawings. These are stand-ard drawings. Individual positions or images might differ from your product.
11.1.2 Parts list
The parts list contains all parts of your product. The spare parts and wear items are indicated as described in the explanation of symbols.
Explanation ofsymbols
Fig. 11-1 Explanation of symbols
A Spare part statusB Availability
14.07.2008 / Page 1 of 1
BCH034580 VS0035 2-Amod ZP-4 M MO mec 3.10 10947-001A
WEtinUytitnauQgniwarDtxeTrebmun metInoitisoP
300 V000134 Y ktS1230-32580029=L V 52-022/022PL sixA-
EktS770.002.71.093SUGI 0.002.71.093 niahc ygrenE4001410203 A
400 0916667 Y ktS2030-32584-PZ egairraC-900 406015-10.00 Worm gear unit AE060/L left
Ratio i=10.00
AE060 2 Stk E B
910 406089 Motor flange 060 18x116x116 ø130/110 8030-018a 2 Stk E C
1000 0910499 Mechanical multi limit switch accessories 750 Y 8523-024 2 Stk
1100 230803 Felt pinion for lubrication
ø40.6x20, Modul m=2.387 pitch P=7.5, Z=15
8102-039d 1 Stk V A
Güdel AGInsustrie Nord
CH-4900 Langnethalphone +41 62 916 91 91fax +41 62 916 91 [email protected]
D00
0094
A
B
Spare part status (column E): EV
==
Spare partWear item
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Spare part supply
The information on availability is given without warranty. The delivery times might in some cases differ.
11.2 Service departments
If you have questions on service, please use the service form at www.gudel.com or contact the offices in the appropriate country:
For urgent service requests, our Helpdesk provides after-hour assistance (24-hour support):
Please have the following information, as labeled on the type plate, at hand:
• Serial no.• Part list no. • Drawing number (if applicable)
Availability (column W): ABC
===
Available from stockDelivery time approx. 2 - 3 weeksDelivery time upon request
Germany: +49 6291 6446 41
Great Britain: +44 24 7669 5444
India: +91 20 5622 7165
Italy: +39 02 9217021
South Korea: +82 2168 98 00
Taiwan: +88 635 97 8808
USA: +1 734 214 0000
All other countries and Switzerland:+41 62 916 91 91
Europe/Asia: +41 62 916 9170
USA: +1 248 456 0440
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Index
12 Index
AAppendix . . . . . . . . . . . . . . . . . . . . . . . 117Arrangement
Roller holder . . . . . . . . . . . . . . . . . . 84Assembly . . . . . . . . . . . . . . . . . . . . .36, 45
Coupling . . . . . . . . . . . . . . . . . .49, 101Drive . . . . . . . . . . . . . . . . . . . . . . . . . 75Guideway . . . . . . . . . . . . . . . . . .45, 87Motor . . . . . . . . . . . . . . . . . . . . . . . . 49Robot . . . . . . . . . . . . . . . . . . . . . . . . 52
Assembly instructions for partly completed machinery . . . . . . . . . . . 9
AttachingOptional components . . . . . . . . . . 51Slings . . . . . . . . . . . . . . . . . . . . . . . . . 38
Authorities . . . . . . . . . . . . . . . . . . . . . 110Auxiliary agents . . . . . . . . . . . . . . . . . . 60Axis names . . . . . . . . . . . . . . . . . . . . . . 33
BBase fixing . . . . . . . . . . . . . . . . . . . . . . . 41
Adhesive anchor . . . . . . . . . . . . . . . 42Welded joint . . . . . . . . . . . . . . . . . . 43
BlockingDrive pinion . . . . . . . . . . . . . . . . . . . 90
Bumper unitReplacing . . . . . . . . . . . . . . . . . . . . . 79
CCables and lines . . . . . . . . . . . . . . . . . . 53Change
Gearbox oil . . . . . . . . . . . . . . . . . . . 73Changes . . . . . . . . . . . . . . . . . . . . . . . . . 21Checking
Delivery . . . . . . . . . . . . . . . . . . . . . . 36Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 106Cleaning agents . . . . . . . . . . . . . . . . . . . 60Commissioning . . . . . . . . . . . . . . . . . . . 34Connecting
Profiles . . . . . . . . . . . . . . . . . . . . . . . 40
Consumables . . . . . . . . . . . . . . . . . . . . 60Coupling
Assembling . . . . . . . . . . . . . . . . . . 101Assembly . . . . . . . . . . . . . . . . . . . . . 49Disassembly . . . . . . . . . . . . . . . . . 101Replacing . . . . . . . . . . . . . . . . . . . . 100
