Robotic Deburring Tool FDB-AC 90 - 180
Contents
1. FDB AC Tool Center Point TCP Dimensions The Figure shows the TCP position and FDB AC dimensions When setting the TCP position in the robot controller use the mid posi tion of the 0 31 inch axial stroke of the compensation piston Also remember to take into account the depth of the Speedeburr adap ter 7 6 3 1 Page 15 In case an additional interface plate is used in order to fit the adapter to the robot this depth must be consi dered as well Without Speedeburr Dx 75mm Dy Omm Dz 70mm adapter With Speedeburr Dx 110 mm Dy O mm Dz 70 mm adapter SCHUNK 07 01 01 FDB AC 90 180 en Operating Instructions 7 3 2 TCP FDB AC 180 Max 118 6 Min 110 8 i 84 5 H 55 7 4 240 S36 32 S16 0 O 9 B54 FDB AC Tool Center Point TCP Dimensions The Figure shows the TCP position and FDB AC dimensions When setting the TCP position in the robot controller use the mid posi tion of the 0 31 inch axial stroke of the compensation piston Also remember to take into account the depth of the Speedeburr adap ter 7 6 3 1 Page 15 In case an additional interface plate is used in order to fit the adapter to the robot this depth must be consi dered as well Without Speedeburr adapter Dz 115 mm With Speedeburr adapter Dz 150 mm 01 01 FDB AC 90 180 en SCHUNK Om Operating Instructions 7 4 Operational2. Page 22 surrounding the installa tion may be installed Plexiglas or Lexan is preferred The axial force air supply pressure regulator should have a 0 45 psi range When testing for the proper contact force start with a very low pressure and increase slowly until the desired chamfer is achieved typically 3 psi for aluminum and more for steel workpieces Before start up make sure the air lubrication system is filled with oil 7 8 3 Page 31 01 01 FDB AC 90 180 en Handling Installation Storage and Transportation Lack of lubrication will cause destruction of the motor within a relatively short time If the lubrication is not working properly you can hear the motor running slower than normal and the speed may be varying e Install the lubrication equipment near the robot base maxi mum 16 feet away from the FDB AC for proper operation 7 8 3 Page 31 6 4 Transportation and Protection during Transportation 6 5 The FDB AC is packaged in a wooden crate designed to secure and protect it during transportation Always use the crate when trans porting the FDB AC in order to minimize the risk of damage When taking the FDB AC out of the crate and carrying or perform ing maintenance try to always grab and hold it around the motor housing Drawings Storage and Preventive Maintenance during Storage The FDB AC should be stored in the wooden crate when it is not in use The FDB AC should a
3. and operational safety of the product Wear protective equipment NOTE More information are contained in the relevant chapters Personnel qualification The assembly initial commissioning maintenance and repair of the product may be performed only by trained specialist person nel Every person called upon by the operator to work on the product must have read and understood the complete assembly and operating manual especially the chapter Basic safety notes 2 Page 7 This applies particularly to personnel only used oc casionally such as maintenance personnel Using personal protective equipment When using this product observe the relevant industrial safety regulations and use the personal protective equipment PPE re quired e Use protective gloves safety shoes and safety goggles e Observe safe distances 01 01 FDB AC 90 180 en SCHUNK 07 SCHUNK e Basic safety notes 2 6 Notes on particular risks Never use or start the tool without first reading and under standing the Installation and Operation Manual Make sure that the tool is mounted as described in chapter Mounting 7 6 3 1 Page 15 Never use the tool for other purposes than those explicitly de scribed in the Installation and Operation Manual Make sure that the pneumatic control equipment is mounted as described in chapter Pneumatics FDAB AC 6 3 2 Pa ge 17 6 3 3 Page 18 Only original spare parts and files burrs
4. Damage to health due to inhalation of air containing oil Long time exposure to air containing oil could be dangerous for personnel e It is recommended that the exhaust containing lubrication be filtered through an oil recovery system before exhausting it to the atmosphere NOTICE Lack of lubrication will cause untimely wear on the motor and failure within a relatively short period If the lubrication is not working properly the motor will run slower than normal and may vary in speed Install the lubrication equipment near the robot base maximum 16 feet from the FDB AC for best results SCHUNK 07 01 01 FDB AC 90 180 en Maintenance 8 4 Replacement of Burrs Holder for Compensation piston Burr Compensation piston ID No 9951362 ID No 9951359 wg contained in the Key Set ID No 9962489 Holder for Burr Burr Replacement The Figure shows the burr changing tools the Compensation pis ton and burr rotary file The Compensation piston and the Cy linder should be inspected whenever a burr is replaced The Com pensation piston should rotate freely by hand in the Cylinder with no binding If binding is detected the Compensation piston and or Cylinder should be replaced 7 8 1 Page 27 To change the burr unscrew it with the burr changing tools and replace it with a new one Re assemble the parts 8 1 Page 27 After the burr is changed a
