Schmalz FQE Series Bedienungsanleitung

Gripping System FQE

Assembly Instructions

WWW.SCHMALZ.COM EN-US · 30.30.01.02497 · 00 · 08/20

Note

The Assembly instructions were originally written in German. Store in a safe place for future reference.

Subject to technical changes without notice. No responsibility is taken for printing or other types of er-

rors.

Published by

This document is protected by copyright. J.SchmalzGmbH retains the rights established thereby. Repro-

duction of the contents, in full or in part, is only permitted within the limits of the legal provisions of

ten agreement from J.SchmalzGmbH.

Contact

J. Schmalz GmbH

Johannes-Schmalz-Str. 1

72293 Glatten, Germany

T: +49 7443 2403-0

[email protected]

www.schmalz.com

Contact information for Schmalz companies and trade partners worldwide can be found at:

www.schmalz.com/salesnetwork

2 / 48 EN-US · 30.30.01.02497 · 00 · 08/20

Contents

EN-US · 30.30.01.02497 · 00 · 08/20 3 / 48

Contents

1 Important Information ...................................................................................................................................5

1.1 Warranty and Liability ........................................................................................................................... 5

1.2 The technical documentation is part of the product ........................................................................... 5

1.3 Note on Using this Document ............................................................................................................... 5

1.4 Warnings in this document.................................................................................................................... 6

1.5 Symbol..................................................................................................................................................... 6

1.6 Type Plate ............................................................................................................................................... 6

1.7 Other Applicable Documents ................................................................................................................ 6

2 Fundamental Safety Instructions...................................................................................................................7

2.1 Intended Use........................................................................................................................................... 7

2.2 Non-Intended Use .................................................................................................................................. 7

2.3 Danger Zone ........................................................................................................................................... 7

2.4 Environmental and Operating Conditions............................................................................................ 8

2.5 Personnel Qualifications ........................................................................................................................ 8

2.6 Personal Protective Equipment ............................................................................................................. 9

2.7 Technical Condition................................................................................................................................ 9

2.8 Responsibility of the Integrator ............................................................................................................ 9

2.9 Country-Specific Regulations for the Operating Company ................................................................. 9

3 Product Description ......................................................................................................................................10

3.1 Description of the Gripper................................................................................................................... 10

3.2 FQE ... M................................................................................................................................................ 11

3.3 FQE ... Xb............................................................................................................................................... 12

3.4 FQE ... Xc ............................................................................................................................................... 13

4 Technical Data ...............................................................................................................................................14

4.1 General Parameters.............................................................................................................................. 14

4.2 Dimensions............................................................................................................................................ 16

4.3 Pneumatic Circuit Diagram (Version FQE ... Xc) ................................................................................. 17

4.4 Circuit Diagram for Valves (Version FQE ... Xc) .................................................................................. 18

4.5 Display Elements (Version FQE ... Xc) .................................................................................................. 18

5 Transport and Storage..................................................................................................................................20

5.1 Checking the Delivery .......................................................................................................................... 20

5.2 Reusing the Packaging......................................................................................................................... 20

6 Installation.....................................................................................................................................................21

6.1 Installation Instructions........................................................................................................................ 21

6.2 Mechanical Attachment....................................................................................................................... 21

6.3 Electrical Connection............................................................................................................................ 24

6.4 Pneumatic connection.......................................................................................................................... 26

7 Start of Operations .......................................................................................................................................28

7.1 Personnel Qualification........................................................................................................................ 28

7.2 Before Initial Start of Operations........................................................................................................ 28

8 Operation ......................................................................................................................................................31

8.1 Preparations.......................................................................................................................................... 31

Contents

4 / 48 EN-US · 30.30.01.02497 · 00 · 08/20

9 Troubleshooting............................................................................................................................................32

9.1 Safety .................................................................................................................................................... 32

9.2 Faults, Causes, Solutions ...................................................................................................................... 32

10 Maintenance..................................................................................................................................................34