DDeclaration of incorporation . . . . . . 22Decommissioning . . . . . . . . . . . 104, 105Delivery
Checking . . . . . . . . . . . . . . . . . . . . . 36Design . . . . . . . . . . . . . . . . . . . . . . . . . . 29Disassembly . . . . . . . . . . . . . . . . . . . . 109
Coupling . . . . . . . . . . . . . . . . . . . . 101Drive with pinion . . . . . . . . . . . 71, 96Guideway . . . . . . . . . . . . . . . . . . . . 87Motor . . . . . . . . . . . . . . . . . . . . . . 101
Disposal . . . . . . . . . . . . . . . . . . . . . . . . 108Disposal facilities . . . . . . . . . . . . . . . . 110Drive
Assembly . . . . . . . . . . . . . . . . . . . . . 75Disassembly with pinion . . . . . 71, 96
Drive pinionBlocking . . . . . . . . . . . . . . . . . . . . . . 90
EExplanation
Abbreviation . . . . . . . . . . . . . . . . . . 10Symbols . . . . . . . . . . . . . . . . . . . . . . 10
Explanation of abbreviations . . . . . . . 10Explanation of symbols . . . . . . . . . . . . 10
FFastening . . . . . . . . . . . . . . . . . . . . . . . . 37Felt insert
Preparing . . . . . . . . . . . . . . . . . . . . . 82Final tasks . . . . . . . . . . . . . . . . . . . . . . . 89Function . . . . . . . . . . . . . . . . . . . . . . . . 29
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Functional check . . . . . . . . . . . . . . . . . . 56Functional description . . . . . . . . . . . . . 33Fundamentals of safety . . . . . . . . . . . . 27
GGearbox
Oil change . . . . . . . . . . . . . . . . . . . . 73Replacing . . . . . . . . . . . . . . . . . .96, 98Setting the backlash . . . . . . . . . . . . 99
General inspection . . . . . . . . . . . . . . . . 67General rules for occupational safety .
21Greases . . . . . . . . . . . . . . . . . . . . . . . . . 62Guideway
Assembly . . . . . . . . . . . . . . . . . .45, 87Disassembly . . . . . . . . . . . . . . . . . . . 87Lubricating . . . . . . . . . . . . . . . . . . . . 66Replacing . . . . . . . . . . . . . . . . . . . . . 86
HHazard symbols
Operating manual . . . . . . . . . . . . . . 23Product . . . . . . . . . . . . . . . . . . . . . . 26
Hazard warningCaution . . . . . . . . . . . . . . . . . . . . . . 23Danger . . . . . . . . . . . . . . . . . . . . . . . 23Note . . . . . . . . . . . . . . . . . . . . . . . . . 23Warning . . . . . . . . . . . . . . . . . . . . . . 23
IIdentification
Lubrication points . . . . . . . . . . . . . 60Improper handling of cables . . . . . . . . 53Inspecting
Rack transition . . . . . . . . . . . . . . . . 48Installation instructions . . . . . . . . . . . . 21
LLabeling . . . . . . . . . . . . . . . . . . . . . . . . 106Liability . . . . . . . . . . . . . . . . . . . . . . . . . . 21Load
Attaching . . . . . . . . . . . . . . . . . . . . . 51
Lubricants . . . . . . . . . . . . . . . . . . . . . . . 60Lubricating
Guideways . . . . . . . . . . . . . . . . . . . . 66Pinions . . . . . . . . . . . . . . . . . . . . . . . 66Racks . . . . . . . . . . . . . . . . . . . . . . . . 66
Lubricating pinionReplacing . . . . . . . . . . . . . . . . . . . . . 69
MMaintenance . . . . . . . . . . . . . . . . . . 58, 76
10000 hours . . . . . . . . . . . . . . . . . . 71150 hours . . . . . . . . . . . . . . . . . . . . 662000 hours . . . . . . . . . . . . . . . . . . . 69500 hours . . . . . . . . . . . . . . . . . . . . 67Schedule . . . . . . . . . . . . . . . . . . . . . 64Tasks . . . . . . . . . . . . . . . . . . . . . . . . 65
Maintenance schedule . . . . . . . . . . . . 64Maintenance tasks 100 hours after
commissioning . . . . . . . . . . . . . . . . 65Material groups . . . . . . . . . . . . . . . . . 110Measuring instruments . . . . . . . . . . . . 77Monitoring equipment . . . . . . . . . . . . 27Motor
Assembling . . . . . . . . . . . . . . . . . . 101Assembly . . . . . . . . . . . . . . . . . . . . . 49Disassembly . . . . . . . . . . . . . . . . . 101Replacing . . . . . . . . . . . . . . . . . . . . 100
Mounting aid . . . . . . . . . . . . . . . . . . 45, 87
OOil change