5. N N ou oS 0 29 58 87 116 14 5 17 4 203 232 261 29 319 348 Control pressure psi Axial contact force measured with rotary burr pointing downwards Each FDB AC goes through a thorough test procedure before it is shipped In the figure are theoretical and measured forces relative to applied axial air pressure Please note that theoretical calcula tions are not necessarily identical to actual data Measurements may vary from one product to another and should only be treated as nominal 300 N a e 200 Torq ue Pow er a e a Roboter torque M in Nmm Output power P in W 0 5000 10000 15000 2000 0 25000 30000 Rotor velocity in rpm Theoretical calculations FDB AC output torque and power Due to pressure losses between the pressure regulator and the compensation piston the axial force is lower than theoretical cal culations will predict The actual force characteristics will change from installation to installation due to different types of pneumat ic components used 01 01 FDB AC 90 180 en SCHUNK o7 SCHUNK e Technical data 30000 25000 20000 15000 Spe ed Rotary speed in RPM 10000 5000 0 14 5 29 43 5 58 72 5
6. 496 QMO8 SEE S ll 01 01 FDB AC 90 180 en SCHUNK 07 Table of Contents Table of Contents 1 About TAS AINA sees cons scbeesectadvercarcterscti essences aden senate vedere eed ares 5 LL RN UIE S esis ons hoesetcct csc anea sient cots ad ota wap ha need na cI EEEE 5 1 2 Varia MiSs inyu nonono anit aba a trot i a G 6 1 3 Applicable docUMENtS i sincnirnnen enans ERE EEE 6 2 Basicsafety Notes isscsrssivsrsirsirissicsseseyivsrssisssssiedundasiveisisiisi decns esivsridisi ionisasi nivea 7 2 1 Intended USec rieien ERr A TE E NAE 7 2 2 Environmental and operating conditionS ssssesesessssssseerrrrsssrrssserrerseerennsseerenreerena 7 2 3 Product Se Ty sete titca ct ew tsetcn eee cae pice EE A asta xan rida TAE NENE 8 24 Personnel QuAalIMCATION ssescccsssivericinevsansetssomnnneshaniiere a AEE E 8 2 5 Using personal protective CQUIPMENL ccesssececesssnececesssecececssseeeecesssaeeeseesanaes 8 26 N teson particular riSKSroisasnorsesirsi snn ERE ER 9 Warranty ica sisisnacienesaas Sadun wcinntansadesidancdvs sviuin videira ANSE kan KOiaE reS CE Nares ieira isar ani 10 A Scope of delivery asissnnassicewacacacesencensedcnnasaveusndnananpeunssausavarnedsesssanuatswenneauanssaenesseacnaaniies 10 5 Technical Gate siivasscscccersswincdstavostestncennsaiawostcemmsnaenctndebswcakousieuednasmeiedawdeacamneecaniennaebeues 11 5 1 Technical SOSCIICALOMS sascaissssnansoeven eset vacvnaneteadauslpemeantuceasunsanebas
7. 87 Drive pressure in psi Idle speed as function of applied drive pressure We recommend a working speed of 15 000 to 25 000 RPM for maximum possible output A speed lower than 15 000 RPM is not recommended as it increases the risk of stalling the motor due to the higher torque at lower speeds 01 01 FDB AC 90 180 en Technical data 5 2 General Operation Storage Conditions Environmental Limitations Gas group ignition group None Installation position e Mounted to robot by means of the Speedeburr adapter and flange The flange is specific to each type of robot This flange not supplied by SCHUNK e Mounted to a table or stand by means of the Speedeburr adapter the robot is carrying the workpiece Temperature range 5 C 35 C 41 F 95 F Temperature range 0 C 45 C 32 F 113 F The tool should be stored in its crate and in a dry place The tool should be kept dry and full of pneumatic oil when stored Keep unit in crate if possible 6 4 Page 20 01 01 FDB AC 90 180 en SCHUNK 07 Handling Installation Storage and Transportation 6 Handling Installation Storage and Transportation 6 1 Inspection of Condition when Delivered Upon receipt the following must be checked e Delivery in accordance with freight documents e Damage to packaging If there is damage to any of the packaging or if any of the goods have been exposed to abnormal handling unpack those
8. C 90 180 en Maintenance 6 Inspect the Compensation piston and Cylinder for scratches Deep scratches may require replacement of the part s Check the Burr 16 condition and replace as necessary Lightly lubricate the outside diameter of the Compensation pistonn and the inside diameter of the Cylinder with the same oil used for operational air lubrication 9 Assemble the Compensation piston in the Cylinder and assure the Piston moves freely without excessive play The fit be tween the Compensation piston and the Cylinder provides the seal for the axial down force air pressure therefore the fit must be consistent and without excessive play If the play is excessive replace the Cylinder 10 Install the Cylinder and the Compensation piston assembly on the Motor Housing 11 Replace the Lock Ring NOTICE Do not over tighten the Lock Ring 12 Assure the axial down force and the drive are working properly The FDB AC should not be operated for extensive periods of time with the cutting tip pointing up This orientation will in crease the amount of debris entering the cylinder and cause premature wear of the cylinder and piston possibly preventing the piston from floating altogether The burr must be replaced at regular intervals During initial pro duction the burr and the workpiece should be examined often in order to determine at what interval the burr should be replaced 7 8 4 Page 32 At regular i
