guideline for modular gripping system tgt series · 2020-03-24 · tgt series . 31.07.2014 ver 1.0...

31.07.2014 ver 1.0

TÜNKERS Maschinenbau GmbH Am Rosenkothen 4-12 40880 Ratingen Germany Tel +49 2102/4517-0 [email protected] www.tuenkers.de

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Guideline for Modular Gripping System TGT Series

mailto:[email protected]

http://www.tuenkers.de/

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Documentation modifications

Date Subject Comment



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1. General Information ..............................................................................................4

1.1 Prolog ..................................................................................................................... 4 1.2 Contact.................................................................................................................... 4

Gripper System Categories .........................................................................................5 1.3 Handling Gripper Systems....................................................................................... 5 1.4 Processing Gripper Systems ................................................................................... 5 1.5 Fixturing Gripper Systems ....................................................................................... 5 1.6 Gripper Systems for Closures ................................................................................. 5

Benefits of TUNKERS-Gripper-Systems .....................................................................6 1.7 General requirements to gripper constructions ......................................................7

1.8 Clamping- and absorption technology ...................................................................9 1.9 Sequence of utilized TUNKERS-Gripper- Components ....................................... 10

2. Components Overview ...............................................................................................12 2.1 Octagonal profile .........................................................................................................16 2.2 Basic Frame ...........................................................................................................19 2.3 Adaptor robot frame ...............................................................................................20 2.4 Profile connections .................................................................................................21 2.5 Adapter ..................................................................................................................24

2.5.1 TGT100 ...........................................................................................................24 2.5.2 TGT119 ...........................................................................................................24 2.5.3 TGT120 ...........................................................................................................24

2.6 Connection tube 30 to 30 .......................................................................................25 2.6.1 TGT142 ...........................................................................................................25 2.6.2 TGT143 ...........................................................................................................25 2.6.3 TGT144 ...........................................................................................................25

2.7 Clamping connection ..............................................................................................26 2.7.1 TGT182 ...........................................................................................................26 2.7.2 TGT244 ...........................................................................................................26 2.7.3 TGT245 ...........................................................................................................26 2.7.4 TGT289 ...........................................................................................................27 2.7.5 TGTxxx ...........................................................................................................27 2.7.6 TGTxxx ...........................................................................................................27

2.8 Standard parts ........................................................................................................28 2.9 General assembling instructions: ........................................................................ 30

2.10 Torques ..................................................................................................................30 2.11 Important and considered assembly guidelines ......................................................31 2.12 Nord-Lock® washers ..............................................................................................33 2.13 Blind rivet nuts ........................................................................................................34 2.14 Assembly ...............................................................................................................35

2.14.1 Single horizontal connection............................................................................35 2.14.2 Single vertical connection ................................................................................35 2.14.3 H base frame ..................................................................................................36

2.15 Pneumatic and electrical components ....................................................................37 2.16 List of refercences: ............................................................................................ 38



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1. General Information

1.1 Prolog

The Tünkers-Gripper-Tooling is based on a modular-based principle. The concept is based on an octagonal profile which facilitates modular integration of clamping and centering units for gripper in body-in-white via connectors, adapters and tubes. In the European car manufacturing is usually used as:

- Handling system built on Robots

- Fixture building system for floor mounting operations

- Flexible system for any kind of support, stand or loading station

Although established as a common standard for BMW, VW, AUDI and Daimler, each OEM developed his own derivate on it. Patents for the basic TGT system are pending in dedicated European counties. Outside Europe there are no restrictions for marketing, selling or usage of the TGT components and systems.

1.2 Contact

Mr. Matthias Heina, Productmanager Gripper-Technology E-Mail: [email protected] Fon: +49 2102 4517-282 Fax: +49 2102 4517-9999




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Gripper System Categories

TUNKERS offers special gripper systems for specific customer requirments, which are explain in the following explanations:

1.3 Handling Gripper Systems Handling Gripper Systems transfer components or component assemblies. The component is at various stages of assembly. Typical applications for the Part Handling Gripper System are the moving of assemblies between work or rest stations, unloading and loading of turnover systems, or storage pallets. The structural accuracy required of Handling Gripper Systems is less than that required in Processing and Assembly Fixture Gripper Systems. The frame structure can be lighter due to the lower forces acting upon the Gripper.

