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SCHUNK 0322200, Assembly And Operating Manual

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SCHUNK 0322200 Assembly And Operating Manual Download Page 35

Maintenance

1. Remove and/or lock-out the spindle motor air supply for

safety.

2. If the burr is to be replaced with one of an identical type,

measure and record the burr length extending beyond the
collet lock nut.

3. Use the one of the open-end wrenches to hold the spindle just

behind the collet nut.

4. Use the second wrench to turn the collet locknut

counterclockwise (when viewed from the burr tip) to loosen
the collet.

5. To remove a worn burr, pull the burr out of the loosened

collet.

6. If the collet is being replaced, completely remove the nut and

extract the old collet. Insert the new collet and refit the nut
leaving it loose

7. If an identical new burr is replacing a worn one, insert the new

burr and measure and adjust the length of its exposed portion
according to the measurement taken in the first step.

8. Tighten the collet by reversing the steps above.
9. Restore the air supply.

8.3.2 Air Motor Replacement

If the air motor is operated using oil laden air, it will fail and
require replacement. Failure of the motor due to oil in the spindle
air is not covered under warranty. The motor may also require
replacement after an extended operating life. There are no user-
serviceable parts in the air motor. FDB units with defective motors
should be returned to SCHUNK during the warranty period.
The air motor is replaced as a subassembly. Should the customer
wish to replace the motor subassembly after the warranty period,
the steps in the following chapters must be performed:

35

04.00 | FDB | Assembly and Operating Manual | en | 389072

Summary of Contents for 0322200

Page 1: ...Translation of Original Operating Manual Assembly and Operating Manual FDB Chamfering spindle ...

Page 2: ...on 04 00 30 08 2022 en Dear Customer thank you for trusting our products and our family owned company the leading technology supplier of robots and production machines Our team is always available to answer any questions on this product and other solutions Ask us questions and challenge us We will find a solution Best regards Your SCHUNK team Customer Management Tel 49 7133 103 2503 Fax 49 7133 10...

Page 3: ... and Handling 16 5 3 Mounting 16 5 3 1 Axial Mounting Installation 17 5 4 Pneumatics 18 6 Operation 21 6 1 General Precautions 21 6 2 Working Environment 22 6 3 Operational Considerations 22 6 4 Lock axis for compensation in one direction FDB 900 FDB 1040 22 6 5 Tool Center Point TCP Position and Programming 24 6 6 Cutter Operation and Burr Selection 26 6 6 1 Burr Selection Table 26 7 Troubleshoot...

Page 4: ... 3 4 Ring Cylinder Assembly Replacement 49 8 3 5 Spindle Boot Replacement FDB 660 52 9 Transport and storage 54 9 1 Transportation and Protection during Transportation 54 9 2 Storage and Preventive Maintenance during Storage 54 10 Translation of original declaration of incorporation 55 4 04 00 FDB Assembly and Operating Manual en 389072 ...

Page 5: ...ments listed under 1 1 4 6 are applicable NOTE The illustrations in this manual are intended to provide a basic understanding and may deviate from the actual version 1 1 1 Presentation of Warning Labels To make risks clear the following signal words and symbols are used for safety notes DANGER Danger for persons Non observance will inevitably cause irreversible injury or death WARNING Dangers for ...

Page 6: ...ms of business Catalog data sheet of the purchased product The documents labeled with an asterisk can be downloaded from schunk com 1 1 5 Sizes This operating manual applies to the following sizes FDB 150 FDB 300 FDB 340 FDB 900 FDB 1040 1 2 Warranty The warranty of the Chamfering spindle FDB is valid for 24 months This does not apply to the air motor The air motor is warranted for a period of 100...

Page 7: ...eces that are not designed to be used with the unit the product is operated without protective equipment in accordance to the EC Machinery Directive the statutory safety and accident prevention regulations and the standards and guidelines valid at the usage site are not observed 2 2 Safety Precautions WARNING High sound levels can occur during cutting Failure to wear hearing protect can cause hear...

Page 8: ...s WARNING Flying debris and rotating parts can cause injury Never be present near the deburring tool while it is started or in operation If it is necessary to approach the deburring tool while in motion stand behind appropriate Plexiglas windows Provide a barrier to prohibit people from approaching the deburring tool while in operation must secure the installation WARNING Injury or equipment damag...

Page 9: ...explicitly described in this manual Follow installation instructions and pneumatic connections as described in this manual All pneumatic fittings and tubing must be capable of withstanding the repetitive motions of the application without failing The routing of pneumatic lines must minimize the possibility of stress strain kinking rupture etc Failure of critical pneumatic lines to function properl...