Gearbox . . . . . . . . . . . . . . . . . . . . . 71Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Operating personnel . . . . . . . . . . . . . . 20Operation . . . . . . . . . . . . . . . . . . . . . . . 57Optional components
Attaching . . . . . . . . . . . . . . . . . . . . . 51Options . . . . . . . . . . . . . . . . . . . . . . . . . 19Other documents . . . . . . . . . . . . . . . 103
PPackaging symbols . . . . . . . . . . . . . . . . 35Parts list . . . . . . . . . . . . . . . . . . . . . . . 111
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Personnel qualification .34, 59, 77, 104, 108
PinionLubricating . . . . . . . . . . . . . . . . . . . . 66
Position drawings . . . . . . . . . . . . . . . . 111Preparing
Felt insert . . . . . . . . . . . . . . . . . . . . . 82Wiper . . . . . . . . . . . . . . . . . . . . . . . . 81
Prerequisites . . . . . . . . . . . . . . . . . . . . . 36Base . . . . . . . . . . . . . . . . . . . . . . . . . . 36Lifting unit . . . . . . . . . . . . . . . . . . . . 36Lines . . . . . . . . . . . . . . . . . . . . . . . . . 36Maintenance, repair . . . . . . . . .65, 79Positioning . . . . . . . . . . . . . . . . . . . . 36
ProductDescription . . . . . . . . . . . . . . . . . . . 17Designation . . . . . . . . . . . . . . . . . . . 18Integrating . . . . . . . . . . . . . . . . . . . . 52Positioning . . . . . . . . . . . . . . . . . . . . 39Safety . . . . . . . . . . . . . . . . . . . . . . . . 20
Product-specific hazards . . . . . . . . . . . 27Profiles
Connecting . . . . . . . . . . . . . . . . . . . 40Protective measures . . . . . . . . . . . . . . 21Purpose of the document . . . . . . . . . . . 9
RRack
Inspecting transition . . . . . . . . . . . . 48Lubricating . . . . . . . . . . . . . . . . . . . . 66
Recommissioning . . . . . . . . . . . . . . . . 107Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . 79Replacing
Bumper unit . . . . . . . . . . . . . . . . . . . 79Coupling . . . . . . . . . . . . . . . . . . . . . 100Gearbox . . . . . . . . . . . . . . . . . . .96, 98Guideway . . . . . . . . . . . . . . . . . . . . . 83Guideways . . . . . . . . . . . . . . . . . . . . 86Lubricating pinion . . . . . . . . . . . . . . 69Motor . . . . . . . . . . . . . . . . . . . . . . . 100Roller . . . . . . . . . . . . . . . . . . . . . . . . 83
Residual danger . . . . . . . . . . . . . . . . . . 20Robot
Mounting . . . . . . . . . . . . . . . . . . . . . 52Roller backlash
Setting . . . . . . . . . . . . . . . . . . . . . . . . 90Roller holder
Arrangement . . . . . . . . . . . . . . . . . . 84
Installation types . . . . . . . . . . . . . . 83Roller holder installation types . . . . . 83Rust-proofing . . . . . . . . . . . . . . . . . . . 106
SSafety . . . . . . . . . 20, 34, 59, 76, 104, 108Safety data sheets . . . . . . . . . . . . . . . . 28Safety equipment . . . . . . . . . . . . . . . . . 27safety regulations
disregarding . . . . . . . . . . . . . . . . . . . 21Screw locked . . . . . . . . . . . . . . . . . . . . 11Service departments . . . . . . . . . . . . . 112Setting
Gear backlash . . . . . . . . . . . . . . . . . 99Roller backlash . . . . . . . . . . . . . 90, 91Tooth flank backlash . . . . . . . . 90, 92
Setting the roller backlash . . . . . . . . . 91Setting the tooth flank backlash . . . . 92Setup . . . . . . . . . . . . . . . . . . . . . . . . 36, 37Shutdown . . . . . . . . . . . . . . . . . . . . . . 105Slings
Attaching . . . . . . . . . . . . . . . . . . . . . 38Spare part supply . . . . . . . . . . . . . . . . 111Spare parts list . . . . . . . . . . . . . . . . . . 111
Explanation of symbols . . . . . . . . 111Explanations . . . . . . . . . . . . . . . . . 111
Special symbols . . . . . . . . . . . . . . . . . . 25Special tools . . . . . . . . . . . . . . . . . . . . . 77Storage . . . . . . . . . . . . . . . . . . . . . . . . 104Storage conditions . . . . . . . . . . . . . . 104
TTarget readership . . . . . . . . . . . . . . . . 10Technical data . . . . . . . . . . . . . . . . . . . 19Temperature ranges . . . . . . . . . . . . . . 19Testing instruments . . . . . . . . . . . . . . 77Thread rolling screws . . . . . . . . . . . . . 16Tightening torques