1.4 Processing Gripper Systems Processing Gripper Systems move the component or subassemblies through a production process. Applications for Processing Gripper System include, passage of the part through welding, riveting, piercing, or adhesive apply operations. Potential high stress forces during these operations, as well as a greater accuracy requirement of locating and clamping points, demand a more rigid frame structure on the Processing Gripper Systems.

1.5 Fixturing Gripper Systems Fixturing Gripper Systems usually replace the fixture in the process. The greatest demands in terms of accuracy and rigidity are made on these systems, since undue flexibility in the Gripper System structure directly influences accuracy of the part form or size. Appropriately designed and closely toleranced clamping and positioning components ensure correct location of these parts during the production process. A fixturing Gripper System normally combines the load function (manual or automated) with the process function described above (such as spot welding by ped welder).

1.6 Gripper Systems for Closures These include handling, processing and fixturing gripper systems for doors, hoods, trunk lids, etc. The extreme part tolerance requirements (gap widths), sensitive vehicle exterior surfaces and materials such as aluminum of these parts create special demands on the Gripper Systems.

This also applies to systems in which smaller parts are pressed into place or operated on as in seam folding, staking or hammering (force requirements are comparable to those of a conventional handling unit!) For this reason, in spite of possible smaller part dimensions and weights, the frame structures must be designed as rigidly as possible with precisely dimensioned contour locating components. Optimal design assures correct positioning of the part in the gripper system.1

1 Mercedes-Benz-Cars, Standard Specifications, p.9-11.



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Benefits of TUNKERS-Gripper-Systems

The Gripper System provides many benefits as listed:

Form controlled main geometry

Simple assembly, 2-4 weeks faster than other gripper type

Repeatability in case of damage due to accurate increments of assembly bores

In theory no measuring is required

Shortens timeline to project

No spare grippers necessary

Easy implementation of change

Unlimited sizing possible: underbody, body side and doors.



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1.7 General requirements to gripper constructions2

The longitudinal profiles of the basic frame generally have to exectued in Profile SW80

Basic frames have to deliver in tight fit

The construction has to arrange with standard components and the construction standards of VW have to be consider

Every standard component is registered in stock lists with an TGT or VGT-No.

Reworking of TGT-components is not acceptable, exception: TGT 192

After start-up of the gripper, as needed, TGT-192-components have to cut to required dimension + 10mm

Special parts are only acceptable after clearance with construction department. This special parts must be produced in steel

The path between carrier section and clamp point must be very short

Bending strength and torsion resistance of the carrier section is to consider

Maximum length of TGT 006 (steel tube Ø 30mm x 3,5mm) between the connection elements amounts to 300mm is to consider

Maximum allowed robot loads with robot handling (inclusive panel) may not be exceed

Blind rivet nuts for profile SW 50 are only settable through 90°, that is constructive to consider

Each clamp– and absorption assembly is keenly to dimension to build them in the workshop and change them at the gripper

The grippers have to be designed parallel simultaneously to the jig

Required interfering contour distance depends on biggest gripper dimension (span length) Dimensions for Gripper/Device:

Length ≤ 800 mm => 10 mm 800 mm < L ≤ 1600 mm => 15 mm L > 1600 mm => 20 mm

2 VW-Assembling guideline (2013), p.8.

Blind rivet nuts for profile SW 50 can only set through 90°



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Each gripper with a total weight over 15 kg has to be prepare with two lifting means.

Used: Load ring VLBG 0,3t M8 special length H=15mm without nut. The mounting occurs with blind rivet nuts M8 in the basic frame. The assembling position has to determine already at construction. Load stands generally have to gather in stocklist. At working process the load straps have to set with cable fixers

Aluminum-Installation boards for pneumatic and electric have to defined during the constructions and consider at Robcad-examination

At apparent surfaces and fold adaptors do not set pendulum measurements

Each clamping-assembly shall adjustable in required directions und particularly changeable

All main dimensions of clamping- and absorption points have to dimension on the assembly drawing

S-Green-Contour blocks at suction device are required for car body shell and aluminum panels

Components in Contour blocks-absorption can be fixed via position adapter for sliding