Page 10: ...ce This allows high feed rates with uniform quality in any orientation The tool also requires no oil allowing clean exhaust air to be vented directly into the work environment Compliance is supported by air pressure applied to the shaft of the unit and is used to perform consistent deburring on irregular part patterns The motor s internal governor maintains high spindle speeds for optimum surface ...

Page 11: ...bstituted to retain numerous cutter shank diameters The collet retaining nut is loosened to open the collet allowing cutting tools to be removed and inserted Once the tool is set to the desired depth spanner wrenches are used to tighten the collet nut causing the collet to collapse and secure the cutting tool The air motor design does not allow the installation of spindle brakes or quick change dr...

Page 12: ... is required The spindle must be supplied with 6 2 6 5 bar The radial flexibility centered must be supplied from a regulated source at 1 0 to 1 4 bar Technical Specifications FDB 150 300 340 Motor Compressed air turbine Idle speed RPM 65 000 30 000 40 000 Power 150 W 0 20 hp at 65 000 RPM 300 W 0 40 hp at 30 000 RPM 340 W 0 46 hp at 40 000 RPM Weight without adapter 1 1 kg 1 2 kg 1 2 kg Compensati...

Page 13: ... N at 1 0 4 1 bar Deburring speed Depending on the geometry of the grinder and the motor speed Spindle air pressure 6 2 6 5 bar 6 9 bar max Air consumption idle 11 8 l s 25 CFM Air consumption blocked 19 l s 40 CFM Noise pressure level 78 dB A without milling cutter Collet diameter standard 6 mm ER 11 Milling cutter commercial units classified for 40 000 RPM or higher Special tools Wrenches 1 pair...

Page 14: ...ol receives a thorough test procedure before it is shipped The following chart shows measured forces relative to applied compliance centering air pressure Measurements may vary from one product to another and should only be treated as nominal FDB 150 Compliance Force N Compliance Air Pressure Bar FDB 300 340 Compliance Air Pressure bar Compliance Force N ...

Page 15: ...stallation due to mounting orientation and condition of the unit The air turbine will attempt to maintain its full rated speed even under loaded conditions However when extremely heavy cuts are taken the motor may eventually stall Therefore multiple light passes are preferred over slow heavy cuts 15 04 00 FDB Assembly and Operating Manual en 389072 ...

Page 16: ...ables are attached bundled and must be strain relieved in a manner that allows for freedom of movement during operation 5 3 Mounting The FDB is capable of rear axial or side radial mounting SCHUNK offers a blank rear interface plate kit for rear mounting and a simple foot bracket for bench mounting CAUTION When using the side mounting pattern the mounting screws must not exceed maximum depth from ...

Page 17: ...5 3 1 Axial Mounting Installation Clamping Collar Blank InterfacePlate Clamping Collar 2x M5 Socket Head Cap Screws Axial Mounting Flange on rear Housing Assembly Axial Installation A blank robot adapter plate is also available to allow axial mounting off the rear of the deburring tool housing This plate may be modified by the system integrator or by the owner user of the FDB SCHUINK can provide c...

Page 18: ...y Precision Regulator 0 4 2 bar Supply Air clean dry non lubricated 6 9 bar min Filter High Flow Regulator 6 2 bar Pneumatic connections FDB 150 and FDB 300 340 Spindle Air Solenoid Valve 2 way High Flow Regulator 6 2 bar Spindle Motor Vent to Atmosphere Compliance centering Cylinders Precision Regukator 0 4 2 bar Filter Supply Air clean dry non lubricated 6 9 bar min Pneumatic connections FDB 900...

Page 19: ... components are not used Conventional customer supplied pneumatic components are used to control the air supply to the deburring tool SCHUNK recommends that the user install a high flow pneumatic pressure regulator and a high flow valve to properly supply a stable air supply to the spindle motor 4 12 for the maximum flow requirement The FDB will not operate properly if supplied air is below 6 2 ba...

Page 20: ...mum Exhaust air Emitted to the environment via the housing N A It is recommended that flexible plastic tubing be used for the motor air supply and the compliance force air supply The installed fittings can be removed to expose tapped supply ports thus allowing the use of alternate customer supplied components The turbine air motor is extremely quiet and vents dry air to the environment through the...