HV sets . . . . . . . . . . . . . . . . . . . . . . 13Roller holders . . . . . . . . . . . . . . . . . 14Roller support . . . . . . . . . . . . . . . . 15Screws . . . . . . . . . . . . . . . . . . . . . . . 11
Tooth flank backlashInspecting . . . . . . . . . . . . . . . . . . . . 94Setting . . . . . . . . . . . . . . . . . . . . . . . 90
Torque tables . . . . . . . . . . . . . . . . . . . . 11
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Training of operating personnel . . . . 57Transport . . . . . . . . . . . . . . . . . . . . . . . 35Transport securing devices . . . .55, 106Type plate . . . . . . . . . . . . . . . . . . . . . . . 18
UUnpacking . . . . . . . . . . . . . . . . . . . . . . . 36Use
Improper . . . . . . . . . . . . . . . . . . . . . 17Intended . . . . . . . . . . . . . . . . . . . . . . 17Purpose . . . . . . . . . . . . . . . . . . . . . . 17
WWarning symbols . . . . . . . . . . . . . . . . . 25Waste management compliant assemblies 109Wiper
Preparing . . . . . . . . . . . . . . . . . . . . . 81
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Appendix
13 Appendix
The appendix of this operating manual contains the following documents:
• Hazard analysis / Risk analysis
• Layout
• Options
• Third-party products
• Spare parts list
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Hazard analysis / Risk analysis
Hazard analysis / Risk analysis
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Ligh
t
Med
ium
Sev
ere
Rar
e
Ofte
n
Fre
quen
t
A B C D E F G H I J K L M 1 4 10 1 2 3 The following should be prevented:
1.1 x x x x x x x x x x x x x x
Processing of hazardous materials.Fire and danger of explosionThermal factors
All Noncompliance with the intended use Persons are injured or killed x x 10 3/d Intended use of the product.
A Güdel device is only used to bring objects to a specific position, hold them there or to move simultaneously with other machine movements.No hazardous (e.g. poisonous or explosive) objects may be moved. A Güdel device may not be operated in a potentially explosive area. The ambient temperature during operation must be between 12° and 40 °C.
If the intended use is modified, hazards can results that are not covered by the safety concept.
x J
1.2 x x x x x x x x Suspended loads
TechniciansCommissio
ning technicians
Improper use of lifting equipmentPerson is surprised by unexpected movement and injured or killed as a result.
x x 10 3/d No persons may be injured by falling parts.Use appropriate lifting equipment. Wear protective
clothing. Keep a safe distance.Do not walk under suspended loads. x J
1.3 x
Movement of the axes.Suspended loads(Z-axis and workpieces)
OperatorMaintenance
personnel
Gripper problemsDefective motor brakeGeneral problems in the drive train
Person is surprised by vertical movement and injured as a result. x x 20 3/d
The areas of movement must be secured so that neither operating personnel nor third parties can reach or walk into the hazardous locations where automatic movements are performed.
The areas of movement must be enclosed by light grids,
light curtains as well as mechanical safety fences so that
it is impossible to enter this area from any direction.
There must be door elements or light curtains that allow
entry into the danger area or to a portion of the danger
area.
The height of the safety fences is described in EN ISO
13857.
Safety shutdown situation:
The vacuum system remains active in a de-energized
state.
Door elements: when opening the danger area, a safety
shutdown is performed for at least the drives that pose a
hazard in this area.
The door elements are also locked electromechanically.
Light barriers: these are to be monitored so that when
contact is broken, at least the drives that pose a hazard
in this area are shutdown. The distance between the
source of the danger and the light barriers is described
in EN 999 Art. 6.
