SCHUNK FDB-AC 90 Assembly And Operating Manual Download

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Original Manual

Assembly and Operating Manual
FDB-AC

Robotic Deburring Tool

Summary of Contents for FDB-AC 90

Page 1: ...Original Manual Assembly and Operating Manual FDB AC Robotic Deburring Tool ...

Page 2: ...erations for the purpose of technical improvement Document number 389513 Version 02 00 15 08 2019 en SCHUNK GmbH Co KG All rights reserved 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 challe...

Page 3: ...dangers 10 2 11 1 Protection during handling and assembly 11 2 11 2 Protection during commissioning and operation 11 2 12 Notes on particular risks 12 3 Technical data 13 3 1 Technical Specifications 13 3 2 Environmental Limitations 15 4 Handling Installation Storage and Transportation 16 4 1 Inspection of Condition when Delivered 16 4 2 Unpacking and Handling 16 4 3 Installation 17 4 3 1 Pneumati...

Page 4: ...ser Serviceable parts FDB AC 90 32 6 1 2 User Serviceable parts FDB AC 180 33 6 2 Recommended Inspection and Cleaning Procedure 34 6 3 Lubrication 36 6 4 Replacement of Burrs 37 6 5 Replacement of Other FDB AC Parts 38 6 6 Overhaul 38 6 7 Repairs and Spare Parts 38 7 Drawings 39 7 1 FDB AC 90 39 7 2 FDB AC 180 40 8 Translation of original declaration of incorporation 41 9 Annex to Declaration of I...

Page 5: ...is manual Illustrations in this manual are provided for basic understanding and may differ from the actual product design In addition to these instructions the documents listed under Applicable documents 6 are applicable 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 ...

Page 6: ...ool FDB AC 90 Robotic Deburring Tool FDB AC180 1 2 Warranty If the product is used as intended the warranty is valid for 24 months from the ex works delivery date under the following conditions Observe the ambient conditions and operating conditions Ambient conditions and operating conditions 8 Observe the specified maintenance intervals Maintenance 31 Parts touching the workpiece and wear parts a...

Page 7: ...uct is used with machines systems or workpieces 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 Constructional changes Implementation of structural changes By conversion...

Page 8: ... the complete assembly and operating manual Observe the national safety regulations and rules and general safety instructions The following personal qualifications are necessary for the various activities related to the product Trained electrician Due to their technical training knowledge and experience trained electricians are able to work on electrical systems recognize and avoid possible danger...

Page 9: ...ggles when handling hazardous substances Wear close fitting protective clothing and also wear long hair in a hairnet when dealing with moving components 2 7 Notes on safe operation Incorrect handling of the personnel Incorrect handling and assembly may impair the product s safety and cause serious injuries and considerable material damage Avoid any manner of working that may interfere with the fun...

Page 10: ...ied Test the product after a malfunction to establish whether it still functions properly and no increased risks have arisen 2 10 Disposal Handling of disposal The incorrect handling of disposal may impair the product s safety and cause serious injuries as well as considerable material and environmental harm Follow local regulations on dispatching product components for recycling or proper disposa...

Page 11: ...evention rules Use suitable assembly and transport equipment and take precautions to prevent jamming and crushing Incorrect lifting of loads Falling loads may cause serious injuries and even death Stand clear of suspended loads and do not step into their swiveling range Never move loads without supervision Do not leave suspended loads unattended 2 11 2 Protection during commissioning and operation...

Page 12: ...umatics FDB AC 90 17 Pneumatics FDB AC 180 18 Only original spare parts and files burrs delivered from the tool manufacturer must be used Repairs and Spare Parts 38 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 ...

Page 13: ...pe straight fluting 2 90 coned shape spiraled fluting 3 C2 C5 Carbide Other rotary burr file qualities on request Special tools Burr changing tool Notes about Sound pressure level All noise emission measurements were taken at a distance of 3 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...