Page 21: ...g processes should not be performed by the FDB It may be dangerous to operate the FDB deburring tool 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 is intended to perform deburring only The FDB should not be used to deburr materials that are prone to fracture A fracturing workpiece may resul...

Page 22: ...g frequently is Always use hearing protection while working in the neighborhood of the deburring cell 6 3 Operational Considerations For instructions on how to replace the burr please consult 8 3 34 In many robotic deburring applications including steel and aluminum no cooling or lubrication of the rotary burr is necessary For some materials and situations the addition of coolants or compressed ai...

Page 23: ...m the housing M4 x 16 mm Button Head Socket Cap Screws Compliance after Lock is applied 3 Apply Loctite 7649 primer and Loctite 222 to the 4 hexagon socket screws M4 x 16 mm 4 Using a 2 5 mm hexagon socket wrench insert the 4 hexagon socket screws M4 x 16 mm into the threads on the housing from which the 4 hexagon socket screws M5 x 6 mm were removed Tighten the screws to 2 82 Nm 5 Connect all com...

Page 24: ...machining center or the robot During teaching the compliance air must be on and supplied above a minimum of 1 4 bar FDB 150 or 0 35 bar FDB 300 340 660 990 1040 Two programming methods are suggested but others are possible In the first method a dowel pin of suitable diameter is inserted in place of a cutting tool simulating the cutter shank diameter when teaching the robot path For 6mm 1 8 collets...

Page 25: ...h which will prevent the cutter from simultaneously contacting two perpendicular surfaces A tapered cutter may reach further into such an inside corner if the tool is presented in an inclined orientation and closer to the tip of the tool Note When working near the tip of a tapered cutter the surface cutting speed is reduced When deburring inside radii a similar situation may arise The customer is ...

Page 26: ...s the machine robot continues along its path The selection of a cutting tool is highly dependent upon the part material and geometry and the depth of cut It is not practical to present all the possibilities in this document Please see 6 6 1 26 of this document for a short list of burrs and suitable applications It is worth mentioning here that a specific family of burrs is available for working wi...

Page 27: ...on Features Benefits Double Cut Straight 1 8 Burr Diameter 9 16 Burr Length 1 8 Shank For hardened and tough materials super alloys and stainless steel alloyed cast steel and fiber reinforced plastics Edge and surface working Built up Welds of high tensile strength in mold and die making Higher cutting capacity than standard cuts Smoother finish for surface treatments Double Cut 14 Cone 1 8 Burr D...

Page 28: ...r reinforced plastics Edge and surface working Built up Welds of high tensile strength in mold and die making Higher cutting capacity than standard cuts Smoother finish for surface treatments Lower axial force than ADC Standard Cut 3 8 Burr Diameter 3 4 Burr Length 1 4 Shank For steels of high tensile strength die steels cast steel built up welds tough materials and welds For beveling For chamferi...

Page 29: ...aluminum Easy chip flow through positive rake angle rounded base of tooth convex tooth back No loading of the flutes not even while cutting sticky metals Smooth operation due to the peeling effect of the teeth Cut FVK 1 4 Burr Diameter 5 8 Burr Length 1 4 Shank For trimming and contour milling of all glass and carbon fiber reinforced plastics Special cut geometry allows high feed rates due to low ...

Page 30: ...linder Replace ring cylinder 8 3 4 49 Poor finish on work piece Feed rate is too fast Reduce feed rate Burr is worn Inspect burr if worn replace 8 3 34 Motor bearings are worn Inspect spindle shaft if shaft feels loose or has play replace 8 3 2 35 Burr Chattering during cut Feed rate is too fast Reduce feed rate Lack of rigidity Increase radial compliance pressure Too heavy a cut Decrease width of...

Page 31: ...stalls Not enough or no drive air Check drive air regulator for 6 2 Bar and for leaks Burr is not secure in collet Properly tighten burr in collet Too much side load Decrease width of cut make multiple passes Air motor needs replacing Replace air motor 8 3 2 35 Sticking spindle Motor bearings are worn Replace air motor 8 3 2 35 31 04 00 FDB Assembly and Operating Manual en 389072 ...

Page 32: ...in Serviceable Parts 8 1 Recommended Spare Parts For repair and spare parts please contact SCHUNK Suggested user replaceable optional and spare parts are listed in the tables below All other repairs must be performed by SCHUNK Available spare parts FDB 150 1 8 collet 3 mm collet Clamping nut Replacement motor FDB 300 340 Ø 3 mm collet Ø 1 8 collet Ø 3 16 collet Ø 6 mm collet Ø 1 4 collet Clamping ...

