pneumatically actuated clutch/brake combined unit series 0 406

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1 Technical product information No. 650 EN pneumatically actuated clutch/brake combined unit series Contents Page About this Technical Product Information (TPI) 2 The ORTLINGHAUS numbering system 2 About the product 3 Delivered state 4 Spare parts 5 Initial assembly and commissioning 6 Maintenance 10 Complete assembly - only for customer service 13 Fault finding 20 Edition: Ortlinghaus-Werke GmbH Postfach Wermelskirchen Kenkhauser Str Wermelskirchen Deutschland Phone Fax Internet

2 About this Technical Product Information (TPI) Who is this TPI directed at? This TPI is directed at qualified personnel who are entrusted with the assembly, commissioning and operation of the product and who have obtained the necessary qualifications by reading and understanding the instructions by training or instruction It is intended for Fitters at the manufacturer of the machine / plant Maintenance fitters at the machine users. What will you find in the TPI? The TPI provides all the necessary information for the assembly and maintenance of the product described on the title page Notes on the symbols used in the text On the pages which follow, important sections of text are highlighted with the following symbols. This symbol means: There is a risk of injury during the activity described or in operational running! This symbol means: There is a risk of material damage during the activity described or in operational running! This symbol indicates sections of text to which particular attention must be paid. The Ortlinghaus numbering system Example: = Code for products Code number for the model rage Code number for design features Size Sequencial number Other design features Pass this TPI on to your customers! You can either order further copies of this TPI from us or you are free to make copies, for use by your customers. 2

3 About the product Purpose and mode of functioning of the clutch/brake combined unit Single plate clutch/brake combined units are well suited for high torques even where the thermal loading is high, e.g. in the accelerating and deceleration of heavy gyrating masses with high engaging/disengaging frequencies. They are used above all in presses and guillotine shears. Do not use clutch/brake combined units in rooms with high air humidity or in which the air contains oil. Otherwise there is the risk that the plates will slip and the action of the brake will be significantly reduced /6 A Fig. 1: Function of the clutch/brake combined unit Braking: Springs 5/6 press against the piston 2 in the cylinder 1.2. The piston 2 pulls the pressure plate 7 with brake plate 14 against the friction surfaces of the hub 1.1 by means of the bolts 8/9 and screws 11, thus activating the brake. Engaging the clutch: Compressed air is applied to the piston via air intake A. This causes brake plate 14 to be released and clutch plate 13 to engage. The normal operating pressure is 5.5 bar, the maximum permissible pressure 6 bar. Never operate the clutch/brake combined unit with a higher pressure since this can lead to the risk of the cylinder breaking. Always use dustfree, dry compressed air (a maintenance unit is required). Set the oiler of your maintenance unit so that it delivers from 1 to 2 drops of oil per m³ air. It is essential that the friction linings are kept free of oil. 3

4 Delivered state The clutch/brake combined units are delivered in a fully assembled state (exception: clutch plate). Different ways in which the plates are suspended The clutch and brake plates can be suspended in one of three different ways: Twelve-point suspension of the plates series Two-point suspension of the plates series series Combined suspension of the plates series series series Different friction linings The clutch/brake combined units can be fitted with one of two different kinds of friction linings: - with lining segments which are glued or riveted on - with friction blocks Housing plates with friction blocks series Combination of housing plates with series friction blocks and plates with friction series segments series Special versions Clutch/brake combined units with twelve-point suspension can be fitted with six spring pots per plate, these being positioned at intervals of 60 to one another, in order to give quieter running when the clutch is disengaged. In addition in the case of the twelve-point suspension of the plates, two damping studs (studs with spring-loaded balls) displaced at 120 to one another can be fitted. The balls must point outwards. These keep the unit free of play when the clutch is running disengaged. These can be retrofitted whereby two sleeves are removed. Clutch/brake combined units can be fitted with fan blades to give additional forced cooling. 4

5 Spare parts Our guarantee for our products only applies when you use original Ortlinghaus spare parts. 00 / Abb. 2: Fabrication number Please order spare parts only in writing. You will find the fabrication number, under which your clutch/brake combined unit was manufactured, punched on the hub next to the position mark. Always state this number. It is made up of two digits for the year and a consecutive number, e.g. 00/ In addition state if possible the article number of your clutch/brake combined unit. In the appendix you will find the list of spare parts; this includes the designation of each part and its item number, the latter being also shown on the blow-up drawing. State both this item number and the designation when ordering: 0 = Code number for products Code number for clutch/break type Code number for standard version characteristics Size Consecutive number

