Operating Instructions Cylindrical Ring Index Tables
Contents
1. AUTOMATIONS SYSTEME GMBH Operating Instructions Cylindrical Ring Index Tables Type Serial No BWV_HR_E T fal II NZ QUALIT T IN KURVEN AUTOMATIONS SYSTEME GMBH CONTENTS General 1 Validity 2 Safety instructions 3 Shipment 4 Transport Regulations 5 Weights of gear types 2 Instructions for application of the gears 2 1 Installation position 2 2 Mounting of the gear 2 3 Gear operation 3 Start up 3 1 Gear function 3 2 Oil level 3 3 Interruption operation 3 4 Important instructions 4 Maintenance Instructions 4 1 General remark 4 2 Drive 4 3 Motor brake 4 4 Gear unit 5 Inspection instructions 5 1 Inspection cycle 5 2 Changing or filling up of lubricant 5 2 1 Changing of lubricant 5 2 2 Filling up of lubricant 6 Spare part installation 6 1 Note 6 2 Mechanism 6 2 1 Replacing cam followers barrel cam remains built in 6 2 2 Replacing turret ring barrel cam remains built in 6 2 3 Replacing barrel cam turret ring remains built in 6 2 4 Replacing mechanism completely 6 3 Roller bearings 6 4 Spare part drawing 6 5 Spare and wearing parts 7 Final remark BA _HR_E doc 2 18 fall i NZ QUALIT T IN KURVEN AUTOMATIONS SYSTEME GMBH 1 General 1 1 Validity These operating instructions are valid for cylindrical cam ring tables They are to be read and applied by all persons in the user s premises who are made responsible for the installation operation m2. 150 rpm For rotating speed gt 150 rpm Kldbersynth 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 BA _HR_E doc 9 18 Fil i NZ QUALIT T IN KURVEN AUTOMATIONS SYSTEME GMBH 5 Inspection instructions 5 1 Interspection Intervals We recommend to control the oil level approximately every 8 000 hours of operation to avoid damage of the gear through insufficient lubrication 5 2 Changing or Filling up of Lubricant er NOTE n E To preserve the guarantee on the mechanical function sufficient lubrication of all active elements is mandatorily necessary Regular inspection of the gear boxes for leakage is prerequisite for the safuarding of the function ability S NOIE Position of the Oil Fittings at the different Sizes of indexer ie A Oil Filling and Venting Screw Oil Filling and Oil Drain Venting Screw Oil Drain BA_HR_E doc 10 18 Picture 1 Oil Fittings at HR800 Oil Filling and Ve
3. OMATIONS SYSTEME GMBH r b 7 5 QUALIT T IN KURVEN N Spare part drawing 6 4 N 20 17 22 35 34 12 27 28 13 O 14 15 32 29 24 35 16 50 16 18 BA _HR_E doc fe q NZ QUALIT T IN KURVEN AUTOMATIONS SYSTEME GMBH 6 5 Spare and wearing parts 6 Barelcam o S 7 8 Spurwheel p 9 Switthcam O BA_HR_E doc 17 18 7 Final remark PU l NZ QUALIT T IN KURVEN AUTOMATIONS SYSTEME GMBH All repair work requires a certain amount of experience and should therefore be carried out by HEINZ fitters Address of HEINZ HEINZ AUTOMATIONS SYSTEME GmbH Lilienthalstr 21 D 64625 Bensheim Tel 0049 0 6251 1069 0 Fax 0049 0 6251 1069 99 http www heinz automation de E Mail mail heinz automation de fe a f A eS Y us Q E AUTOMATIONS SYSTEME GMBH LilienthalstraRe 21 D 64625 Bensheim Telefon 49 0 62 51 10 69 0 Telefax 49 0 62 51 10 69 99 E mail mail heinz automation de AZ a www heinz automation de Address of HEINZ for Gear repair HEINZ GmbH Kochhorstweg 33 D 04910 Elsterwerda Bensheim Unche M nchen Ym I Stuttgart Lilienthalstrasse 21 D 64625 Bensheim Telefon 49 0 6251 1069 0 Fax 49 0 6251 1069 99 BA_HR_E doc 18 18
4. aintenance or repair of these gears For the sake of simplicity cylindrical cam ring tables will be referred to as the gears within the following Instructions Every gear is manufactured to the state of the art and according to recognized safety regulations Applications other than specified or exceeding the limiting parameters e g higher speeds and or loads or other installation positions are considered to be contrary to agreement The manufacturer shall not be held responsible for any damage resulting from this In such cases the risk is carried solely by the operating company The agreement regarding application also covers reading the operating instructions and compliance with the inspection and maintenance stipulations