Page 33: ...ain optimum performance The life of the filter elements is dependent on the quality of compressed air at the customer s facility and therefore cannot be estimated 8 2 2 Lubrication Lubrication systems are not to be used The FDB air motor must be supplied with clean dry filtered air Oil in the air stream will cause the air motor to fail prematurely Failure of the motor due to oil in the air stream ...

Page 34: ...worn burr 8 3 Service Procedures 8 3 1 Burr Replacement In normal operation the burr will become worn If improper feeds and speeds are used the cutter may become loaded with material In both instances the cutter will need to be replaced During initial production the burr and the workpiece should be examined often in order to determine at what interval the burr should be replaced Replacing the coll...

Page 35: ...cing a worn one insert the new burr and measure and adjust the length of its exposed portion according to the measurement taken in the first step 8 Tighten the collet by reversing the steps above 9 Restore the air supply 8 3 2 Air Motor Replacement If the air motor is operated using oil laden air it will fail and require replacement Failure of the motor due to oil in the spindle air is not covered...

Page 36: ...rom the outer surfaces 5 Ease the garter spring off the front spindle boot 6 Remove the button head screws and retainer securing the boot to the front of the unit 7 Remove the boot 8 On the air supply block remove the small set screw visible below near the spindle air supply port 9 Remove the two socket head screws securing the air supply block to the side of the unit 10 Remove the air supply bloc...

Page 37: ... the flat surfaces on the gimbal ring 22 Insert the two set screws into the gimbal ring that secure the pin and tighten torque to 0 67 Nm 23 Lubricate the OD of the two pieces of metal tubing that go between the outer gimbal ring and the air supply ring prior to their installation then fit them to the gimbal ring 24 Lubricate the o rings on the inside bore of the air supply ring 25 Locate and alig...

Page 38: ...re air supply block to the housing with the two socket head cap screws and torque to 2 8 Nm 34 Apply Loctite 222 to the thread on the small set screw for the air supply block 35 Install the small set screw in the hole visible below near the spindle air supply port on the air supply block torque to 0 67 Nm 36 Fit the boot to the front of the housing aligning the holes in the boot and housing 37 App...

Page 39: ...eight liquid thread locker Loctite 222 or equivalent to the socket head cap screws and tighten to secure the rear cover Install the spindle air supply fitting in the air motor using non hardening thread sealant Insure that the spindle air supply fitting is centered in the housing side boot opening before tightening the fastener in the pivot post 8 3 2 3 Air Motor Replacement FDB 990 FDB 1040 Spind...

Page 40: ...t spindle boot 8 Using a 2 5 mm Allen wrench remove 6 M3 button head socket cap screws holding the boot retainer ring and disk boot to the front housing assembly 9 Remove the boot retainer ring and disk boot 10 Using a 2 mm Allen wrench remove the 6 M4 socket head cap screws that secure the rear housing 11 Remove the rear housing 12 If the tool is locked to single axis compliance use a 2 mm Allen ...

Page 41: ... as an assembly by twisting it and pulling it backward out of the main housing 1 3 mm Allen Wrench Gimbal Ring M4 Set Screw Threaded Bushing Motor Ring Air Motor 19 Thread M3 fasteners into the pivot pins of the gimbal ring assembly 20 At the front of the gimbal ring assembly use a 2 5 mm Allen wrench to loosen the 2 M5 set screws securing the motor pivot pins until they extend out of the front ho...

Page 42: ...ke sure the wave spring is held in place on the inside of the gimbal ring by coating it with grease 26 Insert the pivot pins to secure the gimbal ring in place 27 Using a 4 mm Allen wrench install the 2 M5 set screw into the gimbal ring to secure the pivot pins Tighten to 2 82 Nm 28 Using a 1 3 mm Allen wrench inserted into the side hole of the threaded bushing turn the bushing in toward the gimba...

Page 43: ...in place Gimbal Ring 2x M4 Set Screws Threaded Bushing 1 3 mm Allen Wrench 32 Using a 4 mm Allen wrench install the 2 M5 set screw into the front housing assembly to secure the pivot pins Tighten to 2 82 Nm 33 Using a 1 3 mm Allen wrench inserted into the side hole of the threaded bushing turn the bushing in toward the housing until contact then back it off 1 6 of a turn one through hole 34 Using ...