Page 14: ...ata Measurements may vary from one product to another and should only be treated as nominal 0 50 100 150 200 250 300 350 400 0 5000 10000 1500 0 2000 0 250 00 30000 Roboter torque M in Nmm Output power P inW Torq ue Pow er 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 i...

Page 15: ...onmental Limitations General Area classification None Gas group ignition group None Operation Installation position 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 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 Stora...

Page 16: ... accordance with freight documents 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 parts that may have been damaged for a closer inspection If necessary notify SCHUNK for assistance in evaluation of the product condition 4 2 Unpacking and Handling The FDB AC tool during transportation storing and handling sho...

Page 17: ...r Exhauset FFP FDB AC Axial force from deburring process External pressure regular 0 3 psi Option 2 on off valve actuated from robot controller Option 2 on off valve actuated from robot controller Connect the FDB AC 90 as shown in the figure Two connection methods are shown Option 1 uses one solenoid valve to control both motor drive air supply and axial force air supply Option 2 uses two solenoid...

Page 18: ...he 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 rotary tungsten carbide fi...

Page 19: ...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 Function Thread Type Pressure Motor inlet 1 8 3 1 5 2 bar maximum 6 2 Axial contact force inlet M5 0 3 1 bar maximum 3 1 bar Control functions M5 Optional Exhaust 1 4 Not Applicable It is recommended that 3 8 plastic tube be used for the ...

Page 20: ...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 Lubrication 36 CAUTION 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 Install the lubrication e...

Page 21: ...is adapter or equivalent should be used for mounting the FDB AC to the robot or to other equipment The adapter facilitates the connection of the pneumatics to the FDB AC 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 ...

Page 22: ...e and carrying or performing maintenance try to always grab and hold it around the motor housing Drawings 4 5 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 also 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 storag...

Page 23: ...tor should be familiar with the task of deburring in general and should have extensive knowledge relating to robots and automation incorporating robots The system integrator is responsible for providing user documentation 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...

Page 24: ...tuations for both personnel and equipment could be created The FDB AC is intended to perform 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 Material removed correctly should be in the form of chips Reduce the robot velocity when the workpiece a...

Page 25: ...the barrier in order to facilitate access to the cell for authorized personnel only The barrier could consist partly or fully of Plexiglas 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 r...

Page 26: ... position in the robot controller use the mid position of the 0 31 inch axial stroke of the compensation piston Also remember to take into account the depth of the Speedeburr adapter Mounting Adapter and Interface Plate 21 In case an additional interface plate is used in order to fit the adapter to the robot this depth must be considered as well Without Speedeburr adapter Dx 75 mm Dy 0 mm Dz 70 mm...

Page 27: ... position in the robot controller use the mid position of the 0 31 inch axial stroke of the compensation piston Also remember to take into account the depth of the Speedeburr adapter Mounting Adapter and Interface Plate 21 In case an additional interface plate is used in order to fit the adapter to the robot this depth must be considered as well Without Speedeburr adapter Dz 115 mm With Speedeburr...

Page 28: ...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 For instructions on how to replace the burr please consult section Replacement of Burrs Replacement of Burrs 37 CAUTION The FDB AC should not be statically mounted with the cutting tip up This will increase the ...

Page 29: ...ial forces The method used will depend on the robot s capabilities and programmer preferences 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 supp...

Page 30: ...n the adjustment screw on the side of the 90 degree bracket User Serviceable parts FDB AC 90 32 and FDB AC 90 39 This adjustment varies the flow rate clockwise to decrease counterclockwise to increase 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...

Page 31: ...ed 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 orientation then a continuous or regular burst of high velocity air should be used to blow debris away from the p...

Page 32: ...1 1 User Serviceable parts FDB AC 90 User Serviceable Parts Item Quantity Description 1 1 Spine Lock Screw 2 1 Male Spline 3 1 Lock Ring 4 1 Compensation piston 5 1 Cylinder 6 1 Rotary File Burr 7 1 Motor Housing 8 1 90 Degree Bracket 9 1 Adjustment Screw 10 1 O ring Set ...

