HEINZ-AUTOMATIONS-SYSTEME GMBH Installation manual
Contents
1. must only be used for setting up the installation or after an emergency shutdown to bring it into the dwell angle In automatic operation you should never shift to the creep speed during motion phase In controls that only allow shifting of the fast speed via the creep speed this must only be carried out within the dwell angle that means only within the range of the marking label or during the standstill of the output flange Non compliance of these instructions shall result in an exclusion of all warranties by the manufacturer in the event of damage Betr Anl H T doc 9 17 AUTOMATIONS SYSTEME GmbH 4 Maintenance instructions 4 1 General information For all correspondence or spare parts orders please always specify the gear type and the serial number of the respective gear 4 2 Drive For the maintenance instructions of the gear brake motor or other drives please refer to the delivered manufacturer s instructions 4 3 Motor brake Due to the unavoidable wear of the motor brake it is necessary to check it from time to time In this connection it is important to ensure that after braking the gear always stops in the dwell angle range If after the braking process the cam has already left the dwell angle range this may be a sign of an incorrectly adjusted limit switch or a loss of efficiency of the brake motor In this case it should be adjusted or replaced When putting into service again and during operation2. to the working principle of the gear the input shaft and the output flange are subjected to variable torques Therefore the gear should be mounted on a stiff machined foundation the mounting bolts must be secured and additional fixing by means of dowel pins should be provided if possible the connection between the gear and the driven useful load should be direct free of play and stiff against torsion This applies also to the driving of the gear make sure that toothed belts and driving chains are sufficiently dimensioned and tightened according to instructions Betr Anl H T doc 5 17 HEINZ AUTOMATIONS SYSTEME GmbH 2 3 Gear operation The MEN instructions must be observed for the operation of the gear elasticity and plays in the driven masses may excite oscillations and must be avoided an overload protection should be mounted on the output shaft in order to ensure optimal protection of the gear and the drive unit the step by step gear should always be stopped and started within the range of the dwell angle Otherwise there is a risk of additional oscillations that could damage the gear incase of E stop even in touch mode there can be considerably higher moments than in normal operation depending on the used driving unit which could damage the gear the usual power supply and frequency at the place of installation must conform to the technical data of the drive motor All connections including earth and ne
3. 570 oil Kl bersynth UH1 6 460 It is lubricated for life i e no oil changes are necessary at all The oil level should be checked at regular intervals Sufficient oil is present if when the gear unit is stationary the oil can be seen in the sightglass The lubrication of the cam rollers and the came is thus guaranteed For rotating speed lt 150 rpm For rotating speed gt 150 rpm Klubersynth UH1 6 460 Klubersynth UH1 6 150 WARNING WARNING Warning Never mix different oil sorts Only top up with the lubricant described above 4 4 2 Grease Lubrication It is lubricated for life i e no grease are necessary at all The grease level should be checked at regular intervals Normal Grease Lubrication NSF H1 registered conform to FDA 21 CFR 178 3570 Castrol Olit 00 Cassida RLS 00 Microlube GB 00 Klubersynth UH1 14 1600 WARNING WARNING Warning Never mix different oil sorts Only top up with the lubricant described above Betr Anl H T doc 11 17 HEINZ AUTOMATIONS SYSTEME GmbH 5 Inspection instructions 5 1 Inspection cycle Under normal operating conditions the following components should be inspected after approx 8000 hours of operation running surface of the cam roller on the cams cam rollers running surface and radial play initial tension of the tapered roller bearing seat and function of the rotary shaft seals Under difficult operating conditions such as high surrounding tempe