Page 44: ...d cap screws Tighten to 2 82 Nm 38 Slide the disk boot over the air motor spindle and align to the front housing assembly 39 Apply Loctite 222 to the 6 M3 button head socket cap screws 40 Fit the boot retaining ring over disk boot and secure with 6 M3 button head socket cap screws using a 2 5 mm Allen wrench Tighten to contact and an additional 1 2 turn Compliance Air Fitting Spindle Supply Fittin...

Page 45: ...vot bearing is subject to wear and should be replaced when excessive spindle motion is observed Contact between the motor air supply fitting and the main housing indicates pivot bearing wear which should be corrected To minimize possible downtime the pivot bearing should be replaced any time the air motor is replaced The pivot bearing may be replaced in one of two ways For quick repairs with minim...

Page 46: ...e bearings out 4 Apply a tiny amount of non hardening gasket sealant Permatex 2 or equivalent to the outer race of the new bearings to secure them during the reassembly process Only the smallest amount is required 5 Insert the pivot bearing without an extended inner race into the bore with the cup seal in the bottom Insert the bearing with the extended inner race into the other bore 6 Reassemble a...

Page 47: ...mbly is the reversal of the previous steps with the following points Insure the dowel pin and small o ring that go between the housing and the rear cover are in place before refitting the rear cover Use liquid thread locker on all the socket head screws but NOT on the brass pivot post plug where applicable Insure that the spindle air supply fitting is centered in the housing side boot opening prio...

Page 48: ... ball Apply low strength thread locker such as Loctite 222 to the socket head screws used to secure the clamping washer and refit both the washer and screws to the rear housing Leave the fasteners finger tight at this time Sparingly apply a low strength thread locker to the keying dowel pin set screws and insert both set screws in the rear housing Adjacent to the keying dowel pin pivot the bearing...

Page 49: ...ont housing assembly 3 Remove the rear housing 4 Invert the unit and press the ring cylinder assembly outwards to the rear Use a non metallic drift to prevent damage It may be necessary to use a small arbor press and support plate to remove the ring cylinder if the unit has been in service for a prolonged time 5 To reassembly apply a thin film of grease or oil to the bore in the front housing asse...

Page 50: ...earance hole for the ring cylinder and use an arbor press for extraction Retain the small o ring and dowel pin for reuse Always replace the large o rings on the outside of the ring cylinder assembly when it is reinstalled 5 Replacing the ring cylinder assembly is the reversal of these steps with the following points Apply a thin film of grease or oil to the housing bore where the ring cylinder sea...

Page 51: ...e the M4 socket head cap screws 3x securing the ring cylinder assembly to the rear housing 8 Place the removed M4 screws in the tapped holes in the ring cylinder body and tighten them slowly and equally so they push the ring cylinder assembly out of the rear housing 9 Apply a thin film of grease or oil to the housing bore where the ring cylinder seats prior to installation 10 Insert the new ring c...

Page 52: ...ing O ring M3 Button Heasd Socket Cap Screws Spindle Supply Fitting Assembly 1 Remove and or lock out the spindle motor air supply for safety 2 Disconnect the air hose from the spindle supply fitting and the compliance air fitting 3 Remove the deburring tool from the robot or work location 4 Clean the debris from the deburring tool using compressed air and a clean rag to wipe any grease from the o...

Page 53: ...ontact plus one additional flat 11 Stretch the O ring over the boot it will seat in the groove on the contact sleeve 12 Install the deburring tool to the robot or work location 13 Connect the air hose to the spindle supply fitting and the compliance air fitting 14 Apply and or unlock the spindle motor air supply 53 04 00 FDB Assembly and Operating Manual en 389072 ...

Page 54: ...lways use the crate when transporting the deburring tool in order to minimize the risk of damage 9 2 Storage and Preventive Maintenance during Storage The FDB should be stored in its crate when it is not in use The FDB should also be stored in a dry place For long term storage the FDB should be thoroughly cleaned of any burrs or debris It should not be disassembled Place the FDB inside a sealed pl...

Page 55: ... Chamfering spindle FDB pneumatic ID number 0322200 0322201 0322202 0322203 0322205 0322208 0322240 0322245 The partly completed machine may not be put into operation until conformity of the machine into which the partly completed 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 doc...

Page 56: ...o KG Clamping and gripping technology Bahnhofstr 106 134 D 74348 Lauffen Neckar Tel 49 7133 103 0 Fax 49 7133 103 2399 info de schunk com schunk com Folgen Sie uns I Follow us 08 2022 2022 SCHUNK GmbH Co KG 04 00 FDB Assembly and Operating Manual en 389072 ...

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