During assignment of vacuum-suctions devices is a double-circle-system required, it has to be guaranteed in case of air leak, the component may not drop

For the control of clinch devices and welding guns it is necessary to attach an reference edit format at the gripper

Standard diameter for initiators amounts to 18 mm (diameter of small parts: 12 mm)



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1.8 Clamping- and absorption technology

Following components of clamping- and absorption technologies are permissible to set in grippers: Standard:

- Alpha-clamp Size 40 (clamp with adjusting function and power curve):

- Clamp-Typ: TUNKERS APH 40.5 H BR2 A60 T12 (with integrated pneumatic self-locking function in housing)

- Clamp-Typ: TUNKERS APH 40.5 V Z RR/RL A60 T12 (clamp with hand lever and locking disc)

- Retracting pin cylinder: Size 30/32 with 40mm-lifting-function

Size 40 if lifting > 40 required

- TUNKERS SZK 30.7 T12 - TUNKERS SZK 40.1 T12 Lifting: 60mm

- Clamping gripper: Size 40

Typ: TUNKERS APG 40.1 AS BR2 A15 (25) T12

Following clamps are only approved after agreement and clearance of PMT/A1: TUNKERS Clamps:

- Retracting pin cylinder: SZK D 40 T12

- Vario clamp: V40.5 A60 T12

- Clamp with hand lever: APH 40.5 V Z RR(RL) A60 T12



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1.9 Sequence of utilized TUNKERS-Gripper- Components

Available types of plates, depending on the Customer requirements:3


TGT017: H-Basic frame 450x600

TGT017 H-Basic frame 300x450

TGT040: Robot flanged plate SW 80

TGT042: Robot flanged plate SW 80

vertical



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Octogonal profiles:

Specific types of connections:

TGT001: Octogonal Profile SW 80x4078 mm

TGT002: Octogonal Profile SW 50x4078mm

TGT006: Round Profile 30x2,5x1000mm

TGT081-TGT085: Cross conncections in

several sizes

Other types of connections:TGT119, TGT120, TGT100, TGT142, TGT144 Clamping connection, flat connection, Universal connection



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2. Components Overview4

4 VW-Assembling guideline (2013), p.16-21.

Picture Component TG-No. Discription Dimension Weight

Octogonal Profile

TGT001_4078 xxxxx

Octogonal Profile SW 80x4078mm with misalignment hole ranging from

208-4078mm In 30mm Increments (129 lenghts)

1x4078mm 4,87kg/m

TGT002_4078 xxxxx

Octogonal Profile SW 50x4078mm with misalignment hole ranging from 208-

4078mm In 30mm Increments (129 lenghts)

1x4078mm 2,05kg/m

TGT006_448 262412

Round Profile 30x2,5x1000mm ranging from 73-358mm In 15mm Increments

(25 lenghts)

1x1000mm Production –

length 1,4kg/m

Basic Frame

TGT016.1 262242 H-Basic frame 300x450 SW80 1 Part 12kg

TGT017.1 258049 H-Basic frame 450x600 SW80 1 Part 24kg



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Picture Component TG-No. Discription Dimension

Adaptor robot frame

TGT040 268846 Flanged plate SW80 1 Set of 2 pieces

TGT041 268847 Flanged plate SW80 90° 1 Set of 2 Pieces

TGT042 268849 Flanged plate SW50/SW80 vertical

1 Set of 3 Pieces

TGT043 268851 Flanged plate SW50 1 Set of 3 Pieces

TGT046 258048

Locating adaptor SW80 with connection to the standard robot flanged platte

1 Set of 2 Pieces

TGT047 266802 Locating adaptor SW80 with connection to the

standard robot flanged plate 90° 1 Set of 2 Pieces


standard robot flanged plate vertical 1 Set of 2 Pieces


standard robot flanged plate 1 Set of 2 Pieces


standard robot flanged plate vertical5

1 Set of 3 Pieces



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Picture Component TG-No. Discription Dimension Weight