6 Initial assembly and commissioning Installation with twelve-point suspension of the plates Fig. 3: Twelve point plate suspension The plates are already in place when delivered. The brake plate halves are held by spring pressure, the clutch plate halves by means of the securing straps. For reasons of space, it can be necessary to remove the clutch plate in order to enable the clutch/brake combined unit to be installed. Do this before you mount the clutch/brake combined unit on the driven shaft. Mount the clutch/brake combined unit on the driven shaft with two feather keys or with clamping sets. The brake plate halves will no longer be held and will fall out if you apply compressed air to the clutch/brake combined unit. Ensure that this cannot happen by, for example, tightening up a number of screws or inserting metal pins provisionally. Apply compressed air to the clutch/brake combined unit. Align the brake plate until the holes in it coincide with those in the machine. Insert sleeve 15 Tighten up self-locking screws 16 to the prescribed torque (see table on page 8). Turn the flywheel or, as the case may be, the toothed wheel until a securing hole is opposite a recess in the brake plate. Insert one of the clutch plate halves if the clutch plate has been removed. Insert sleeve 15 Tighten up self-tightening screw 16 to the prescribed torque (see table on page 8). Insert the remaining five sleeves and tighten up the screws. Proceed in the same way with the other plate half. 6

7 Always fit the clutch plate securing straps on the brake side. Secure the plate halves with two straps 13.4 ( up to size 90 four straps 13.4 and 13.4a). Lock the screws with Loctite type 262 or a similar material a Fig. 3a: Twelve-point mounting up to size 90 7

8 Installation with twelve-point suspension of the housing plates (friction block version) Fig.4: Twelve point plate suspension (friction block version) The housing plates are already in place when the unit is delivered. The brake housing plate halves are held in place by spring pressure, the clutch housing plate halves are loose. Remove the clutch housing plate halves. Mount the clutch/brake combined unit on the driven shaft with two feather keys or with clamping sets. The brake housing plate halves will no longer be held and will fall out if you apply compressed air to the clutch/brake combined unit. Ensure that this cannot happen by, for example, inserting a number of screws or metal pins provisionally. Apply compressed air to the clutch/brake combined unit. Align the brake housing plate until the holes in it coincide with those in the machine. Insert sleeve 15 Tighten up screws 16 to the prescribed torque (see table on p. 6). Turn the flywheel or, as the case may be, the toothed wheel until a securing hole is opposite a recess in the brake housing plate. Insert one of the clutch housing plate halves. Insert sleeve 15 Tighten up screw 16 to the prescribed torque (see table on p. 6). Insert the second sleeve and tighten up the remaining screws. Proceed in the same way with the other clutch housing plate half. Tightening torques for the screws 16 for the different sizes of clutch/brake combined unit. - Strength class: Locking agent: Loctite 262 Size Nm 8,

9 Installation with two-point suspension of the plates 19/ / Fig. 5: Two-point mounting On the brake side the round stud must be fitted at the top. If this is not done, knocking may occur at braking. The square stud permits longitudinal alignment to be carried out in the radial direction. Trim and fit the studs so that there is no play and secure with the small securing straps 19/26. Place lugs 13.2/20.2 to which the shoulder bushes have been fitted on to the studs. Remove the clutch plate. Mount the clutch/brake combined unit on the driven shaft with two feather keys or with clamping sets. Insert the clutch plate again. Screw the plate halves to the lugs tighten up the screws to the prescribed torque (see table below). Installation with combined suspension of the plates Installation is carried out in an analogous manner to that for twelve-point and two-point suspension. Anzugsdrehmomente der Sechskantmuttern Tightening torques for the hexagon head cap screws Strength class: Nuts 8, screws Locking: Locking agent Loctite 262 Size Nm

10 Maintenance Check during operation of the clutch/brake combined unit Check the wear at the air gap between the clutch plate/friction block and the piston. As the friction linings wear down, the braking time increases. When the air gap has become equal to the maximum permissible friction lining wear (see table below), you must change the plates/friction blocks.check in each case the friction lining counter surfaces for wear or scoring (request technical service if necessary). air gap /6 Fig. 6: Checking for wear Air gap between the clutch plate/friction block and piston in mm Size new 0,7 0,8 0, ,2 1,3 1,5 1,7 max 4,7 4,8 5, ,2 12,3 13,5 15,7 Removing and fitting the plates/housing plates Make certain that no unintended machine movement can take place when the brake plate is removed. Place blocks, for example, below the press ram. Follow the correct sequence when removing/refitting the plates: - Removal: first the clutch plate, then the brake plate - Fitting: first the brake plate,then the clutch plate To prevent this type of damage, check the air gap between the clutch plate/friction block and the piston regularly. Do this when the brake is applied. In the case of twelve-point suspension, always fit the clutch plate securing straps on the brake side. 10

11 re-install pressure plate and bolts. tighten screws to respective torque. re-check the air gap. Tightening torques for screws 11 - stress classification: replace after dismantling Size Nm 4,1 8, Twelve-point suspension of the plate Fig. 7: Twelve-point suspension Remove the straps which hold the two clutch plate halves together Remove the clutch plate securing screws. There are recesses in the brake plate to simplify this 16. Remove the clutch plate halves. Apply compressed air to the unit. This will create the necessary space for removing/refitting the brake plate. The brake plate is removed in the same way as the clutch plate. Refitting is carried out in the reverse order to that for removal. 11

