INSTALLATION AND OPERATING INSTRUCTIONS · Tapped holes 8 Screws with a screw class of 8.8 are to be used. Observe the permitted tightening torque The orientation is determined using

INSTALLATION AND OPERATING INSTRUCTIONS

Handling technologyGS seriesO-ring assembly gripper pneumatic

THE KNOW-HOW FACTORY

Zimmer GmbH ● Im Salmenkopf 5 ● 77866 Rheinau, Germany ● Phone: + 49 7844 9138-0 ● Fax: + 49 7844 9138-80 ● www.zimmer-group.de

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cINSTALLATION AND OPERATING INSTRUCTIONS: Pneumatic GS series O-ring gripper


Contents:

1. Supporting documents ........................................................................................................................ 32. Proper use ............................................................................................................................................. 33. Personnel qualifications ...................................................................................................................... 34. Function ................................................................................................................................................. 35. Pneumatic connection ......................................................................................................................... 45.1 Flow chart ............................................................................................................................................... 55.2 O-ring installation technological process .............................................................................................. 56. Technical data ....................................................................................................................................... 67. Installing the gripper ............................................................................................................................ 77.1 Installing the accessories ...................................................................................................................... 77.2 Setting the stroke limitation ................................................................................................................... 88. Troubleshooting .................................................................................................................................... 99. Maintenance ........................................................................................................................................... 910. Accessories ........................................................................................................................................... 1011. Declaration of incorporation ............................................................................................................... 1112. Your notes .............................................................................................................................................. 12

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1. Supporting documents

• Catalog• Drawings, performance data, information about accessory parts, etc.• General Terms and Conditions of Business, including warranty information

Note: The following documents are available for download on our website. Only the documents currently available on the website are valid.

Note: The gripper should only be used in its original state with its original accessories, with no unau-thorized changes and within the scope of its defined parameters for use. Zimmer GmbH accepts no liability for any damage caused by improper use.

2. Proper use

The gripper is designed exclusively for pneumatic operation. The gripper is not suited for operation with any other media. The gripper is used as defined under "Proper use" in enclosed rooms for temporarily gripping and handling O-rings.The gripper is suited exclusively for the exterior installation of O-rings. Its use for other applications is considered to be improper use. Direct contact with perishable goods/food is not permitted.

3. Personnel qualificationsInstallation, commissioning and operation may be undertaken by trained specialists only. They must have read and understood the installation and operating instructions in full.

4. FunctionThe gripper implements the movement sequence for picking up, inserting and wiping when installing O-rings in outer annular grooves using two single-action pneumatic cylinders in io.

in 2-section piston rod

in Pistons for the spread jaws

io Pistons for the wiper

An adjustable stroke 9 for the spread jaws 2 prevents the O-rings from overstretching.

in

in

io

2

7

1

9

2

9

4

1

5

8

6

1 Removal jaws

2 Spread jaw

4 Energy supply

5 Force transmission (bevel gear)

6 Installation holes

7 Groove for magnetic field sensors for position sensing

8 Drive, 2 single-acting pneumatic cylinders

9 Stroke setting for spread jaws

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5. Pneumatic connection

The pneumatic fittings for connecting to the power supply can be mounted directly on the gripper.

Spread jaws em Connection A/A‘ - Retracted in a depressurized stateEjector en Connection B/B‘ - Retracted in a depressurized state

The activation of the gripper is displayed in the image with two 3/2 way valves.The chronological activation process is displayed in a flow chart in Chapter 4.2.

em

en

5.1. Flow chart

NOTE: When returning, the valve B/B 'for the wiper must first be vented, and approx. 0.5 seconds thereafter the

valve A/A´ can be vented for the spread jaws. As a result, there is no air cushion between the piston for the wiper io and the piston for the spread jaws in, which prevents the complete retraction of the spread jaws.

Action on the O-ring: Pick up O-ring

Expand O-ring

PositionWipe

Valve Status Step 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6

Aa

b

t=0.5 t=0.5

Ba

b

Operating situation: Approach(Return)

Dip into position

Movement to the installation

position

In installation position

Extend from installation

position

Return(Approach)

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5.2. Technological process of an O-ring installation

5

◄ Positioning using an O-ring tray

• Gripper at the connections A and B or A‘ and B‘ Completely ventilate Wiper is retracted Spread jaws are retracted

Pick up O-ring ► • Move with the gripper in the O-ring tray Only in the width of an O-ring

◄ Expand O-ring

• Ventilate connection A or A‘ Spread jaws are extended O-ring is picked up and expanded

Positioning via workpiece/dip ► • Position the gripper above the

workpiece in such a way that the lower edge of the spread jaws and the upper edge of the annular groove are aligned with one another