Profile connections

TGT080 262244 Cross connection SW80/SW80 1 Part

TGT081 257591 Connection 90° SW80/SW80 1 Part 0,8kg

TGT082 262245 Cross connection SW80/SW80 1 Part


TGT084 262254 Cross connection SW50/SW50 1 Part 1,2kg


Adaptor

TGT100 262259 80RD30-X90 1 Part

TGT119 257596 Standard Foot 80, SW80-RD30-L90 1 Part

TGT120 257597 Standard Foot 50, SW50-RD30-L906 1 Part



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Picture Component TG-No. Discription Dimension

Connection tube 30 to 30

TGT142 257598 RD30-30-X90 KE 1 Part

TGT143 257599 RD30-30-L90 KE 1 Part

TGT144 257600 RD30-30-L135 KE 1 Part

Clamping connection

TGT183 267602 50-63 Clamping-V 1 Part

TGT182 262284 50-63 Clamping 1 Part

TGT244 284814 Flat connection SW50 short 1 Part

TGT245 284816 Flat connection SW80 short 1 Part

TGT289 257603 Universal connection D30 4kt-50x50 1 Part

TGTxxx xxxxxx Angle positioning 65x100x50 1 Part

TGTxxx xxxxxx Angle positioning 1 Part

Standard parts

TGT212 258206 Positioning Vario Handling System 1 Part

TGT213 268136

Full and Sword Pin Vario Handling

System 1 Set of 2 Pieces

TGTxxx xxxxxx Blind rivet nuts 1 Part

TGTxxx xxxxxx

Cable clips and hose routing for the basic frame

1 Part

TGTxxx xxxxxx Nord-Lock washers 1 Part

TGTxxx xxxxxx Pin with bushing for frame members 1 Part

TGTxxx xxxxxx Load ring 1 Part

TGTxxx xxxxxx

Push button system “Tenax” for fixing Nipolan coverage

1 Part



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2.1 Octagonal profile7

TGT001: Name: Octagonal Profile SW 80x4078mm

Weight: 4,87 kg/m

Lengths available: 208-4078 mm (in 30mm increments)

7 VW-Assembling guideline (2013), p.23



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TGT 0028: Name: Octagonal Profile SW 50x4078mm

Weight: 2,05 kg/m





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TGT 0069: Name: Round Profile SW 30x3, 5x1000mm

Weight: 1,40 kg/m





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2.2 Basic Frame

TGT016.1 Name: H-Basic frame 300x450mm SW80

Weight: 12 kg

TGT017.1 Name: H-Basic frame 450x600mm SW80

Weight: 24 kg

Standard part Qty.

Washer 32

Hexagon socket head screw M8x30

32

M8 Blind river nut 35

Centering pin 5

H-Frame 1

Standard part Qty.

Washer 32


32


Centering pin 5

H-Frame 1



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2.3 Adaptor robot frame

TGT052 Name: Locating adapter SW80 Weight: 9,3 kg

TGT054 Name: Locating adapter SW80 vertical Weight: 10,8 kg

10

VW-Assembling guideline (2013), p.27. 11

VW-Assembling guideline (2013), p.28.

Standard part Qty.

Bracket 1

Retainer adapter 1

Cylinder screw DIN 912 M8x30 10



Shim 10

Standard part Qty.

Bracket 1

Retainer adapter 1




Shim10

1011



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2.4 Profile connections12 TGT080 Name: Cross connection SW80/SW80

Weight: 1,7 kg

Standard part Qty.

Washer 16


16


Centering pin 2

Cross connection 1

TGT081 Name: Connection 90° SW80/SW80 Weight : 0,8kg

TGT082 Name: Cross Connection SW80/SW50 Weight: 1,6 kg

12


Standard part Qty.

Washer 12


12


Centering pin 2

Cross connection 1

Standard part Qty.

Washer 12


12


Centering pin 2

Cross connection 1



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TGT083 Name: Connection 90° SW80/SW50

Weight: 0,75 kg

Standard part Qty.

Washer 12

Hexagon socket head screw M8x30 12


Centering pin 2

Cross connection 113

TGT084 Name: Cross Connection SW50/SW50 Weight: 1,2 kg

TGT085 Name: Connection 90° SW50/SW50 Weight: 0,8 kg

13




Standard part Qty.

Washer 8



Centering pin 2


Standard part Qty.

Washer 12



Centering pin 2




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TGT089 Name: Triple Connection for octogonal profile SW80-SW80-SW80 Weight: 1,9 kg

TGT090 Name: Triple Connection for octagonal profile SW80-SW80-SW50 Weight: 1,8 kg

16


Ibidem

Standard part Qty.