12 Twelve-point suspension of the housing plates (friction block version) Fig. 8: Twelve-point suspension Remove the clutch housing plate securing screws 16. Remove the clutch housing plate halves. Apply compressed air to the clutch/brake combined unit. This will create the necessary space for the removal and refitting of the brake housing plate. Removal of the brake plate is carried out as for the clutch housing plate. Refitting is carried out in the reverse order to that for removal. Two-point suspension of the plates Fig. 9: Two-point suspension Remove the lug screws 13.3 and remove the clutch plate halves. Apply compressed air to the clutch/brake combined unit. This will create the necessary space for the removal and refitting of the brake plate. Removal of the brake plate is carried out as for the clutch plate. When refitting, first place the lugs 13.2 on the studs and then screw the plates to the lugs. Refitting is carried out in the reverse order to that for removal. Setting the oiler Check the setting of the oiler regularly. It should deliver 1 to 2 drops of oil per m 3 air. 12

13 Complete assembly - only for customer service (see attached explosion drawing) Dismantling of the Clutch/Brake Remove the plates/housing disc. Pull the clutch/brake combination out of the shaft by use of the two extractor bores found on the brake-side of the combination. Remove two screws 1.3 which are situated at 180 angle on the clutch side. This will open the extractor bores for use /6 1.3 Fig. 10: Dismantling Remove all screws 1.3. Remove the cylinder 1.2. Place the clutch/brake on the face of the piston 2. Remove the screws 11 on the pressure plate 7 by loosening respective opposite screws slowly and at an equil rate to release the tension of the springs 5/6 equilly. Further dismantling of the clutch/brake as per explosiondrawing. 13

14 Assembly of the dismantled clutch/brake Before assembling, clean all sealing surfaces /6 A 1.1 Abb. 11: Assembly Place the pressure springs 5/6 in the hub at equil distance from each other. Treat O-Rings and their seats with lithium grease. Place O-Rings into the piston and hub by use of a rounded-off tool. Place bolts 8 into the piston. Shove the piston 2 onto the hub. Turn the clutch/brake around. Place the spacers 10 over the bolts 8. Install the disc 12. Place bolts 9 into the pressure plate 7. Shove the pressure plate 7 onto the hub. Tighten screws 11 - cross - tightening of respective opposite screws equilly (see table on page 11). Turn the clutch/brake around. Apply a thin coat of sealant to the sealing faces/surfaces of the cylinder and hub. Connect cylinder 1.2 and hub 1.1 by tightening screws 1.3 and inserting pin. Installation of plates or housing discs see notes on page Adjust airgap (see page 10). 14

15 Tightening torques for screws stress classification: replace after dismantling Size Nm 8,

16 Spare parts list Twelve point plate suspension Item Part 1.1 hub 1.2 cylinder 1.3 screw 1.4 dowel pin 2 piston 3 O-ring (from size 61 sealing ring) 4 O-ring (from size 61 sealing ring) 5 pressure spring 6 pressure spring 7 stop plate 8 bolt 9 bolt 10 spacer sleeve 11 screw 12 fitted disc 13 clutch plate (adhesived up to size 79) 13.1 base plate (from size 82) 13.2 lining segment (from size 82) 13.3 pipe rivet (from size 82) 13.4 lug 13.5 spring washer 13.6 clamping sleeve 13.7 screw 14 brake plate (adhesived up to size 79) 14.1 base plate (from size 82) 14.2 lining segment (from size 82) 14.3 pipe rivet (from size 82) 15 bush 16 hexagonal screw Wearing part are indicated with a shaded backround 16

17 Explosion drawing 11 Twelve-point suspension of the plates

18 Plate with two-point suspension Item Part 13 clutch plate 13.1 plate without straps 13.2 (bonded up to size 79) base plate (from size 82) lining segment (from size 82) pipe rivet (from size 82) 13.2 strap 13.3 screw (from size 61 tight-fit screw) 13.4 hexagon nut 13.5 clamping sleeve (dropped from size 61, not shown) 14 shoulder bush 15 shoulder bush 16 locking ring 17 bolt 18 bolt 19 strap 20 brake plate 20.1 plate without straps 20.2 (bonded up to size 79) base plate (from size 82) lining segment (from size 82) pipe rivet (from size 82) 20.2 strap 20.3 screw (from size 61 tight-fit screw) 20.4 hexagon nut 20.5 clamping sleeve (dropped from size 61, not shown) 21 shoulder bush 22 shoulder bush 23 locking ring 24 bolt 25 bolt 26 strap Friction block version Item Part 13 housing disc 14 friction block 15 centring sleeve 16 screw Wearing part are indicated with a shaded backround 18

19 Explosion drawing Two-point suspension of the plates (20.1)

20 Fault finding Fault Clutch plate/ housing plate slips Brake plate/ housing plate slips Reason Remedy Friction linings/ Replace plate/friction pads worn down blocks check the counter friction surfaces Plate/friction blocks Replace plate/friction moist or oily blocks, eliminate source of moisture/oil Air pressure too low Increase operating pressure to 5.5 bar Valves defective Replace valves (Check: connect the compressed air directly) Otherwise machine damage request technical service Friction linings/ Carry out wear pads worn down compensation. Replace plates/friction blocks, check the counter friction surfaces Plate/friction blocks Replace plate/friction moist or oily blocks check the counter friction surfaces Otherwise machine damage request technical service 20

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