10.1 Safety .................................................................................................................................................... 34

10.2 Maintenance Schedule......................................................................................................................... 34

10.3 Cleaning the Gripper............................................................................................................................ 35

10.4 Removing the Ejector Module............................................................................................................. 36

10.5 Disassembling and Cleaning the Silencer Inserts................................................................................ 37

10.6 Removing the Sealing/Suction Plate ................................................................................................... 38

10.7 Replacing the Sealing Plate (Foam)..................................................................................................... 38

10.8 Replacing Screw-in Suction Cups......................................................................................................... 39

10.9 Replacing Plug-in Suction Cups ........................................................................................................... 40

10.1

Accessories, Spare Parts and Wearing Parts........................................................................................ 41

11 Disposing of the Product..............................................................................................................................45

12 EC Conformity ...............................................................................................................................................46

Important Information

EN-US · 30.30.01.02497 · 00 · 08/20 5 / 48

1Important Information

1.1Warranty and Liability

J. Schmalz GmbH, as a supplier and manufacturer of vacuum technology, takes no responsibility for the

function of the product described below in a specific process.

The exact application parameters and the individual environment are decisive factors for selecting the

right components.

The specifications for our products are based on our current technical knowledge and experience, as well

as the available literature. We encourage you to test the products under the specific conditions that apply

to your application purposes, and we would be glad to use our experience to assist you.

The packaging material, the goods that are packaged, the fill level, porosity, surface condition, center of

gravity or the air content of the workpiece influence the entire handling process.

Following functional testing, different suction cup sizes, additional suction cups, a higher suction rate or

modifications to the configuration may be necessary.

Therefore, J. Schmalz GmbH accepts no liability and excludes all legal claims for damages.

The products and the configurator are subject to technical changes or further development without no-

tice.

We are not liable for any damage resulting from the use of non-original spare parts or accessories.

The exclusive use of original spare parts is a prerequisite for the proper functioning of the gripper and for

the validity of the warranty.

Wearing parts are not covered by the warranty.

1.2The technical documentation is part of the product

1. For problem-free and safe operation, follow the instructions in the documents.

2. Keep the technical documentation in close proximity to the product. The documentation must be ac-

cessible to personnel at all times.

3. Pass on the technical documentation to subsequent users.

ðFailure to follow the instructions in these Assembly instructions may result in life-threatening in-

juries!

ðSchmalz is not liable for damage or malfunctions that result from failure to heed these instructions.

If you still have questions after reading the technical documentation, contact Schmalz Service at:

www.schmalz.com/services

1.3Note on Using this Document

J.SchmalzGmbH is generally referred to as Schmalz in these Assembly instructions.

These Assembly instructions contain important notes and information about the different operating

phases of the product:

• Transport, storage, start of operations and decommissioning

• Safe operation, required maintenance, rectification of any faults

The Assembly instructions describe the product at the time of delivery by Schmalz.

Important Information

6 / 48 EN-US · 30.30.01.02497 · 00 · 08/20

1.4Warnings in this document

Warnings warn against hazards that may occur when handling the product. There are four levels of dan-

ger that you can recognize by the signal word.

Signal word Meaning

DANGER Indicates a high-risk hazard which, if not avoided, will result in death or se-

rious injury.

WARNING Indicates a medium-risk hazard which, if not avoided, could result in death

or serious injury.

CAUTION Indicates a low-risk hazard which, if not avoided, could result in minor or

moderate injury.

NOTE Indicates a danger that leads to property damage.

1.5Symbol

This symbol indicates useful and important information.

üThis symbol represents a prerequisite that must be met prior to an operational step.

4This symbol represents an action to be performed.

ðThis symbol represents the result of an action.

Actions that consist of more than one step are numbered:

1. First action to be performed.

2. Second action to be performed.

1.6Type Plate

The type plate is permanently attached to the product and must always be clearly legible.