In normal operation, all protective hoods must be closed, removable protective hoods must be screwed securely.Required behavior:Inspect the protective hoods before starting normal operation. Safety shutdown situation: do not walk under suspended workpieces and Z-axes.
x J
1.4 xManual workstations
Operator Automatic movements at the manual workstationPerson is surprised by the automation, body parts are crushed and injuries result.
x x 20 3/d
It must be ensured that neither operating personnel nor third parties are injured during manual insertion and ejection of the workpieces.
Insertion or ejection axes may only be moved in jog
mode or with two-hand operation. The drive
configuration is such that at the maximum speed of the
drive motor only a slow axis speed is achieved. The
operating elements for insertion and ejection must be
configured so that the operator has a clear view onto
the movement and cannot be endangered. Areas where
body parts could be crushed are to be prevented with
design measures to the greatest possible extent.
Extra attention is required of the operator at manual workstations.Only perform movements if no other person is in the danger area and none of your own body parts are in the line of danger of the corresponding axis
x J
1.5 x Parts that are flung outOperator
Third parties
Parts clamped improperlyBreakage of rotating tools
Person is surprised by parts flying away and injured as a result x x 10 3/dIt must be ensured that neither operating personnel nor third parties are injured by parts that become loose and fly off.
Mechanical guards must be placed in the possible flight
path of parts that could fly off.
Safety devices are inspected using calculations and
trials.
In normal operation, all protective hoods must be closed, removable protective hoods must be screwed securely.Required behavior: Inspect the protective hoods before starting normal operation.
x J
1.6 x x x x x x x Electrical hazard
OperatorMaintenance
personnel
Technicians
Touching the machineDefective insulationImproper el. installationUnsuitable components
Person suffers an electric shock and is injured or killed as a result. x x 10 3/dIt must be ensured that neither operating personnel nor third parties are injured by direct or indirect electrical contact.
Only contact-protected components are to be used.Before working on electrical installations, always disconnect the system (plug/main switch) and double check.Work on electrical installations, switch cabinets and devices may only be performed by authorized specialists.Control cabinet fuses
Work on electrical installations requires expertise and extra care.
x J
1.7 x Disruption of the energy supply
OperatorMaintenance
personnel Power failure, lightning Person is surprised by unexpected movement and injured as a result. x x 10 3/dThe effects of a power failure must not be dangerous for the operator or for third parties.
The movement of the drives is mechanically limited in case the supply voltage fails (mechanical stops and holding brakes).The movement of the drives is braked if the supply
voltage fails
The operator and third parties are outside the danger
area.
After a crash, defective elements of the mechanical stops cannot necessarily be recognized immediately. The entire bumper unit must always be replaced.
x J
1.8 x Malfunction of the control system
OperatorMaintenance
personnel Failure of control unit components Person is surprised by unexpected movement and injured as a result. x x 10 3/dThe effects of a control system malfunction must not be dangerous for the operator or for third parties.
The areas of movement are to be encompassed by
mechanical safety fences and light curtains and light
grids so that it is not possible to enter this area from any
side.
Movements must transition to static states as quickly as
possible.
In normal operation, all protective hoods must be closed, removable protective hoods must be screwed securely.Required behavior: Inspect the protective hoods before starting normal operation.
x J
Hazard analysis / risk assessment
Safety goal
(negation of the event)
Pro
babi
lity
of
occu
rren
ce
Ris
k as
sess
men
t (<
=3;
4-8
; 9-2
0; >
20)
Inte
rnal
ass
embl
ySpecial operating modes
Nor
mal
ope
ratio
n
Haz
ard
no.