4. AUTOMATIONS SYSTEME GmbH HEINZ AUTOMATIONS SYSTEME GMBH Installation manual Cylindrical cam rotary indexing table Type Serial no Betr Anl H T doc 1 17 AUTOMATIONS SYSTEME GmbH TABLE OF CONTENTS General Scope Safety information Shipment Transport information Weight of the gear types Instructions for installation and operation of the gears Mounting position Gear mounting Gear operation Initial operation Gear function Oil level Intermittent service Important note Maintenance instructions General information Drive Motor brake Gear Inspection instructions Inspection cycle 24 h service Spare parts assembly Note Assembly kit Replacement of cam rollers cylindrical cam remains in place Replacement of follower cylindrical cam remains in place Replacement of cylindrical cam follower does not remain in place Complete replacement of assembly kit Tapered roller bearings Spare parts drawing Spare parts and wearing parts Final note Betr Anl H T doc 2 17 HEINZ AUTOMATIONS SYSTEME GmbH 1 General 1 1 Scope This installation manual has been prepared for cylindrical cam gears and rotary indexing tables lt must be read and followed by any person charged with the installation putting into operation and operation maintenance or repair of these drives in the user s enterprise In the following these cylindrical cam gears and rotary indexing tables will only
5. be called gears Each gear has been manufactured according to the state of the art and the recognized technical safety regulations Any different use or application over and above this such as higher revolution speed and or higher loads or different installation positions is deemed not in accordance with these specifications The manufacturer undertakes no liability for damages resulting therefrom The risk is borne entirely by the user The application according to the specifications also includes reading the installation manual and observance of all inspection and maintenance intervals Maintenance must only be carried out by qualified staff that is familiar with the mode of operation of the step by step gears 1 2 Safety information The gear is in accordance with the recognized technical safety regulations When used as part of a machine or installation screwed on levers continuing chains or belt drives etc could represent a higher risk than the gear itself The user of the gear is responsible for securing the hazardous area at the place of installation in order to avoid any danger caused by revolving levers downstream connected gears and any kind of drives Moreover we assume no responsibility for any possible shearing or crushing which may result from the assembly of the gearing on site 1 3 Shipment Each gear has been carefully checked and duly packed before shipment However upon arrival at the place of installation we k
6. cylindrical cam it is necessary to remove the follower first as explained in chapter 6 2 1 Loosen screws of bearing covers and pull out cover from housing Loosen screws and remove housing cover Take off inner rings of the tapered roller bearings from the output shaft release locking plates and loosen groove nuts Remove drive shaft from cylindrical cam and take out cam from housing Check seat of the feather key and its groove for damages Introduce new cylindrical cam into housing and insert input shaft Make sure that cylindrical cam is in the correct mounting position An incorrect installation prevents the gear from being turned and or may cause considerable damage Slightly tighten groove nuts Use new locking plate Betr Anl H T doc 14 17 AUTOMATIONS SYSTEME GmbH Before reassembling the bearing you should check rolling bearing and their seats Bearings have to be replaced if necessary Fit in remaining parts in reversed order rotary shaft seals and O rings have to be replaced Mount follower Turn input shaft by hand and check assembly kit for regular and smooth running as well as its operability Use groove nuts to make fine adjustment of cylindrical cam Make sure that the cam rollers have contact over the entire width Check with China ink After having adjusted the cam tighten groove nuts and secure by means of locking plate Mount housing cover Bring gear into final mounting position and refill oi