Washer 18



Centering pin 3


Standard part Qty.

Washer 18



Centering pin 3




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2.5 Adapter

2.5.1 TGT100

Name: 80RD30-X90 Weight: 0,7 Kg

2.5.2 TGT119

Name: Standard Foot 80, SW80-RD30-L90

Weight: 0,53 kg

Designation Qty.

Centring pin 1

Blind river nut 4

Cylinder screw M8x30 4

TGT 119 1


Schnorr disc 8.4 5

2.5.3 TGT120

Name: Standard Foot 50, SW-RD30-L90

Weight: 0,39 kg

Designation Qty.

Centring pin 1

Blind river nut 4


TGT 119 1


Schnorr disc 8.4 5

Designation Qty.

80RD 30-x90 1

Fitting screw 1

Slot nut 1

Centring pin 1

Blind river nut 4


Shim DNL8F 4

Clip collar RD30 2


Schnorr disc 8.4 4



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2.6 Connection tube 30 to 3018

2.6.1 TGT142

Name: RD30-30-X90KE

Weight: 0,35 kg

Designation Qty.

TGT 142 RD30-30-X90KE 1


Schnorr disc 8.4 2

2.6.2 TGT143

Name: RD30-30-L90KE

Weight: 0,41 kg

Designation Qty.

TGT 143 RD30-30-L90KE 1


Schnorr disc 8.4 2


Schnorr disc 6.4 2

2.6.3 TGT144

Name: RD30-30-L135KE Weight: 0,38 kg

Designation Qty.

TGT 144 RD30-30-L135KE 1


Schnorr disc 8.4 2

18




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2.7 Clamping connection19

2.7.1 TGT182

Name: 40-50 Clamping V

Weight:

TGT183

Name: 40-50 Clamping

Weight:

2.7.2 TGT244

Name: Flat connection SW 50 short Weight:

2.7.3 TGT245

Name: Flat connection SW80 short

Weight:

19


Designation Qty.

TGT 244 Flat connection SW50 1

Centering pin 1

Blind river nut 4


Washer DNL8F 4

Designation Qty.

TGT 245 Flat connection SW50 1

Centering pin 1

Blind river nut 6


Washer DNL8F 6



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2.7.4 TGT28920

Name: Universal connection D30 4kt-50x50 Weight: 0,27 kg

2.7.5 TGTxxx

Name: Angle positioning 65x100x50

Weight: 0,28 kg

2.7.6 TGTxxx

Name: Angle positioning 65x100x50

Weight: 0,28kg

20




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2.8 Standard parts

Aluminum-baffle plate for locating pin cylinder Thickness: 16mm and 32mm

Adaptor plate for pins and hand clamp

Strain-relief for valve cluster

Mounting plate for parallel gripper, PGN-plus 80

Mounting plate for parallel gripper, PGN-plus 100

Blind rivet nuts M8



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Cable clips and hose routing for basic frame

Nord-lock washers

Pin with bushing for frame members

Centering pin for gripper system

Load ring

Push button system Tenax for fixing Nipolan coverage



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2.9 General assembling instructions21

: The basic frame has to be positive and repeatable

For the Handling Gripper Systems and Processing Gripper Systems all assemblies, besides the basic frame, have to connect positive

For Geo Gripper Systems the assemblies can be can be connect positive and tunable

During the assembling the positions have to be set-out and after that the ring pins have to remove. The setting-out is an appliance for the assembling. Afterwards the Grippers have to calibrate (with calibration-journal) and all TGT-components, starting with the basic frame, have to seal with varnish

At contempt of the modular dimensions, the reproducibility of the positions by center marks is essential

For assembling please only use delivered and required screws and blind rivet nuts

For basic frame and aluminum-components only use the required washers. The listed Nord-Lock-washers are accordingly dimensioned, that no setting back appears by dynamic strain

Never exceed the maximum torque moment, otherwise the allowed bearing pressure will too high. This yields to a loosening blasting of the clamp

To avoid deformation and misalignment keep the clamping surface clean

The assembling of Gripper frames has to take place from outwards to inwards

Attention should be paid to the setting of the blind rivet nuts, which firstly have to set to the profile. After assembling of the frame the accessibility for the setting device is