Maintenance work may only be carried out by qualified personnel who are acquainted with the principles of the gear function 1 2 Safety instructions The gear corresponds to the recognized safety regulations When employed as part of a machine or plant danger of injury or death for the user or a third person can result e g due to removal of the lever gear wheel with chain or similar parts In such cases suitable local protective measures should be taken by the user 1 3 Shipment Every gear is subjected to go through an inspection process and is properly packed In spite of this we request that the gear is unpacked immediately on arrival at the installation location and checked for transport damage Any c
5. e and is divided into a dwell angle and index angle area When the cam is rotated the precise jolt and impact free movement of the output is produced by the cam path and the cam follower As the cam course is constructed standard symmetrically it is possible to choose rotation to the left or to the right The dwell angle area has a zero slope Through this the cam followers result in a precise self locking positioning of the output without an additional locking mechanism A spurwheel is available between the input shaft of the gear and the cylindrical cam with the following possible ratio When a brake motor is employed the positioning of the output shaft is independent on the braking accuracy of the motor as the accurate positioning is dictated by the position of cam followers in the dwell angle area The whole dwell angle area is available for braking see 3 3 BA_HR_E doc 6 18 fall i NZ QUALITAT IN KURVEN AUTOMATIONS SYSTEME GMBH 3 2 Oil level The oil level should be checked before start up It is sufficient if the oil can be observed through the oil level indicating glass see also 4 4 gear unit oil volume Gear type HR 800 1 00 HR 1250 3 9 HR 1600 4 0 3 3 Interruption Operation If the dwell angle area of the cylindrical cam is insufficient for the interval of interruption required for production the interval can be prolonged by using a brake motor The procedure is initiated by an end position swi
6. ecessary Assemble bearing ring 4 adjust initial bearing tension with adaption supplement Assemble V seal inside 20 and outside 21 Bolt on rotary plate 5 Turn pinion shaft 15 and check mechanism for even running Refill oil BA_HR_E doc 13 18 fe NZ QUALIT T IN KURVEN AUTOMATIONS SYSTEME GMBH 6 2 2 Replacing turret ring barrel cam remains built in 6 2 3 Drain oil Turn pinion shaft 15 into dwell angle area Unscrew rotary plate 5 Remove V seal inside 20 and outside 21 Unscrew bearing ring 4 Remove survey anti friction bearing 19 see also adaption supplement Lift switching cam 3 with cam followers 2 out of housing Check barrel cam 6 and replace by new one if necessary see section 6 2 3 Put turret ring 3 and possibly new new cam followers 2 into housing 1 For assembly of cam followers 2 see 6 2 1 Put in survey anti friction bearing 19 Check seal 17 and replace if necessary Assemble bearing ring 4 adjust initial bearing tension with adaption supplement Assemble V seal inside 20 and outside 21 Bolt on rotary plate 5 Turn pinion shaft 15 and check mechanism for even running Refill oil Replacing barrel cam turret ring remains built in Drain oil Turn pinion shaft 15 into dwell angle area Unscrew housing tray 11 Release lock washer 35 and remove lock nuts 34 Drive stub axle 13 from barrel cam 6 Attention It is necessary to fix the p
7. hined surface e The fixing bolts must be secured and if possible the position of the gear should be additionally fixed by means of dowel pins e The connection between the gear and the driven load must be direct free of play and torsionally rigid This also applies to the drive side of the gear e Serrated belt and driving chain have to be dimensioned sufficiently those have to be taut according to regulations 2 3 Gear operation The following should be observed with regards to gear operation e Elasticity and play in the driven masses can result in vibration and must therefore be avoided e The gear should always be stopped