7. eady given by the position of the cam rollers in the dwell angle range The entire dwell angle range can be used for braking see 3 3 Betr Anl H T doc 7 17 Before the initial operation the oil level must be checked It is sufficient when the oil is visible through the sight glass and the gear is located in the intended mounting position When integrating the gear into a more complex installation make sure that an oil change is still possible Oil types see chapter 4 4 Oil charge meo oe 3 3 Intermittent service If the dwell angle range of the cam is not sufficient for the production related standstill the dwell time can be prolonged by means of a brake motor The braking process is started by a limit switch which is actuated by a lifting cog connected to the input shaft When putting into service and during operation make sure that the feather key groove of the input shaft is located parallel to the housing side 1 after braking in case of double shifting also rotated through 180 cam rollers should be located in mid dwell In gears with an additional index hand make sure that the index hand is located within the middle of the marking label after each braking process Betr Anl H T doc 8 17 HEINZ AUTOMATIONS SYSTEME GmbH Important note In drive units with two speeds the higher speed fast speed is in principle used for the standard operation The smaller speed creep speed
8. indly ask you to immediately unpack the gear and inspect it for transportation damages Any complaints must be immediately notified to the carrier Betr Anl H T doc 3 17 AUTOMATIONS SYSTEME GmbH 1 4 Transport information For transport without packaging can be used the existing fixing holes or tapped holes for ring bolts The gear must be attached to these holes only The weight of the gears is given in table 1 5 1 5 Weight of the gear types Betr Anl H T doc 4 17 AUTOMATIONS SYSTEME GmbH 2 Instructions for installation and operation of the gears 2 1 Mounting position Due to its universal construction the gear can be integrated into a machine or installation in nearly every position The mounting position the fixing holes and oils bores if applicable have already been specified by the customer when placing the order The predefined mounting position is decisive for the lubrication of the gear components and must therefore not be changed on site ae hs gt sia NER ZE i 2 f i pa eo Sees Ss Figure 1 Gear mounting positions 2 2 Gear mounting Due
9. l see 3 2 and 4 4 Reinsert gear motor attachment parts and limit switch Fill in oil 6 2 4 Complete replacement of assembly kit For dismounting and mounting of follower and globoidal cam please refer to chapters 6 2 1 to 6 2 3 NOTE All repair works require a certain experience and should therefore only be carried out by service technicians of HEINZ AUTOMATIONS SYSTEME GmbH 6 3 Tapered roller bearings When mounting new tapered roller bearings ensure backlash free adjusting of the bearings Too large or too small bearing play can be adjusted by aligning the bearing covers or the eccentric cover Subsequently the assembly kit has to be checked for proper function and readjusted by turning the input shaft if necessary Betr Anl H T doc 15 17 AUTOMATIONS SYSTEME GmbH 6 4 Spare parts drawing y Ly Fa g wy Man 22 2 2 a r A 142 E i N HEWLE ZS ar aT HERA i SS Si NIN N T WZ Te Ku TF Betr Anl H T doc 16 17 AUTOMATIONS SYSTEME GmbH Spare parts and wearing parts 1 Assembly kit 1 1 Cylindrical cam 1 1 2 Follower 2 1 3 Cam rollers 3 2 Bearing kit 2 1 Cross roller bearing output 4 2 2 Roller bearing output 5 2 2 Tapered roller bearing output 6 3 Seal kit 3 1 Rotary shaft seal input 7 3 2 O ring input 8 3 3 Rotary shaft seal 1 input 9 3 4 Rotary shaft seal 2 input 10 3 0 4 In
10. ollower they are glued in place and remove cam rollers Check cam roller stem bores in the follower for damages and maybe for enlargement If there are damaged bores see 6 2 2 2 Betr Anl H T doc 13 17 HEINZ AUTOMATIONS SYSTEME GmbH lf the bores are flawless press new cam rollers without angle errors no jamming into the follower and secure set screws The race of the cam roller must be easily rotatable For cam rollers without notch use a core hole drill to make a centre bore in each cam roller shaft Centering depth depends on the center point of the set screw DIN 914 Secure cam rollers with set screws glue threads in place Check cylindrical cam and replace it by a new one if necessary see chapter 6 2 3 Reinsert output flange together with follower into housing pay attention to the position of the drilling template in the output flange Turn input shaft and check assembly kit for regular running Refill oil Replacement of follower cylindrical cam remains in place In case of damaged cam roller stem bores pull off cross roller bearing Screw on new follower with mounted cam rollers Lightly heat tapered roller bearing max 80 C and slide it over output flange For further assembly please refer to 6 2 1 Replacement of cylindrical cam follower does not remain in place Dismount motor or components of foreign make Drain oil Turn input shaft into dwell angle range Screw off housing cover To replace the