Page 33: ...perating Manual en 389513 33 6 1 2 User Serviceable parts FDB AC 180 User Serviceable Parts Item Quantity Description 1 1 Spine Lock Screw 2 1 Male Spline 3 1 Lock Ring 4 1 Compensation piston 5 1 Cylinder 6 1 Rotary File Burr 7 1 O ring Set ...

Page 34: ...linder and clean thoroughly Ø Inspect the Compensation piston and Cylinder for scratches Deep scratches may require replacement of the part s Ø Check the Burr I6 condition and replace as necessary Ø 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 Ø Assemble the Compensation piston in t...

Page 35: ...rr and the workpiece should be examined often in order to determine at what interval the burr should be replaced Replacement of Burrs 37 At regular intervals 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 specifications Parts inside the FDB AC such as the blades in the air vane motor...

Page 36: ...t regular intervals CAUTION When the system is first installed use a higher than recommended oil setting approx 2 times until the unit is receiving consistently oiled air Run oil through the entire pneumatic tube between the oiler and the unit prior to operation WARNING Damage to health due to inhalation of air containing oil Long time exposure to air containing oil could be dangerous for personne...

Page 37: ...onal Maintenance 31 To change the burr unscrew it with the burr changing tools and replace it with a new one Re assemble the parts Regular Operational Maintenance 31 After the burr is changed and the unit re assembled check that the Compensation piston is rotating with the burr If the Compensation piston is not rotating static friction may be interfering so that the axial force cannot remain const...

Page 38: ...lied by SCHUNK should be used 6 6 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 overhaul must be performed by SCHUNK in order to maintain the technical specifications and tool life of the FDB AC 6 ...

Page 39: ...C 90 2 optional ports M5 Axial air pressure M5 1 4 Exhaust Drive pressure 1 8 1 4 Exhaust Free Flying Piston Tungsten Carbide Burr File Axial stroke 8 Adjustment screw 0 015 Ø6 0 H7 5 Deep 0 030 Ø50 0 H7 2 Deep Ø66 27 45 B C Ø 40 Ø 54 4x Ø5 for M6 Socket Cap Screws C bore from Far Side ...

Page 40: ...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 ...

Page 41: ...ed invalid if modifications are made to the product Product designation Robotic Deburring Tool FDB AC pneumatic ID number 0322206 0322207 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 dem...

Page 42: ...rinciples of safety integration X 1 1 3 Materials and products X 1 1 4 Lighting X 1 1 5 Design of machinery to facilitate its handling X 1 1 6 Ergonomics X 1 1 7 Operating positions X 1 1 8 Seating X 1 2 Control Systems 1 2 1 Safety and reliability of control systems X 1 2 2 Control devices X 1 2 3 Starting X 1 2 4 Stopping X 1 2 4 1 Normal stop X 1 2 4 2 Operational stop X 1 2 4 3 Emergency stop ...

Page 43: ...able guards X 1 4 2 3 Adjustable guards restricting access X 1 4 3 Special requirements for protective devices X 1 5 Risks due to other hazards 1 5 1 Electricity supply X 1 5 2 Static electricity X 1 5 3 Energy supply other than electricity X 1 5 4 Errors of fitting X 1 5 5 Extreme temperatures X 1 5 6 Fire X 1 5 7 Explosion X 1 5 8 Noise X 1 5 9 Vibrations X 1 5 10 Radiation X 1 5 11 External rad...

Page 44: ...quirements for certain categories of machinery X 2 1 Foodstuffs machinery and machinery for cosmetics or pharmaceutical products X 2 2 Portable hand held and or guided machinery X 2 2 1 Portable fixing and other impact machinery X 2 3 Machinery for working wood and material with similar physical characteristics X 3 Supplementary essential health and safety requirements to offset hazards due to the...

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