or started in the dwell angle area Otherwise supplimentary vibrations may occur which might cause damage to the gear e Incase of an emergency stop also during tap operation the torques may be significantly higher as during normal operation depending on the drive unit being used This can damage the gear BA_HR_E doc 5 18 fall i NZ QUALIT T IN KURVEN AUTOMATIONS SYSTEME GMBH 3 Start up 3 1 Gear function HEINZ gears form a compact robust unit which through the use of accurately calculated cylindrical cams enable the transformation of a constant input speed into an optimum precise and impact free intermittent output movement The cam rollers fitted in the turret are guided precisely in the cylindrical cam by the hardened and ground cam path This cam path is formed with a variable slop
8. n BA_HR_E doc 12 18 fe NZ QUALIT T IN KURVEN AUTOMATIONS SYSTEME GMBH 6 Spare part assembly 6 1 Note Read through the complete text attentively before beginning with the following dismantling work Clean all components before installation and check their faultless condition For dismantling and assembly of the components the spare part list is helpful 6 2 Mechanism The mechanism consists of barrel cam roller followers and turret Due to wear of roller followers barrel cam and turret it might be necessary to replace cam followers turret complete mechanism 6 2 1 Replacing cam followers barrel cam remains built in Drain oil Turn pinion shaft 15 into dwell angle area Unscrew rotary plate 5 Remove V seal on the inside 20 and on the outside 21 Unscrew bearing ring 4 Remove survey anti friction bearing 19 see also adaption supplement Take out turret ring 19 with cam followers of housing 1 Turn cylinder head screws from turret ring 3 remove cam followers Check shaft bore of cam followers regarding damage and possibly extension In case of faulty bore hole see 6 2 2 In case of faultless bore holes press new cam followers 2 into turret ring 3 Secure cam followers 2 with cylinder head screws Check barrel cam 6 and replace if necessary by new one see section 6 2 3 Put back turret ring 3 into housing 1 Put in wire ball bearing 19 Check seal 17 replace if n
9. nting Screw Picture 3 Oil Filling at HR1250 HR600 BA _HR_E doc y Fal i NZ QUALIT T IN KURVEN S3 AUTOMATIONS SYSTEME GMBH Picrure 2 Oil Fittings at HR1100 Oil Drain Picture 4 Oil Drain HR1250 HR1600 11 18 fe NZ QUALIT T IN KURVEN AUTOMATIONS SYSTEME GMBH 5 2 1 Changing of Lubricant In case an oil change is required the oil drain screw has to be opened to remove all the old oil out of the housing WARNING No residues of waste oil may remain inside the housing If necessary the indexer needs to be rinsed with a qualified cleanser After the oil drain screw at the gear housing needs to be securely closed again and the new lubricant can be filled in Oil level gauge please also see 3 2 Oil level 5 2 2 Filling up of Lubricant In case of a leakage or a loss of oil filling up of lubricant is required For that the filling and venting screw need to be opened to fill up the lubricant to the required level S NOTE Check the lubricant inside the housing When the oil level is right the lubricant is visible in the oil level gauge Oil level gauge please also see 3 2 Oil level Some types of gear housings do not have an oil level glass gauge S NOTE So in case of doubt if the oil quantity meets the requirements please continue with 5 2 1 Changing of Lubricant WARNING Performance and life time of indexer depend on proper handling and sufficient lubricatio