• Ventilate connection B or B‘

◄ Wiper/installation

Wiper is extended O-ring is pushed by the spread jaws O-ring slides into the ring groove of the workpiece

Return ► • Remove the gripper from the

workpiece • First, ventilate connection B or B` Wiper is retracted • After that, ventilate connection A or A` Spread jaws move back

Start new cycle ►

2

4

1A B

3A B

5A B

6A B

A B

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Zimmer GmbH ● Im Salmenkopf 5 ● 77866 Rheinau, Germany ● Phone: + 49 7844 9138-0 ● Fax: + 49 7844 9138-80 ● www.zimmer-group.de 6

6. Technical data

Parameters ValuesGS65

ValuesGS810

ValuesGS1015

Expanding stroke per gripper jaw, minimum (adjustable) [mm] 3 4 1.6 mm

Expanding stroke per gripper jaw, maximum (adjustable) [mm] 6 8 10

Wiper stroke [mm] 5 10 15

Expanding force [N] 300 1200 1450

O-ring diameter, minimum (recommended) [mm] 4 30 40

O-ring diameter maximum (recommended) [mm] 60 120 150

Number of spread jaws 6 8 10

Closing time [s] 0.05 0.05 0.05

Opening time [s] 0.05 0.05 0.05

Repeatability [+/-] [mm] 0.05 0.05 0.05

Minimum operating pressure. [bar] 4 3 3

Maximum operating pressure [bar] 8 8 8

Minimum operating temperature [°C] +5 +5 +5

Maximum operating temperature [°C +80 +80 +80

Weight [kg] 0.5 2.5 5.4

Installation

Straight pin [Ø] 2 x 5H7 x 8 2 x 6H7 x 6 2 x 8H7 x 8

Straight pin [Ø] 3 x M6 x 10 3 x M6 x 8 3 x M8 x 12

Tightening torque [Nm] 10.2 10.2 24.9

Pneumatic connection A/B [Ø] 2 x M5 2 x M5 2 x M5

Pneumatic connection A‘/B‘ [Ø] 2 x M5 2 x G1/8" 2 x G1/8"

NOTE: Please observe the data sheets on our website for the real-world dimensions of the mounting piece.

*) as an example, the data sheet of the GS8B ►

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7. Installing the gripperGripper is fastened via the 3Tapped holes 8

Screws with a screw class of 8.8 are to be used.Observe the permitted tightening torque

The orientation is determined using straight pins in both alignment holes bl.

The dimensions for the mounting piece can be taken from the data sheets, which are available at www.zimmer-group.de.

8

bl

7.1 Installation of accessories

◄ Removal jaws Insert centering pins bm in the center holes of the wiper Position the removal jaws 1 on the centering pins Secure the removal jaws with strength class 8.8 cylinder screws

Spread jaws ►By inserting the centering rings, cm the gripper jaws are prepared for the installation of the spread jaws 2.

Position removal jaws 2 in the centering sleeve and align with one another - The gripper jaws must be exactly centrally positioned

To align the spread jaws, use an adjusting ring with the diameter of the later O-rings when not under tension

Secure the spread jaws with strength class 8.8 cylinder screws

◄ SensorsDetecting the end position allows you to have a shorter cycle time and an integrated control system.

◄ Inductive proximity switch Install the mounting block hn on the mounting surface below the

spread jaws Insert the proximity switch hm in the mounting block Position the spread jaws and adjust the proximity switch Clamp proximity switch in the mounting block

Magnetic field sensors ► 4 Insert the magnetic field sensors 7 into the corresponding

grooves Ventilate the gripper completely and set each sensor to the lower

position of the two pistons (LED on) Mark the point Push the magnetic field sensor 7 until it reaches the switch-off

point (LED off). Mark the point Then push the sensor back again until it reaches the switch-on

point (LED on). The optimal magnetic field sensor position 7 is

between the two tagged points. Position the spread jaws and the ejector Perform an adjustment procedure to both of these sensors as

previously described as well.

bm 1

7

2 cm

hn hm hn

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7.2 Setting the stroke limitationThe spread jaw stroke can be fit to the respective O-ring by twisting the adjustment ring 9.

To prevent an unintentional adjustment of the stroke limitation, the ring has to be secured with a locking screw jm.

9 Adjustment ring spread jaw stroke

jm Locking discs

The adjustment ring can be turned a maximum of 3.5 revolutions.

Turning clockwise Expansion becomes smaller (gripper in position, as shown in the adjacent image)

Turning counter clockwise Expansion becomes smaller (gripper in position, as shown in the adjacent image)

The path which the piston for the spread jaws can be moved into is changed 9 by the rotation of the adjustment ring. Dimension A

The position of the limit stop jn determines how far the piston in slide into the cone 5 between the spread jaws 2.