9. Considerations To obtain best results it is important for the Compensation piston to be running with low friction in the cylinder 7 1 Page 21 The FDB AC should not be statically mounted with the cutting tip up This will increase the amount of debris entering the cylinder and cause premature wear of the cylinder and piston possibly preventing the piston from floating altogether If the FDB AC must be mounted in this orientation then a continuous or regular burst of high velocity air should be used to blow debris away from the piston and cylinder to insure low friction between the Compensa tion piston and the cylinder For instructions on how to replace the burr please consult section Replacement of Burrs 7 8 4 Page 32 SCHUNK e 7 5 NOTICE The FDB AC should not be statically mounted with the cutting tip up This will increase the amount of debris entering the cylinder and cause premature wear of the cylinder and piston possibly pre venting the piston from floating altogether Under normal conditions no cooling or lubrication of the rotary burr is necessary The FDB AC is used in most robot deburring installations with aluminum and steel workpieces without any coolants Programming The FDB AC must never be running while programming the robot There are various techniques that may be used to program the ro bot path In any case the burr should be nominally at the mid point of its stroke w
10. NK About this manual 1 About this manual This instruction is an integral part of the product and contains im portant information for a safe and proper assembly commission ing operation maintenance and help for easier trouble shooting Before using the product read and note the instructions especial ly the chapter Basic safety notes 1 1 Warnings To make risks clear the following signal words and symbols are used for safety notes Danger for persons Non compliance will inevitably cause irreversible injury or death Dangers for persons Ignoring a safety note like this can lead to irreversible injury and even death Dangers for persons Non observance can cause minor injuries Material damage Information about avoiding material damage PP SCHUNK 07 01 01 FDB AC 90 180 en About this manual 1 2 Variants This operating manual applies for the following variations e Robotic Deburring Tool FDB AC 90 e Robotic Deburring Tool FDB AC180 1 3 Applicable documents e General terms of business e Catalog data sheet of the purchased product The documents listed here can be downloaded on our homepage www schunk com 01 01 FDB AC 90 180 en SCHUNK e Basic safety notes 2 Basic safety notes 2 1 Intended use The product is to be used only for the deburring of workpieces The product is intended for installation on a robot The requ
11. Original Manual Robotic Deburring Tool FDB AC 90 180 Assembly and Operating Manual Superior Clamping and Gripping SCHUNK 07 Imprint Imprint Copyright This manual remains the copyrighted property of SCHUNK GmbH amp Co KG It is solely supplied to our customers and operators of our products and forms part of the product This documentation may not be duplicated or made accessible to third parties in particu lar competitive companies without our prior permission Technical changes We reserve the right to make alterations for the purpose of technical improvement Document number 0389513 Edition 01 01 10 07 2015 en SCHUNK GmbH amp Co KG All rights reserved Dear customer congratulations on choosing a SCHUNK product By choosing SCHUNK you have opted for the highest precision top quality and best service You are going to increase the process reliability of your production and achieve best machining results to the customer s complete satisfaction SCHUNK products are inspiring Our detailed assembly and operation manual will support you Do you have further questions You may contact us at any time even after purchase Kindest Regards Yours SCHUNK GmbH amp Co KG Spann und Greiftechnik Bahnhofstr 106 134 D 74348 Lauffen Neckar or Tel 49 7133 103 0 Net Fax 49 7133 103 2399 Foo E Net info de schunk com Qa wr www schunk com Reg No 003496 QMO8 Reg No 003
12. ases the Speedeburr adapter will mount directly to the robot without an interface plate The interface plate is manufactured either by the robot supplier the FDB AC supplier the system integrator or by the owner user of the FDB AC The FDB AC with the Speedeburr adapter may be mounted to a table or stand using an interface plate or directly using the Spee deburr pneumatic adapter 01 01 FDB AC 90 180 en SCHUNK e Handling Installation Storage and Transportation 6 3 2 Pneumatics FDB AC 90 Option 1 on off Mist Air supply valve actuated lubrication Filter 5 bar from robot controller Option 2 on off valve actuated from robot controller Vane motor Exhauset 1 I 1 i FFP L Option 2 on off San I valve actuated from robot controller 1 l External pressure regular 0 3 psi FDB AC Axial force from deburring process Connect the FDB AC 90 as shown in the figure Two connection methods are shown e Option 1 uses one solenoid valve to control both motor drive air supply and axial force air supply e Option 2 uses two solenoid valves to independently control the two air supplies SCHUNK 07 01 01 FDB AC 90 180 en Handling Installation Storage and Transportation 6 3 3 Pneumatics FDB AC 180 Electric on off valve actuated from robot controller Mist lubrication Filter External pressure control valve 0 3 bar Axial for
