Bosch Rexroth Tightening System 350 - Table of Contents

System 350 | 3 608 878 300/2019-03
Schraubtechnik | Bosch Rexroth AG 5/641
Contents
1 About this documentation 9
1.1 Overview of this documentation . . . . . . . . . 10
1.2 Validity of the documentation . . . . . . . . . . . 10
1.3 Additional documentation . . . . . . . . . . . . . . . 11
1.4 Representation of information . . . . . . . . . . . 11
1.4.1 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.4.2 Symbols and representations. . . . . . . . . . . . . . . . . . .12
1.4.3 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.4.4 Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2 Safety instructions 17
2.1 About this chapter . . . . . . . . . . . . . . . . . . . . . . 18
2.1.1 Using and communicating the safety instructions . .18
2.1.2 Instructions for use . . . . . . . . . . . . . . . . . . . . . . . . . . .19
2.1.3 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . .20
2.1.4 Cleaning instructions . . . . . . . . . . . . . . . . . . . . . . . . .20
2.1.5 Maintenance and repair instructions . . . . . . . . . . . . .21
2.1.6 Disposal instructions. . . . . . . . . . . . . . . . . . . . . . . . . .21
2.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
2.2.2 Application areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
2.3 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.4 Personnel qualifications . . . . . . . . . . . . . . . . 23
2.5 General safety instructions . . . . . . . . . . . . . . 24
2.6 Product- and technology-dependent
safety instructions for Rexroth tightening
system 350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.6.1 Protection against accidental contact with
electrical parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
2.6.2 Protective extra-low voltage for protection against
electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
2.6.3 Protection against dangerous movements . . . . . . . .27
2.6.4 Protection against magnetic and electromagnetic
fields during operation and assembly . . . . . . . . . . . .30
2.6.5 Protection against accidental contact with hot parts30
2.6.6 Protection during handling and assembly. . . . . . . . .31
2.6.7 Protection when handling batteries. . . . . . . . . . . . . .31
2.6.8 Protection against pressurized lines . . . . . . . . . . . . .32
3 Introduction to the
Tightening System 350 33
3.1 The Tightening System 350 . . . . . . . . . . . . . 34
3.2 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.3 System design . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.3.1 Compact system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
3.3.2 Modular system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
3.4 Description of the Tightening System 350 39
3.4.1 CS351 compact system . . . . . . . . . . . . . . . . . . . . . . 39
3.4.2 Modular system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.4.3 Tightening spindles . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.4.4 ErgoSpin hand-held nutrunner . . . . . . . . . . . . . . . . . 47
3.4.5 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.4.6 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.5 Integration in an entire system . . . . . . . . . . .55
3.5.1 Compact system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.5.2 Modular system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.5.3 Communication between the tightening system
and the BS350 operating system . . . . . . . . . . . . . . 57
3.5.4 External communication . . . . . . . . . . . . . . . . . . . . . . 58
3.6 Process Quality Manager (PQM) . . . . . . . . . .58
4 Construction guidelines 59
4.1 Design of a bolted connection . . . . . . . . . . . .60
4.1.1 Clamp force and distortion of connected parts,
operating forces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.1.2 Determination of the required torque to create a
bolted connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.1.3 Torque ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.1.4 Tightening case (soft – hard) . . . . . . . . . . . . . . . . . . 64
4.1.5 Tightening processes . . . . . . . . . . . . . . . . . . . . . . . . 65
4.2 Tightening system design . . . . . . . . . . . . . . .65
4.2.1 Tightening spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.2.2 ErgoSpin hand-held nutrunner . . . . . . . . . . . . . . . . . 69
4.2.3 Connection cables. . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.2.4 Control and power electronics . . . . . . . . . . . . . . . . . 74
4.2.5 Connected load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.2.6 Calculation of power loss . . . . . . . . . . . . . . . . . . . . . 82
4.2.7 Reduce cycle time . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.2.8 Electrical connections between the tightening
system and the production environment . . . . . . . . . 88
4.2.9 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.3 Integration of the tightening system in
an installation . . . . . . . . . . . . . . . . . . . . . . . . . . .89
4.3.1 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.3.2 Design of mains connection . . . . . . . . . . . . . . . . . . . 98
4.3.3 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.3.4 Performance level (PL) within the
Rexroth Tightening System 350. . . . . . . . . . . . . . . 103
4.3.5 Identification of the compact system/card rack
field and the modules . . . . . . . . . . . . . . . . . . . . . . . 106
4.3.6 Assembly notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.3.7 Rework station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.3.8 Use of additional components (accessories) . . . . 109
4.4 Compatibility with foreign substances . . .112
4.5 Planning guidelines . . . . . . . . . . . . . . . . . . . .112
4.6 Planning assistance . . . . . . . . . . . . . . . . . . . .112
4.6.1 3-D/CAD data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.6.2 Circuit diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . 113