The type plate contains the following data:

• Product key

• Product service number

• Order number

• QR code – access to the Schmalz app

4Please specify all the information above when ordering replacement parts, making warranty claims

or for any other inquiries.

1.7Other Applicable Documents

Depending on the configuration of the gripper FQE, the following operating instructions must also be ob-

served:

• The operating instructions for the ejector nozzle SEP

• The operating instructions for the vacuum switch VSi

Fundamental Safety Instructions

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2Fundamental Safety Instructions

2.1Intended Use

The product described below is a universal gripper and is therefore not limited to a specific application.

Due to its small size, low weight and energy efficiency, the gripper is suitable for applications on small ro-

bots or even for human-robot collaboration applications.

The system must be operated only at the supply voltage specified for the components.

The load must only be vacuum-gripped in the position defined in advance or on initial set-up of the prod-

uct.

Ensure that the load cannot slide or tip over during all phases of operation.

Use only the connections, mounting holes and attachment materials that have been provided.

The gripping system is built in accordance with the latest standards of technology and is delivered in a

safe operating condition; however, hazards may arise during use.

The maximum lift capacity must not be exceeded (> See ch. Technical Data).

2.2Non-Intended Use

Schmalz accepts no liability for damage caused by the use of the gripper for purposes other than those

described under Intended Use.

Non-intended use includes the following:

• Lifting people or animals

• Storing loads while picked up

• Supporting the lifting process by applying external forces

• Applying suction to building components, equipment or supporting surfaces.

• Applying suction to bulk materials (e.g. granulates)

• Evacuation of objects that are in danger of imploding

• Use in potentially explosive atmospheres

• Freeing building components or immovable equipment

2.3Danger Zone

Persons in the danger zone of the gripper may suffer life-threatening injuries.

Gripper operating modes

• Automatic operation on the industrial robot or gantry

• Collaborative operation on the lightweight robot (cobot)

For both operating modes, the system integrator must carry out a risk assessment of the entire system and

define the danger zone precisely. In doing so, country-specific provisions and regulations must be ob-

served.

Automatic operation on the industrial robot or gantry

• During automatic operation of the handling system, no persons or animals may be present in the

danger zone.

• In other operating modes, ensure that no unauthorized persons or animals are present in the dan-

ger zone.

• Ensure that collisions with the surrounding environment and objects do not occur to prevent the

load from breaking off.

During automatic operation of the handling system, the danger zone must be secured to prevent access

by persons (protective barrier or sensor system).

The danger zone of the gripper includes the following areas:

• The area directly below the gripper and load.

Fundamental Safety Instructions

8 / 48 EN-US · 30.30.01.02497 · 00 · 08/20

• The area immediately surrounding the gripper and load.

• The working area of the automatic handling system.

2.4Environmental and Operating Conditions

The gripping system must not be operated under the following conditions:

• In potentially explosive atmospheres

• In environments with acidic or alkaline media

CAUTION

Dangerous gases, vapors or dusts are sucked in and dispersed by the vacuum gen-

erator.

Difficulty breathing.

4Before commencing work, ensure that the ambient air does not contain any hazardous

substances.

4Make sure that there are no hazardous substances on the load that can be sucked in.

4If the ambient air is dusty, use a dust filter (particle size max. 5µm).

CAUTION

Blockage of the vacuum system from sucking in liquids

Risk of injury from falling load!

4Do not pick up liquids or bulk materials.

4Observe the vacuum display.

4If the suction of liquids cannot be avoided, use a water separator (contact Schmalz ser-

vice).

The gripping system must be operated only under the following conditions:

• The environment must be free from humidity, moisture, dirt, dust, oil or other climatic conditions

that may reduce friction levels.

• The gripping system must be sufficiently dimensioned for the loads to be lifted.

4If in doubt, consult Schmalz before the start of operations.

2.5Personnel Qualifications

Unqualified personnel cannot recognize dangers and are therefore exposed to higher risks!

The operating company must ensure the following points:

• The personnel must be commissioned for the activities described in these instructions.