9

jm

2

5

9

jn

A

inRevolutions Height adjustment Expansion

1 1 mm ± 1 mm

¾ 0.75 mm ± 0.75 mm

½ 0.5 mm ± 0.5 mm

¼ 0.25 ± 0.25 mm

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8. Troubleshooting

Issue Cause Remedies

O-ring not installed or pulled out again

Is the O-ring position on the spread jaw correct after being picked up by the gripper?

► Check the pickup position

Was the O-ring picked up correctly by the spread jaw?

► Check the immersion depth of the spread jaws

► Check the pickup position of the gripper

Is the gripper position to the workpiece correct and is the position of the O-ring to the recess correct?

► Check the exact position

Was the O-ring removed when retracting the gripper into the workpiece?

► Check the installation position, the gripper needs to be positioned exactly centrally above the workpiece

The distance between the spread jaws and workpiece is too small, the gripper cannot retract above the shaft.O-ring cannot slide into the ring groove and remains on the workpiece

► Increase the stroke of the spread jaws using the adjustment ring

9. MaintenanceIf the following points are observed, the gripper is maintenance-free for 5 million gripping cycles.

• Operation with compressed air in accordance with ISO 8573.1 with the following parameters: - Solid content class 2 - Moisture content class 4 - Oil content: Class 1 (unoiled air)• Clean environment• Use in accordance with performance data• Ambient temperature not over 60°C for long periods

If the requirements are not adhered to, the maintenance interval will be reduced according to the application case.

NOTE: Therefore we recommend using the Zimmer GmbH repair service for maintenance and the replacement of seals.

Dismantling and reassembling the gripper without authorization may result in complications as in some cases special installation equipment is required.

CAUTION! When dismantling a gripper with integrated springs (recognizable by the

spring symbol on the housing), use an apparatus that prevents the piston or piston cover from being expelled by the pre-tensioned springs.

► Risk of injury ► Disassembly must be carried out by Zimmer service personnel only!

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Pneumatic fittingStraight fittingGV series

Order No.: GVM5

plug-in connectorAngle, cable 5 mM8 female connector

Order No.: KAW500

Mounting blockHolder for inductive sensor

Order No.: KB6.5-02

plug-in connectorStraight, cable 5 mM8 female connector

Order No.: KAG500

Magnetic field sensorMFS seriesAngle, cable 5m

Order No.: MFS103KHC

plug-in connectorStraight, field-attachableInsulation displacement connectionSeries S, M8 connector

Order No.: S8-G-3

Magnetic field sensorMFS seriesAngle, cable 0.3 mM8 connector

Order No.: MFS103SKHC

plug-in connectorStraight, field-attachableInsulation displacement connectionSeries S, M12 connector

Order No.: S12-G-3

Universal jaw UBEjector jawSteel

Order with indication of gripper size

Inductive proximity switchContact-free, wear-free,short circuit-proof

Order No.: NJ8-E2S

Universal jaw UBSpread jawAluminum

Order with indication of gripper size

10. Accessories

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11. Declaration of incorporationin terms of the EU Machinery Directive 2006/42/EC (Appendix II 1 B)

Name and address of the manufacturer: Zimmer GmbH, Im Salmenkopf 5, D-77866 Rheinau, Germany, Phone: +49 7844 91380,

www.zimmer-group.de

We hereby declare that the incomplete machines described below

Product designation: pneumatic O-ring assembly gripper

Type designation: GS �� series

conform to the requirements of the Machinery Directive, 2006/42/EC, Article 2g, Appendix VII,b - Appendix II,b, in their design and the version we put on the market.The following harmonized standards have been used:•Basic health and safety requirements: No. 1.1.2, No. 1.1.3, No. 1.1.5, No. 1.3.1, No. 1.3.2, No. 1.3.4, No. 1.3.7, No. 1.5.1, No. 1.5.3, No. 1.5.4, No. 1.6.4, No. 1.7.1, No. 1.7.3.DIN EN ISO 12100:2011-03 Safety of machinery - General principles for design - Risk assessment and risk reduction•DIN EN ISO 4414 Hydraulic fluid power - General rules and safety requirements for hydraulic systems and

their components

A full list of applied standards is available for viewing at the manufacturer's facilities.Commissioning of the incomplete machine is prohibited until it has been found that - where applicable - the machine in which the above-mentioned incomplete machine is to be installed complies with the Machinery Directive (2006/42/EC).

Authorized representative for compiling the relevant technical documents

Kurt Ross See manufacturer's address Rheinau, Germany, 2/1/2016 Martin ZimmerFirst name, last name Address (Place and date of issuing) (legally binding signature)

Managing Partner

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12. Your notes

Documents

INSTALLATION AND OPERATING INSTRUCTIONS · Tapped holes 8 Screws with a screw class of 8.8 are to be used. Observe the permitted tightening torque The orientation is determined using