Inte
rnal
com
mis
sion
ing
Inte
rnal
dis
asse
mbl
y
Com
mis
sion
ing
at th
e cu
stom
er
Tra
inin
g at
the
cust
omer
Tra
nspo
rt
Ass
embl
y at
the
cust
omer
Source of danger
Ext
ent o
f the
da
mag
e
Cat
egor
y / P
Lr (
SIL
) m
inim
al
Risk assessment/safety goals/protective measures/residual risks1)
Solution suggested to the customer (cursive, Times New Roman)
Güdel solution (Arial)
Saf
ety
requ
irem
ent f
ulfil
led
[Y/N
]
Residual risks
Ope
ratin
g m
anua
l
Protective measures
(existing protective measures)
Affe
cted
per
son(
s)C
orre
spon
ding
ope
ratin
g m
ode
Triggering factor
Event
(Worst case)(Without protective measures)
Set
up/c
hang
eove
r
Cle
anin
g
Tro
uble
shoo
ting
and
repa
ir
Mai
nten
ance
Dis
asse
mbl
y
Dis
posa
l
Customer:
Machine type: all modules without control system
Project no.:
Document no.:
Copyright © 2009 by GÜDEL AG Process owner: M. Knuchel Version 30 / Risikobeurteilung_en.xls Page1 / 3
![Page 120: BA TMF 1-4 - Сервотехника Нева20TMF$201-4$20english.pdf · TMF Size 1-4 Project: ... For cross-reference Page ... moly grease Slightly oiled M12 100 120 M16 250 350](https://reader030.vdocuments.mx/reader030/viewer/2022013006/5b572b437f8b9ab7348d5c73/html5/thumbnails/120.jpg)
Ligh
t
Med
ium
Sev
ere
Rar
e
Ofte
n
Fre
quen
t
A B C D E F G H I J K L M 1 4 10 1 2 3 The following should be prevented:
Hazard analysis / risk assessment
Safety goal
(negation of the event)
Pro
babi
lity
of
occu
rren
ce
Ris
k as
sess
men
t (<
=3;
4-8
; 9-2
0; >
20)
Inte
rnal
ass
embl
ySpecial operating modes
Nor
mal
ope
ratio
n
Haz
ard
no.
Inte
rnal
com
mis
sion
ing
Inte
rnal
dis
asse
mbl
y
Com
mis
sion
ing
at th
e cu
stom
er
Tra
inin
g at
the
cust
omer
Tra
nspo
rt
Ass
embl
y at
the
cust
omer
Source of danger
Ext
ent o
f the
da
mag
e
Cat
egor
y / P
Lr (
SIL
) m
inim
al
Risk assessment/safety goals/protective measures/residual risks1)
Solution suggested to the customer (cursive, Times New Roman)
Güdel solution (Arial)
Saf
ety
requ
irem
ent f
ulfil
led
[Y/N
]
Residual risks
Ope
ratin
g m
anua
l
Protective measures
(existing protective measures)
Affe
cted
per
son(
s)C
orre
spon
ding
ope
ratin
g m
ode
Triggering factor
Event
(Worst case)(Without protective measures)
Set
up/c
hang
eove
r
Cle
anin
g
Tro
uble
shoo
ting
and
repa
ir
Mai
nten
ance
Dis
asse
mbl
y
Dis
posa
l
Customer:
Machine type: all modules without control system
Project no.:
Document no.:
1.9 x x x x x Malfunction of protection measures
OperatorMaintenance
personnelAging, fatigue fracture, failure due to vibration or overloading
Person is surprised by unexpected situation and injured as a result. x x 10 3/d Averting an emerging hazard
The plant is equipped with emergency stop devices,
which trigger an emergency stop of the plant. A lock-out
(overview of the switch off locations) draws attention to
the switch-off devices.
Do not walk under suspended workpieces or Z-axes. Only possible in setup mode.Permanent workstations are not permitted in the direction of movement of the axes.
x J
1.1 x
Movement of the axes.Suspended loads(Z-axis and workpieces)
TechniciansRemoval of transport securing device without supporting suspended loads and axes.
Person is surprised by unexpected movement and injured as a result. x x 10 3/dIt must be ensured that suspended loads do not fall down.
Before removing the transport securing device, support
the suspended loads or axis.Do not walk under suspended loads. x J
1.11 x x x xMovement of the axes.Parts that are flung out
OperatorMaintenance
personnelCleaning
personnel
Unexpected start Person is surprised by unexpected situation and injured as a result. x x 10 3/dIt must be ensured that an expected start of moving parts is prevented.
A start-up of the plant without the permissive button
being pressed must be prevented.
With the permission device pressed, moving plant parts
can be moved in a controlled manner, even if the plant
is unsecured.
When the permissive button is pressed, it must not be
possible for the operator to be endangered by an
automatic movement triggered by a third party.
Do not walk under suspended workpieces and Z-axes.
In confirmation mode, the operator must pay great attention and have a high level of individual responsibility.
x J
1.12 x Movement of the axes. Setters Unexpected start Person is surprised by unexpected situation and injured as a result. x x 10 3/d
When the permissive button is pressed, it must not be possible for the operator to be endangered by an automatic movement triggered by a third party.
Axes can only be moved individually by one two-hand
operating device in jog mode. For multiple carriages on
one gantry, the individual carriages must be selected
using a key switch. The permissive button is a "shock
button".
For the permissive button to be activated, only one
safety door may be open and the others must be closed
and reset. Safety-relevant parts of the control are
inspected in appropriate time intervals by the machine
control system.