Requirement to achieve the necessary holding force: All screws have to set with the prescriptive torque. See following table for tightening torque:

2.10 Torques The following table shows the tightening torques for all screw used:

Designation Torque

Connection to octagon profile with screw M8x30 33 Nm

Clamp TGT 205 with screw M8x35 20 Nm

Fitting bolt TGT 201 M6x36 12 Nm

Fitting bolt TGT 202 M6x50 12 Nm

Clamping element connection with screw M6 12 Nm

Clamping element connection with screw M8 20 Nm

Clamping element connection, nut, clamping mandrel M10 33 Nm

TGT 210, 211 brackets for robot flange plate with screw M10 40 Nm

TGT 208, 209 brackets for perpendicular connection, screw M12 66 Nm

Quick change device, screw M10 70 Nm

CAUTION: At first all screws have to set hand-tight. Subsequent with the prescriptive torque the screws have to mutually retorque

21




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2.11 Important and considered assembly guidelines

Half-shell must lie with form fit in the V-shape on the profile

Assembly sequence

First assemble outside frame, then inside frame. Example: First screw all parts together loosely, then first tighten the M8 screws, profiles with 90° angle and then tighten the screws of the H-frame. All screws must be set in the H-base frame.

First tighten screws by hand alternately and then retighten alternately to a torque of 33 Nm.

Order of correct tightening of a screwed connection

Blind rivet nuts must not project

Surface contact between the two profile surfaces and the two half-

shell surfaces

Set 12 screws



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Sources of error at assembling process:22

Required Assembling tool: Torque wrench in the range of 10 to 80 Nm:

Application for hexagon socket SW 5 mm




22


Centering pin TGT 213 inadequately stamped or missed

Steel tube TGT 006 inadequately in foot insert



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2.12 Nord-Lock® washers23

To secure a safety mutually locking the screws firstly have to tighten hand-tight. Afterwards the screws have to release through 90° and then to tight with the given torque.

Based on different angles the screw locks itself. The dimension of the Nord-Lock®-locking washers-pair is bigger than the longitudinal shift alongside the thread. The Nord-Lock®-locking-washers safe each screw connection, even if they have to face extreme vibration or dynamic loads.

CAUTION: Always shore in pairs

Correct use

Incorrect use

23




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2.13 Blind rivet nuts24

Installation process:

Setting device Octogonal profile SW 50 Octogonal profile SW 80

CAUTION: Blind river nuts only through 90° applicable

At assembling process the heads of the blind rivet nuts may not overlap the profile surface. To avoid overlapping the following points must be to consider:

Correct setting of the snap heads for the combination of SW80-profile and blind rivet nuts to check the torque of 35 Nm by conduction of ten bolting tests

Blind rivet nut has to set vertical to the surface

Setting hub of the blind rivet device must be set between 4,0 and 4,2 mm

In face of quality controls it can happen that in individual cases the abatements of the profiles are not 0,7 – 1,0mm deep. In that case: Profile has to claim and change or

24




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2.14 Assembly

2.14.1 Single horizontal connection

Attention: guarantee the maximum values by using the calculation formulas!

2.14.2 Single vertical connection

It is really important to assure the right assembling sequence for the vertical connection. For that reason, it is strongly recommended to follow the following steps: 1) Pin (5) bracket (1) with retainer adapter (3) and screw together with 66 Nm. 2) Screw together 8-edged profile (4) and bracket (1) and fasten with 33 Nm. 3) Screw together alternately bracket (2) on the 8-edged profile (4) and retainer adapter (3) until hand-tight and then fasten alternately with the appropriate torque!



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2.14.3 H base frame

Attention: guarantee the maximum values by using the calculation formulas! TGT016 300X450

TGT017 600X450



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2.15 Pneumatic and electrical components

All pneumatic and electrical components are subject to customers standards.



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2.16 List of refercences:

1. Daimer-Benz-Cars, Standard Specifications, Version 05.00

2. VW-Guideline, 14 D 300 647, 01.10.2013



guideline for modular gripping system tgt series · 2020-03-24 · tgt series . 31.07.2014 ver 1.0...

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