13. ce from deburring process t Pneumatic Connection Connect the FDB AC 180 as shown in the figure A special Speedeburr adapter is available as extra equipment to enable standard air nipples to be coupled to the Straight FDB AC Air silencers can be coupled to the exhaust ports of the adapter to take away the noise when exhaust air enters the atmosphere The drive air to the vane motor should be mist lubricated by use of conventional pneumatic equipment An external pressure control valve for example mounted on the industrial robot s upper arm will control the axial force on the ro tary tungsten carbide file The axial force is adjusted until a chamfer with the correct width is produced for a given path speed NOTE Poor performance will result if the correct components are not used Pneumatic components used for the motor drive circuit must be able to meet the air consumption requirements 5 1 Page 11 Conventional pneumatic components not supplied with the FDB AC tool are used to control the air supply to the FDB AC SCHUNK recommends that the user install a pneumatic pressure regulator in order to achieve a stable air supply and to reduce the air supply to the maximum of 90 psi 01 01 FDB AC 90 180 en SCHUNK 07 SCHUNK e Handling Installation Storage and Transportation The solenoid operated valve s are actuated from the robot con troller by means of a digital output signal The external pres
14. delivered from the tool manufacturer must be used 7 8 7 Page 33 Never stand near the tool while it is started and running If it is necessary to approach the tool while in motion stand behind appropriate Plexiglass windows Be aware of rotating parts A barrier to prohibit people from approaching the tool while in operation must secure the installation Be aware of high sound levels Always use earplugs while work ing near the tool Provide protective equipment to prevent objects from falling or being ejected such as processed workpieces tools chips fragments rejects The danger zone must be surrounded by a safety fence during operation 01 01 FDB AC 90 180 en Scope of delivery 3 Warranty If the product is used as intended the warranty is valid for 24 months from the date of delivery from the production facility un der the following conditions e Observe the applicable documents 1 3 Page 6 e Observance of the ambient conditions and operating conditions 7 2 2 Page 7 e Observe the mandatory maintenance and lubrication intervals 8 Page 27 Parts touching the work piece and wearing parts are not part of the warranty 4 Scope of delivery The scope of delivery includes e Robotic Deburring Tool FDB AC in the ordered model 01 01 FDB AC 90 180 en SCHUNK e Technical data 5 Technical data 5 1 Technical Specifications Motor Speed Torque Power Weight total Weight c
15. eccnapeuncasaveonstuegeane 23 3 2 TCP PD BG ee acai cs cen ea ENE E ERE 24 7 4 Operational Considerations sisicicccscccsecensssssesttacsessnsanssaaetannvessstberannssdiaasssaaccineianseesns 25 io Programming ecenirsscere nen r Maen eS 25 8 Wai EOI ACG os soi sacs sccoicicdaciecasdecnarscntwarccndnvnaseincensannns a aae ar aR E EENET asap assa R saiae 27 8 1 Regular Operational Maintenance sssssssssssersesrerrsssrrrrreseersssrrrerteerensssrrrensesreeese 27 SCHUNK 07 01 01 FDB AC 90 180 en Table of Contents 8 1 1 User Serviceable parts FDB AC 90 o ce eeeesssscecessseeeeessseneeceesssaeeeeeesnees 28 8 1 2 User Serviceable parts FDB AC 180 cesssccecesssnecessssereecesssseeeeeeesnees 29 8 2 Recommended Inspection and Cleaning Procedure cccccsscccesssseeeeeesseeeeeeeees 29 8 3 lL bricati heisene ATE RES E E EA EA EENES 31 SA Replacement Of BUTTS cacian nia E ER eae ceed 32 8 5 Replacement of Other FDB AC PartS essssssseseseeesssrrrrrreseersssrrrrrsesressssrreerseereeese 33 8 6 Ovy rhaUl serienr e EEE E EEE E EE EEEE 33 8 7 R pairs and Spare PartSisssteninpenpsriatnp nan a a aiia 33 9 1 ee re 34 91 FDB ACIO ree atau esnne ayia d nism tsasioe E sue adap ena siatosgeate 34 9 2 FDB AC 260 aiciscanccaareutieeiecbinacereracgee A nearness 35 10 Translation of original declaration of incorporation ssssssssosssssssssssssoossssssssssssosee 36 01 01 FDB AC 90 180 en SCHU