10. omplaints should be reported immediately to the transport company 1 4 Transport regulations Eyebolts may be screwed into the fixing holes provided Lifting ropes or chains may only be applied on these eyebolts The weight of the gear should be taken from table 1 5 BA _HR_E doc 3 18 fall i NZ QUALIT T IN KURVEN AUTOMATIONS SYSTEME GMBH 1 5 Weight of gears types HR 800 Weight without motor kg HR 1250 HR 1600 a BA_HR_E doc 4 18 fall a NZ QUALIT T IN KURVEN AUTOMATIONS SYSTEME GMBH 2 Instructions for application of the gears 2 1 Installation position Due to is construction the gear can be integrated in one position into a machine or a plant At the same time the axis of rotation has to be located vertically while the output has to be located above the input It has to be ensured that the gear will be operated in this mounting position The predefined mounting position is decisive for the lubrication of the lubrication of the gear components and may not be changed In case the mounting position should be changed the tightness of the gear is not ensured any longer and mechanical damages can may occur Illustration 1 Gear mounting position 2 2 Mounting of the gear Due to the principle of the functioning of the gear the output shaft as well as the input shaft are subjected to variable torques The following must therefore be observed e The gear must be mounted on a rigid mac
11. osition of barrel cam 6 Take barrel drum 6 out of housing tray 11 Dismantle spur wheel 8 flange 7 and switch cam 9 Replace angular ball bearings 22 23 and insert into new barrel cam 6 replace damaged bearings by new ones Fit spur wheel 8 flange 7 and switch cam 9 to barrel cam 6 Place barrel cam 6 into housing tray 11 Drive stub axle 13 into housing tray 11 and barrel cam 6 Attention It is necessary to fix the position of barrel cam 6 Tighten lock nuts 34 and safeguard lock washer 35 Bolt on housing tray 11 It is important to have an even contact reflection of the cam followers and the barrel cam during the dwell angle Check by means of inking past Turn pinion shaft 15 and check even running of mechanism Refill oil 6 2 4 Replacing mechanism completely For dismantling and mounting of turret ring cam follower and barrel cam please refer to sections 6 2 1 to 6 2 3 BA_HR_E doc 14 18 fe NZ QUALIT T IN KURVEN AUTOMATIONS SYSTEME GMBH 6 3 Roller bearing With regard to the installation of new roller bearings please consider that the bearing has to be adjusted free of play In case the bearing play should be to big or too small this can be corrected by adjustment of the shim and distance bushing or also with the torque of the lock nut Afterwards check the perfect running of the mechanism by turning the pinion shaft re adjust if necessary BA_HR_E doc 15 18 AUT
12. rruption in the dwell angle area as described in 3 3 should be checked from time to time The brake should be re adjusted or renewed if necessary BA_HR_E doc 8 18 fall i NZ QUALITAT IN KURVEN AUTOMATIONS SYSTEME GMBH 4 4 Gear unit 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 KlUbersynth GHE 6 460 Klubersynth 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 3570 oil Klubersynth 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
13. tch which is operated by one of the cams connected to cylindrical cam During the start up as well as during operation it has to be oberserved that after the breaking has occured the mounted end position switch is always activated cam followers should be in the middle of the dwell 3 4 Important Instructions With two speed drives normal operation occurs always at the higher speed high speed The lower speed low speed may only be used for setting up the unit or moving into the dwell angle area after an emergency stop During automatic operation the gear may not be switched into the low speed position while the unit is in the movement phase With control systems which only allow switching of the high speed through the low speed this may only occur during the dwell angle this means during the standstill period of the output shaft Any damage which is caused by failure in complying with these instructions will result in the rejection of any guarantee claim by the manufacturer BA _HR_E doc 7 18 fall i NZ QUALIT T IN KURVEN AUTOMATIONS SYSTEME GMBH 4 Maintenance Instructions 4 1 General Remark In case of queries i e spare part orders please state the type and serial number of the gear in question 4 2 Drive The maintenance instructions for the gear brake motor or other drive units should be taken from the instructions supplied by the corresponding manufacturer 43 Motor brake Due to wear of motor brake the inte
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