In confirmation mode, the operator must pay great attention and have a high level of individual responsibility. Only perform movements if no other person is in the danger area and none of your own body parts are in the line of danger of the corresponding axis.
x J
1.13 xSuspended loads.(Z-axes, telescopic axes, counter balance cylinders and workpieces)
Setters
Gripper problemsDefective motor brakeTorn belt (telescopic axis)Pressure drop (load balancing)General problems in the drive train
Person is surprised by unexpected situation and injured as a result. x x 10 3/d
It must be ensured that no persons can be endangered by Z-axes, telescopic axes and workpieces that fall down when the permissive button is not pressed.
Grippers must remain in the de-energized state in the
clamp position.
For very frequent set-up under Z-axes, Z-axes can be
secured redundantly with an additional brake on the
pinion and the motor brake.
Telescopic axes: and load balancing cylinders: Special
attention is required here. The axis (for a telescopic
axis, the 2nd stage) is to be secured with a mechanism.
Operation in setup mode only when the safety area is
closed off.
Do not walk under suspended workpieces or Z-axes. Take especial care with telescopic axes. Inspect belts before every setup procedure for cracks and tears.
x J
1.14 xSuspended loads.(Z-axes, telescopic axes, counter balance cylinders and workpieces)
Setters Inattention and/or careless operation by operator Person is surprised by unexpected situation and injured as a result. x x 10 3/dWorkpieces must not be dropped accidentally.
Grippers can only be operated in the storage position.
Do not walk under suspended workpieces or Z-axes. Take especial care with telescopic axes. Inspect belts before every setup procedure for cracks and tears.
x J
1.15 x Parts that are flung outSetters
Third parties
Gripper problemsDefective motor brakeTorn belt (telescopic axis)Pressure drop (load balancing)General problems in the drive train
Person is surprised by parts flying away and injured as a result x x 10 3/d No parts may be flung out.The axes can only be moved with reduced speed.
Rotating parts must be shut down securely.
Work in this mode requires a high level of individual responsibility from the operator. Only perform movements if no other person is in the danger area and none of your own body parts are in the line of danger of the corresponding axis.
x J
1.16 x x Disruption of the energy supply Setters Power failure, lightning Person is surprised by unexpected situation and injured as a result.The effects of a power failure must not be dangerous for the operator or for third parties.
The movement of the drives is limited by mechanical stops in case the supply voltage fails. The drives have already been switched off in case of a
power failure (safety shutdown situation). The
movement of the drives is braked in case of supply
voltage failure by the motor brake or holding brake in
the drive train.
After a crash, defective elements of the mechanical stops cannot necessarily be recognized immediately. The entire bumper unit must always be replaced.
x J
1.17 x Malfunction of the control system Setters Failure of control unit components Person is surprised by unexpected movement and injured as a result. x x 10 3/dThe risk of possible hazard must be kept as low as possible.
Only drive systems are used. They comply with the state
of the art and the standards referenced in the machine
directives.
Work in this mode requires a high level of individual responsibility from the operator. There is no way to completely ensure that a malfunction of the control system does not create a dangerous situation by moving the axes.The operator must therefore try to never be in the possible direction of travel of the axes and ensure that no third parties are in the possible danger zones.
x J
Copyright © 2009 by GÜDEL AG Process owner: M. Knuchel Version 30 / Risikobeurteilung_en.xls Page2 / 3
![Page 121: BA TMF 1-4 - Сервотехника Нева20TMF$201-4$20english.pdf · TMF Size 1-4 Project: ... For cross-reference Page ... moly grease Slightly oiled M12 100 120 M16 250 350](https://reader030.vdocuments.mx/reader030/viewer/2022013006/5b572b437f8b9ab7348d5c73/html5/thumbnails/121.jpg)
Ligh
t
Med
ium
Sev
ere
Rar
e
Ofte
n
Fre
quen
t
A B C D E F G H I J K L M 1 4 10 1 2 3 The following should be prevented:
Hazard analysis / risk assessment
Safety goal
(negation of the event)
Pro
babi
lity
of
occu
rren
ce
Ris
k as
sess
men
t (<
=3;
4-8
; 9-2
0; >
20)
Inte
rnal
ass
embl
ySpecial operating modes
Nor
mal
ope
ratio
n
Haz
ard
no.