16. erhaul must be performed by SCHUNK in order to maintain the technical specifica tions and tool life of the FDB AC Repairs and Spare Parts For repair and spare parts please contact SCHUNK User serviceable parts are shown in Figure Burr Replacement 8 4 Page 32 For the replacement of the burr a Keyset ID number 99624839 is available All other repairs must be performed by SCHUNK SCHUNK recommends stocking the following spare parts in addi tion to burrs e Compensation piston ID number 9951362 e Cylinder ID number 9951361 Use only original spare parts and burrs from SCHUNK 01 01 FDB AC 90 180 en Drawings 9 Drawings 9 1 FDB AC 90 1 4 Exhaust Axial air pressure M5 Free Flying Piston 2 optional ports M5 Tungsten Carbide Burr File L 8 T 2 Drive pressure 1 8 1 4 Exhaust Adjustment screw 6 H7 5 Deep 4x 5 for M6 32 1 TY t Socket Cap Screws H C bore from Far Side 0 030 66 0 H7 2 Deep 01 01 FDB AC 90 180 en SCHUNK Om Drawings 9 2 FDB AC 180 Control pressure ae Cylinder 8mm axial stroke Piston Tungsten carbide file The Compensation piston is an important part of the Straight FDB AC The Compensation piston is pushed forward into contact with the burr edge by use of a remotely controlled air pressure The air vane motor is decoupled from the linear movement of the Compen
17. hamfer 6 3 3 Page 18 Addition FDB AC 90 To change the drive speed adjust the main supply pressure The greater the pressure the greater the speed and vice versa It is al so possible to adjust the speed by using a small flat blade screw driver to turn the adjustment screw on the side of the 90 degree bracket 7 8 1 1 Page 28 and 9 1 Page 34 This adjustment varies the flow rate clockwise to decrease counterclockwise to in crease the flow rate and speed In most applications it is best to adjust the regulator to a maximum pressure 75 90 psi with the adjustment screw in the full out position approximately flush with the surface The FDB AC must never run without proper lubrication Damage to the unit will occur 7 8 3 Page 31 01 01 FDB AC 90 180 en SCHUNK Maintenance 8 Maintenance 8 1 Regular Operational Maintenance To obtain best results it is important for the piston to be running with low friction in the cylinder This should be checked at regular intervals Some debris will al ways enter the cylinder and regular cleaning is recommended The FDB AC should not be operated for extensive periods of time with the cutting tip pointing up This orientation will increase the amount of debris entering the cylinder and cause premature wear of the cylinder and piston possibly preventing the piston from floating altogether If the FDB AC must be operated in this orienta tion the
18. hile deburring the part It will move up and down with part and path variation One programming method is to teach the path using the point of the burr as a guide following the edge of the part then manually or automatically adding offsets to the path points to achieve the final correct burr path Another method is to program the actual points making sure that at each point the burr is at its nominal mid point when in contact with the part and that there are no radial forces The method used will depend on the robot s capabili ties and programmer preferences 01 01 FDB AC 90 180 en Operating Instructions If you are deburring sharp inner corners it may be required to use the area of the burr closer to its tip Note that in this case some of the compensation ability of the FDB AC as well as the cutting surface speed is reduced When running the robot program the first time observe the path with the axial supply turned off When in creasing the path speed it is important to notice that path deviation may increase with speed Verify that at operational robot path speed the FDB AC burr remains near the mid point of its axial travel The brass Cylinder 5 amp 8 1 1 Page 28 8 1 2 Page 29 that encloses the Compensation piston must be protected from colli sions If struck it may be damaged and need replacement The axial force of the burr should be adjusted in order to achieve a correct sized and even c
19. ine into which the incomplete machine is to be installed with the provisions of the Machinery Directive 2006 42 EC is confirmed The manufacturer agrees to forward on demand the relevant technical documentation for the partly completed machinery to state offices The special technical documents according to Appendix VII Part B belonging to the in complete machine have been compiled Person authorized to compile the technical documentation Robert Leuthner Address see manufacturer s address Signature see original declaration Lauffen Neckar June 2014 p p Ralf Winkler Head of Gripping Systems Development 01 01 FDB AC 90 180 en SCHUNK 07
20. ions Neglecting safety precautions can create hazardous situations In the worst case personnel can be injured or the deburring in stallation and the FDB AC can be damaged e Itis important that all personnel involved in operation of the FDB AC have a thorough understanding of the operating pro cedures e The FDB AC must only be used for robotic deburring applica tions The FDB AC is a deburring tool only e Never use the FDB AC for purposes other than robotic deburring Grinding countersinking or other metal forming processes should not be performed by the FDB AC It may be dangerous to operate the FDB AC for these purposes If a failure occurs due to forces caused by improper use hazardous situations for both personnel and equipment could be created The FDB AC is intended to per form deburring only The FDB AC should not be used to deburr materials that are prone to fracture A fracturing workpiece may result in pieces of material damaging surrounding working environment and personnel Ma terial removed correctly should be in the form of chips Reduce the robot velocity when the workpiece and the FDB AC are making initial contact Making the contact movement between the FDB AC and the workpiece too fast may in some situations result SCHUNK 07 01 01 FDB AC 90 180 en Operating Instructions in a collision Collisions may create hazardous situations for both personnel and equipment When perf