11. please ensure that the feather key groove of the input shaft or the marking are always parallel to the housing side 1 after braking In case of double shifting also rotated through 180 cam rollers should be located in mid dwell In gears with an additional index hand make sure that after each braking process the index hand is located within the middle of the marking label Betr Anl H T doc 10 17 5 wa a i r g kr j i r 7 rh i 1 J hh ek n gt i 1 i h i j E 4 a a J a eT 4 _ 2D fi i J k j AUTOMATIONS SYSTEME GmbH 4 4 Gear 4 4 1 Oil Lubrication In Standard the gear unit is delivered with the synthetic lubricating oil Klubersynth GHE 6 460 It is lubricated for life i e no oil changes are necessary at all The oil level should be checked at regular intervals Sufficient oil is present if when the gear unit is stationary the oil can be seen in the sightglass The lubrication of the cam rollers and the came is thus guaranteed For rotating speed lt 150 rpm For rotating speed gt 150 rpm Kl bersynth GHE 6 460 Kl bersynth GHE 6 100 Mobil Glygoyle HE 460 ISO V6 460 Mobil Glygoyle 22 ISO V6 150 Shell Omala S4 WE 460 Shell Omala S4 WE 150 WARNING WARNING Warning Never mix different oil sorts Only top up with the lubricant described above If used for the food industry the gear unit is delivered with NSF H1 registered conform to FDA 21 CFR 178 3
12. put shaft 11 7 Final note All repair works require a certain experience and should therefore only be carried out by HEINZ service technicians HEINZ AUTOMATIONS SYSTEME GMBH Lilienthalstr 21 64625 Bensheim Phone 49 0 6251 1069 0 Fax 49 0 6251 1069 99 http www heinz automation de E Mail mail heinz automation de Betr Anl H T doc 17 17
13. rature heavy vibrations etc this maintenance interval should be reduced accordingly Betr Anl H T doc 12 17 HEINZ AUTOMATIONS SYSTEME GmbH 6 Spare parts assembly 6 1 Note Before starting with the following disassembly you should carefully read the text below Before reinsertion all components must be cleaned and checked for proper function When using solvents make sure that they don t come into contact with the O rings or the rotary shaft seals For any possible further enquiries and spare parts orders please have ready the type and serial number A spare parts list and general assembly drawing are attached to this installation manual 6 2 Assembly kit The assembly kit is one unit and consists of the cylindrical cam the follower and the cam rollers The possible wear of cam rollers and globoidal cam may require the replacement of cam rollers follower cylindrical cam complete assembly kit 6 2 1 Replacement of cam rollers cylindrical cam remains in place Drain oil Remove all parts or fixtures attached to the indexing plate by the customer Turn input shaft into dwell angle range Unscrew output flange you only have to twist off the cylinder screws from the outer ring of the output bearing Take off out bearing together with follower vertically upwards Before this remove rotary shaft seal and bearing if applicable remove output flange with follower from housing Unscrew set screw from f
14. utral lines have to be carried out according to the regulations of the VDE and or the competent electric power company outside the machine appropriate safety devices have to be provided Betr Anl H T doc 6 17 AUTOMATIONS SYSTEME GmbH 3 Initial operation 3 1 Gear function The gears form a compact robust unit and allow through the use of exactly calculated cylindrical cams the transformation of a constant input speed into an optimal exactly defined smooth and jerkless intermittent output movement The cam rollers arranged in the follower are exactly guided by the hardened and ground curved path in the cylindrical cam This curved path has different slopes and is divided into a dwell angle and an indexing angle range Turning of the cam produces via the curved path and the cam roller the predefined smooth and jerkless movement of the output flange Cam roller Follower output flange G Y NS i Z NV PF WE __ PTI Input shaft Cylindrical cam The course of the curve being symmetrical by default allows optionally turning to the left or to the right The slope of the dwell angle range is zero This allows via the cam rollers an exact self locking positioning of the output flange without additional locking When using a brake motor the positioning of the output flange is independent of the braking accuracy of the motor because the exact position is alr
Download Pdf Manuals
Related Search