Inte
rnal
com
mis
sion
ing
Inte
rnal
dis
asse
mbl
y
Com
mis
sion
ing
at th
e cu
stom
er
Tra
inin
g at
the
cust
omer
Tra
nspo
rt
Ass
embl
y at
the
cust
omer
Source of danger
Ext
ent o
f the
da
mag
e
Cat
egor
y / P
Lr (
SIL
) m
inim
al
Risk assessment/safety goals/protective measures/residual risks1)
Solution suggested to the customer (cursive, Times New Roman)
Güdel solution (Arial)
Saf
ety
requ
irem
ent f
ulfil
led
[Y/N
]
Residual risks
Ope
ratin
g m
anua
l
Protective measures
(existing protective measures)
Affe
cted
per
son(
s)C
orre
spon
ding
ope
ratin
g m
ode
Triggering factor
Event
(Worst case)(Without protective measures)
Set
up/c
hang
eove
r
Cle
anin
g
Tro
uble
shoo
ting
and
repa
ir
Mai
nten
ance
Dis
asse
mbl
y
Dis
posa
l
Customer:
Machine type: all modules without control system
Project no.:
Document no.:
1.18 x x xMovement of the axes.Parts that are flung out
Service personnelCleaning personnel
Unexpected start Person is surprised by unexpected situation and injured as a result. x x 10 3/d Starting up the plant must be prevented.The lockable main plant switch breaks all main and
control circuits.
If motors or gearboxes are removed, vertical axes must always be secured or supported.
x J
1.19 x x x
Suspended loads(Z-axes, telescopic axes, counter balance cylinders and workpieces)
Service personnelCleaning personnel
Unexpected startDefective motor brakeTorn belt (telescopic axis)Pressure drop (load balancing)General problems in the drive trainDisassembly of the Z-axis motor
Person is surprised by unexpected situation and injured as a result. x x 10 3/d Z-axes falling down must be prevented.
Workpieces must be deposited beforehand in automatic
or setup mode.
Z-axes must be secured with the Z-axes device or with
the transport securing device.
Telescopic axes must be secured against falling down
with appropriate auxiliary means (cables, auxiliary
supports, etc.).
Avoid walking under suspended workpieces or Z-axes. Take especial care with telescopic axes. Inspect belts before every maintenance procedure for cracks and tears.Workpieces must be deposited beforehand in automatic or setup mode.Z-axes must be secured with the Z-axes device or with the transport securing device.Telescopic axes must be secured against falling down with appropriate auxiliary means (cables, auxiliary supports, etc.).
x J
1.20 x x Incorrect assembly All Incorrectly assembled plant Person is surprised by unexpected situation and injured as a result. x x 10 3/d Incorrect assembly must be prevented. The content of the operating manual is known.
Before a Güdel device is transported to the location of use, unpacked, assembled and commissioned, the operating manual must first be read and understood.
x J
1.21 x x Loss of stability All Inattention and/or careless operation Machine/plant tips over x x 10 3/dTipping over or falling down of equipment must be prevented.
Equipment without base supports:To connect to customer supports, the specified screw configuration according to the Güdel layout must be used with the corresponding screws.Equipment with base supports:The supplied screws for assembly must be used.For the connection of the supports to the floor, the anchoring suggestion according to the Güdel layout must be taken into consideration.Fall protection must be mounted for surface gantries.
Check the connections that are responsible for the stability of the device before starting the plant. The operating manual must be read and understood.
x J
1.22 xImproper disposal can cause environmental damage.
All Disposal regulations are not observed Environmental hazard x x 10 3/dThe device and its consumables must be disposed of accordingly after the end of its service life.
Statewide regulations regarding disposal of the plant must be observed.
x J
1) Protective measures (comments):
The suggested solutions printed in italics are binding suggestions for achieving CE conformity.We point out, however, that before commissioning of the plant, suitable protective measures must be implemented for all hazards to ensure CE-compliant use of the Güdel devices. According to the CE Machinery Directive 2006/42/EC, these suitable protective measures, including all modifications, must comply with the "state of the art" and ensure the necessary safety category. If not all protective measures are implemented for any reason, or if any protective measures supplied and/or installed by Güdel have been been modified or not installed, Güdel will not commission the plant and will not assume liability or provide a warranty relating to any resulting events.
Copyright © 2009 by GÜDEL AG Process owner: M. Knuchel Version 30 / Risikobeurteilung_en.xls Page3 / 3
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OPERATING MANUAL TMF
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Layout
Layout
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OPERATING MANUAL TMF
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Options
Options
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OPERATING MANUAL TMF
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Third-party products
Third-party products
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OPERATING MANUAL TMF
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Spare parts list
Spare parts list