21. ire ments of the applicable guidelines must be observed and complied with The product may be used only in the context of its defined applica tion parameters The product is designed for industrial use To use this unit as intended it is also essential to observe the technical data and installation and operation notes in this manual and to comply with the maintenance intervals Use which is not specified as an intended use is for instance when e the product is used with machines systems or workpieces that are not designed to be used with the unit e the product is operated without protective equipment in ac cordance to the EC Machinery Directive e the statutory safety and accident prevention regulations and the standards and guidelines valid at the usage site are not ob served 2 2 Environmental and operating conditions e Make sure that the product may be used only in the context of its defined application parameters 5 Page 11 e Make sure that the environment corresponds to the specifica tions of the catalog amp 5 2 Page 14 SCHUNK 07 01 01 FDB AC 90 180 en Basic safety notes 2 3 2 4 2 5 Product safety Dangers arise from the product if e the product is not used in accordance with its intended pur pose e the product is not installed or maintained properly e the safety and installation notes are not observed Avoid any manner of working that may interfere with the function
22. lso be stored in a dry place For short term storage limited to a few weeks no preventive maintenance is needed except for cleaning For long term storage the FDB AC should be thoroughly cleaned of any burrs or debris It should not be disassembled After cleaning the FDB AC should be filled with oil of the same type used as lubrica tion during operation The oil should be poured into the FDB AC through the adapter or through the FDB AC bracket Place the FDB AC inside a sealed plastic bag and place the FDB AC inside the crate This is necessary in order to keep the blades in the air vane motor from drying out and for preventing the risk of corrosion 01 01 FDB AC 90 180 en SCHUNK e Operating Instructions 7 Operating Instructions These operating instructions are intended to help system integra tors program start up and complete a robotic deburring cell con taining a FDB AC deburring tool The system integrator should be familiar with the task of deburring in general and should have ex tensive knowledge relating to robots and automation incorporat ing robots The system integrator is responsible for providing user documen tation for the complete deburring installation This document is not intended to cover all aspects of such an installation although it contains some information vital for the system user such as maintenance instructions for the FDB AC and instructions related to safety 7 1 General Precaut
23. mnvechoustancnpunnseansansss 11 5 2 Environmental Limitations siisiciscsscsssdsicuccsacksbhswnsscinntcanvassoedxssesenesatwsntstandtaackeemeadaccons 14 6 Handling Installation Storage and Transportation ccccsssccssssccccssccccsssccessseeees 15 6 1 Inspection of Condition when Delivered ceecccccsssseeecesssnececeesseeeceeseseeeeeseeaees 15 6 2 Unpacking and Haile ccvncssssccnccetcauraeueaaidenbtnabranntancransceesvestuebncanbancitasveanckapatecteben 15 6 3 MASE ATVOM esner a E E E TEE 15 6 3 1 Mounting Adapter and Interface Plate sssssseeesesssssssrrsresreesssrrrrrresreee 15 6 3 22 Pneumatics FDB AC 90 a ica ccaniteruninestvaesnhas tn sEV E ARAE tana nena 17 6 3 3 Pneumatics FDB AC 180 sesesesesrsrsrsereserrnenenenenanenananananananananananananananan 18 6 4 Transportation and Protection during Transportation sssssssssesessessssrrrseeresessee 20 6 5 Storage and Preventive Maintenance during Storage ccscccccsssstecessesseeeeeseenees 20 7 Operating Instructions lt igceiuciadiieressarssiviciin danasin eieiei earen kansissa moxie 21 Fok General PRECAUTIONS seriernes a RE O EE ER ERES 21 7 2 FDB AC Working Environment sssssssssesssssrssssserrsssrrerssetressssrrttssttrentssreeesteerenesset 22 7 3 Tool Center Point TCP Position s sincizecivorsarnivusiennniorinenseeenramaenerseiianneeutwom tants 23 Fock TCP PDB AG OO sikisctannceacesisitantannceacuesechansanpanmeuanestanvaeetentuat