• The staff must be at least 18 years of age and physically and mentally capable.

• The product must be operated only by persons who have undergone appropriate training.

• Personnel must receive regular safety briefings (frequency as per country-specific regulations).

• Work on electrical equipment must be carried out only by qualified electrical specialists.

• Installation, maintenance, and repairs must be carried out only by specialists from J.SchmalzGmbH

or by persons who can prove that they have undergone appropriate training at Schmalz.

The following target groups are addressed in these instructions:

• Mechanical and electrical specialists who are responsible for installing, troubleshooting and main-

taining the product.

Fundamental Safety Instructions

EN-US · 30.30.01.02497 · 00 · 08/20 9 / 48

The operator of the system must comply with country-specific regulations regarding the age, ability and

training of the personnel.

Valid for Germany:

A qualified employee is defined as an employee who has received technical training and has the knowl-

edge and experience – including knowledge of applicable regulations – necessary to enable him or her to

recognize possible dangers and implement the appropriate safety measures while performing tasks. Qual-

ified personnel must observe the pertinent industry-specific rules and regulations.

2.6Personal Protective Equipment

To avoid injury, always use appropriate protective equipment that is suitable for the situation. The protec-

tive equipment must meet the following standards:

• Protective work shoes in safety class S1 or higher

• Sturdy work gloves in safety category 2133 or higher

• Industrial helmet

• Ear protection class L or higher

• Eye protection class F

• Hair net

• Closely fitting clothing

2.7Technical Condition

If the product is operated while in a defective state, safety and function will be impaired.

• Only operate the gripper when in perfect working order as originally delivered.

• Follow the maintenance schedule.

• Use only original spare parts from Schmalz.

• If the operating behavior changes, check the gripper for faults. Rectify faults immediately!

• Do not independently modify or alter the gripper.

• Safety features must not be disabled under any circumstances.

Schmalz assumes no liability for consequences of modifications over which it has no control.

2.8Responsibility of the Integrator

The integrator is obligated to perform a risk assessment for the environmental conditions at the installa-

tion location.

The integrator is also responsible for third parties in the working area of the gripper. The operating com-

pany must ensure that they have the appropriate qualifications and skills.

• Ensure that regular breaks are taken.

• Ensure that the gripper cannot be started up by unauthorized persons.

• During maintenance or repair work, ensure that the gripper cannot be operated.

• Clearly define the responsibilities for the various activities performed with the gripper.

• Ensure that these responsibilities are observed.

• When handling unfamiliar loads, carry out tests where necessary to ensure safe operation:

– The load is sufficiently rigid that it cannot be damaged during handling.

2.9Country-Specific Regulations for the Operating Company

1. Observe the country-specific regulations regarding accident prevention, safety testing and environ-

mental protection.

2. The gripper is to be used in combination with an automated handling system (gantry/robot). Ensure

that the appropriate country-specific regulations and safety regulations are adhered to.

Product Description

10 / 48 EN-US · 30.30.01.02497 · 00 · 08/20

3Product Description

3.1Description of the Gripper

Gripping systems use a vacuum to lift defined products. One or more workpieces of different sizes can be

lifted. The gripping system achieves its maximum load-bearing capacity when all the suction cups or the

sealing foam are placed on an airtight workpiece with a smooth surface.

The handling system is responsible for the motion in the various axes (robot/gantry). The gripper is con-

nected to the handling system through the integrated threaded bushes or special robot flanges (> See ch.

Accessories).

The gripper FQE is available in three basic technical designs:

• Version FQE ... M, for an external vacuum supply

• Version FQE ... Xb, with internal vacuum generation

• Version FQE ... Xc, with internal vacuum generation and control of “suction” and “blow-off”

Each gripper is individual thanks to its customized design. Therefore, the grippers differ in detail in terms

of the size of the suction area, the number of vacuum generators (SEP), the arrangement and design of

the suction cups or suction cells in the sealing plate, the flow restrictors, etc.

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