24. n a continuous or regular burst of high velocity air should be used to blow debris away from the piston and cylinder to insure low friction between the Compensation piston and the cylinder Additionally the outside of the FDB AC should be kept clean to en sure proper cooling SCHUNK 07 01 01 FDB AC 90 180 en Maintenance 8 1 1 User Serviceable parts FDB AC 90 User Serviceable Parts item Quantity Deserption a fa compensation psn e h rotary ite eur a 1 so degree racket e x__JadjustmentSerew 01 01 FDB AC 90 180 en SCHUNK o7 SCHUNK e Maintenance 8 1 2 User Serviceable parts FDB AC 180 User Serviceable Parts 1 1 Spine Lock Screw 2 1 Male Spline 1 Lock Ring a a a piston a Rotary File Burr 8 2 Recommended Inspection and Cleaning Procedure Position of the position numbers 8 1 1 Page 28 8 1 2 Page 29 1 Remove the Lock Ring 3 from the FDB AC Motor Housing 7 using the hook spanner wrench not shown Gently pull the Cylinder 5 and Compensation piston 4 as sembly from the FDB AC Motor Housing Thoroughly clean the Male Spline the interior of the Motor Housing and the Lock Ring with a mild solvent Spin the burr by holding the Compensation piston and assure it spins freely If it does not spin freely replace the Compensa tion piston Separate the Compensation piston from the Cylinder and clean thoroughly 01 01 FDB A
25. nd the unit re assembled check that the Compensation piston is rotating with the burr If the Compen sation piston is not rotating static friction may be interfering so that the axial force cannot remain constant In that case clean the Compensation piston and inspect for any visible scratches If a burr with an imbalance is used the Compensation piston may also stop rotating All burrs are checked for imbalance before they are shipped Only original SCHUNK burrs should be used 01 01 FDB AC 90 180 en SCHUNK 07 SCHUNK e 8 5 8 6 8 7 Maintenance Replacement of Other FDB AC Parts In addition to burrs FDB AC parts such as the blades in the air vane motor and bearings should be replaced at regular intervals nominally every 2 years as part of a general overhaul 8 6 Page 33 Experience has shown that during installation programming and sometimes during operation the FDB AC and the workpiece col lide or the radial forces acting are too high This sometimes results in damage to the Cylinder and or the Compensation piston In this case these parts may also need to be replaced 8 1 Page 27 Only original spare parts supplied by SCHUNK should be used Overhaul As described in previous sections of this User Manual the motor unit and Compensation piston should be inspected and overhauled at regular intervals In addition to the above the FDB AC should be thoroughly cleaned inspected and tested This ov
26. ntervals normally once every two years or more often depending on the application an overhaul of the FDB AC should be performed in order to fully comply with the technical specifica tions Parts inside the FDB AC such as the blades in the air vane motor and bearings should be replaced as part of the overhaul 7 8 6 Page 33 At regular intervals the pneumatics used to control the FDB AC should also be checked especially the air filter and lubricator Re member to fill the lubricator with oil 01 01 FDB AC 90 180 en SCHUNK Maintenance 8 3 Lubrication Before start up be sure a lubricator is installed as described in the pneumatic diagram Drawings Make sure the air lubrication system is filled with oil Use oil similar to machine oil 10 spindle oil 60 Shell Exxon ATF DEXRON II automatic transmission oil or similar Oilfog air lubrication systems are not recommended as a means for providing lubricated air for this product Only microfog systems should be used The system should be adjusted to 10 15 drops per minute Only part of the oil drop actually enters the air stream Fill the lubricator with the proper type of oil at regular intervals e When the system is first installed use a higher than recom mended oil setting approx 2 times until the unit is receiving consistently oiled air e Run oil through the entire pneumatic tube between the oiler and the unit prior to operation
27. ompensation piston Compensation burr float Burr surface speed Air consumption Sound pressure level Sound pressure value Rotary burrs Special tools Air motor vane type Idle 30 000 RPM while deburring 18 000 25 000 RPM 0 4 Nm at lower speeds 250 W at 20 000 RPM FDB AC 90 0 5 kg FDB AC 180 0 51 kg 0 05 kg halfway between center tip and outer rim 1 90 coned shape straight fluting 2 90 coned shape spiraled fluting 3 C2 C5 Carbide Other rotary burr file qualities on request Burr changing tool Notes about Sound All noise emission measurements were taken at a distance of 3 pressure level feet from the FDB AC and at a height of 5 feet from the floor The FDB AC was mounted on a laboratory test bench No barriers or noise reduction facilities were used except for exhaust return to an oil recovery unit located beneath the test bench A drive pres sure of 75 psi was applied full FDB AC drive pressure No axial force pressure was applied The FDB AC was running at full idle speed Because the working environment is not known this me thod was considered the best method for measurements The equivalent continuous A weighted sound pressure level was measured as 75 dB A The peak C weighted instantaneous sound pressure value was measured as 87 dB C SCHUNK e 01 01 FDB AC 90 180 en Technical data Axial contact force w P n Axial force lbs
28. orming maintenance always remember to tighten nuts and bolts thoroughly and use a removable thread lock adhesive When replacing burrs always attach the burr correctly 8 4 Page 32 Never use the FDB AC as a hand held machine 7 2 In order to increase the life of the FDB AC motor and bearings al ways use proper lubrication 8 3 Page 31 FDB AC Working Environment As described in previous sections the FDB AC should only be used in conjunction with a robot in a secured work cell chamber The work cell must be secured by means of barriers to prohibit per sonnel from entering the cell A lockable door should be included as a part of the barrier in order to facilitate access to the cell for autho rized personnel only The barrier could consist partly or fully of Plexig las to facilitate observation of the deburring operations During system or FDB AC maintenance make sure the FDB AC and robot are stopped before entering the robot cell When installing and testing never be present in the cell when the FDB AC is running Be aware of rotating parts Use eye protection while working around the FDB AC Be aware of high sound levels Always use hearing protection while working in the neighborhood of the deburring cell 01 01 FDB AC 90 180 en SCHUNK Operating Instructions 7 3 Tool Center Point TCP Position 7 3 1 TCP FDB AC 90 Max 32
29. parts that may have been damaged for a closer inspection If necessary noti fy SCHUNK for assistance in evaluation of the product condition 6 2 Unpacking and Handling The FDB AC tool during transportation storing and handling should always be placed inside the accompanying box crate 6 3 Installation 6 3 1 Mounting Adapter and Interface Plate Fitfor centring pin o N o N A re Fit for centring bolt circle M 4x Through bore for screw 36 7 connection with screw G1 n N o L w 5 G1 8 2 8 Speedburr FDB AC Adapter The Figure shows the Speedeburr pneumatic adapter Id No 9951358 This adapter or equivalent should be used for mount ing the FDB AC to the robot or to other equipment The adapter facilitates the connection of the pneumatics to the FDB AC SCHUNK 07 01 01 FDB AC 90 180 en Handling Installation Storage and Transportation The FDB AC can be mounted on the robot or on a stand in which case the robot carries the part to be deburred to the FDB AC The FDB AC is mounted to the Speedeburr adapter by means of 8 screws M4 Be sure the O rings are positioned correctly into the grooves on the FDB AC bracket before mounting the FDB AC to the pneumatic adapter Removable thread locker should be used for all mounting bolts The Speedeburr adapter is mounted to the wrist of the robot usually by means of a robot specific interface plate In some c
30. sation piston to reduce inertia and increase the stability of the contact force when deburring The spline coupling transmits torque to the rotary file Ball bearings ensure an even running of the tungsten carbide file A very little friction torque is transmitted through the ball bearings to the Compensation piston cylinder which rotates slowly inside the stationary outer cylinder Thus stick slip or static friction of the Compensation piston is avoided The Compensation piston cy linder is in addition precision ground to ensure very little friction in the axial direction SCHUNK 07 01 01 FDB AC 90 180 en Translation of original declaration of incorporation 10 Translation of original declaration of incorporation in terms of the Directive 2006 42 EG Annex II Part 1 B of the European Parliament and of the Council on machinery Manufacturer SCHUNK GmbH amp Co KG Spann und Greiftechnik Distributor Bahnhofstr 106 134 D 74348 Lauffen Neckar We hereby declare that on the date of the declaration the following incomplete machine complied with all basic safety and health regulations found in the directive 2006 42 EC of the European Parliament and of the Council on machinery The declaration is rendered invalid if modifications are made to the product Product designation Robotic Deburring Tool FDB AC 90 180 ID number 0322206 0322207 The incomplete machine may not be put into operation until conformity of the mach
31. sure regulator is used to control the air supply to the axial force compliance mechanism thus enabling control of the axial force on the rotary burr If the complete workpiece can be deburred with equal axial force a conventional manual pres sure regulator can be used If the burrs to be removed are varying from place to place on the workpiece and this variation is repeatable for all workpieces of the same type it may be neces sary to adjust the axial force by using an analog pressure regulator controlled from the robot controller An analog output port in the robot controller will be needed Thread Type Pressure Motor inlet 1 8 3 1 5 2 bar maximum 6 2 Axial contact M5 0 3 1bar force inlet maximum 3 1 bar Control functions Optional It is recommended that 3 8 plastic tube be used for the motor air supply inlet and 5 32 tube for the axial force air supply inlet Note that a M5 connection is used for the axial force air supply inlet and a 1 8 connection for the motor air supply inlet Use two silencers di rectly mounted on the two 1 4 exhaust outlets 5 1 Page 11 If more noise suppression in desired install silencers on the ex haust line further away from the Speedeburr adapter An oil re covery unit may be installed on the exhaust line to avoid the mist lubrication droplets from entering the atmosphere around the ro bot installation Additionally to reduce the sound in neighboring working areas a barrier 7 2
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