SCHUNK MFT User instructions

Translation of the original manual
Assembly and operating manual
MFT
Polishing Spindle

Imprint
2
03.00 | MFT | Assembly and operating manual | en | 389545
Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights
reserved. Any reproduction, processing, distribution (making available to third parties),
translation or other usage - even excerpts - of the manual is especially prohibited and
requires our written approval.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 389545
Version: 03.00|19/11/2019|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 challenge us. We will find a solution!
Best regards,
Your SCHUNK team
SCHUNK GmbH & Co. KG
Spann- und Greiftechnik
Bahnhofstr. 106 – 134
D-74348 Lauffen/Neckar
Tel. [phone]
Fax [phone]
[email protected]
schunk.com

Table of Contents
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Table of Contents
1 General.................................................................................................................... 5
1.1 About this manual ................................................................................................ 5
1.1.1 Presentation of Warning Labels ...............................................................5
1.1.2 Applicable documents ..............................................................................6
1.2 Warranty .............................................................................................................. 6
1.3 Scope of delivery .................................................................................................. 6
2 Basic safety notes ................................................................................................... 7
2.1 Intended use......................................................................................................... 7
2.2 Not intended use.................................................................................................. 7
2.3 Constructional changes ........................................................................................ 7
2.4 Spare parts ........................................................................................................... 7
2.5 Recommended Spare Parts .................................................................................. 8
2.6 Environmental and operating conditions ............................................................. 8
2.7 Personnel qualification......................................................................................... 8
2.8 Personal protective equipment............................................................................ 9
2.9 Transportation and Protection during Transportation......................................... 9
2.10 Safety Precautions.............................................................................................. 10
3 Technical Specifications ..........................................................................................11
4 Description and function.........................................................................................14
4.1 Description ......................................................................................................... 14
4.2 Spindle Operation and Media Selection ............................................................. 15
5 Assembly and settings ............................................................................................16
5.1 Mechanical connection ...................................................................................... 16
5.2 Pneumatic Connection ....................................................................................... 16
5.3 Electrical Connections ........................................................................................ 19
5.4 Initial Operation ................................................................................................. 20
5.4.1 Media Considerations.............................................................................20
5.4.2 Tool Position and Programming .............................................................21
6 Maintenance and repair..........................................................................................22
6.1 Routine Operational Maintenance..................................................................... 22
6.2 Media Replacement ........................................................................................... 22
6.3 Boot Replacement .............................................................................................. 23
6.4 Air Motor Replacement...................................................................................... 24
6.5 Sensor Replacement........................................................................................... 25
6.5.1 Sensor for monitoring: Spindle extracted (Option-F) .............................25
6.5.2 Sensor for monitoring: Spindle retracted (Option-R) .............................26

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6.5.3 Sensor for rotation speed: Tachometer sensor (Option -T) ...................27
6.6 Pneumatic -lines/-connections........................................................................... 28
6.7 Lubrication of the polishing spindle ................................................................... 29
6.8 Storage and Preventive Maintenance during Storage........................................ 29
7 Troubleshooting .....................................................................................................30
7.1 Troubleshooting Matrix...................................................................................... 30
8 Drawings.................................................................................................................31
9 Translation of original declaration of incorporation ................................................35
Glossary of Terms ...................................................................................................36

General
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1 General
1.1 About this manual
This manual contains important information for a safe and
appropriate use of the product.
This manual is an integral part of the product and must be kept
accessible for the personnel at all times.
Before starting work, the personnel must have read and
understood this operating manual. Prerequisite for safe working is
the observance of all safety instructions in this 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 cause irreversible injury or death.
WARNING
Dangers for persons!
Non-observance can lead to irreversible injury and even death.
CAUTION
Dangers for persons!
Non-observance can cause minor injuries.
CAUTION
Material damage!
Information about avoiding material damage.

General
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1.1.2 Applicable documents
• General terms of business *
• Catalog data sheet of the purchased product *
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
1.2 Warranty
The warranty of the Polishing Spindle MFT is valid for 24 months.
This does not apply to the air motor.
The air motor is warranted for a period of 1000 hours at not
lubricated operations and 2000 hours with lubricated air or 12
month of operation from date of delivery from the production
facility, whichever occurs first.
Parts touching the work piece and wear parts are not part of the
warranty.
1.3 Scope of delivery
The scope of delivery includes
• Polishing Spindle MFT in the version ordered

Basic safety notes
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2 Basic safety notes
2.1 Intended use
The Polishing Spindle MFT is intended to perform robotic and non-
robotic material finishing operations.
• The product may only be used within the scope of its technical
data.
• The product is intended for industrial use.
• The product is intended for installation in a machine/system or
for mounting to a robot. The applicable guidelines must be
observed and complied with.
• Appropriate use of the product includes compliance with all
instructions in this manual.
• When implementing and operating components in safety-
related parts of the control systems, the basic safety principles
in accordance with DIN EN ISO 13849-2 apply. The proven safety
principles in accordance with DIN EN ISO 13849-2 also apply to
categories 1, 2, 3 and 4.
2.2 Not intended use
It is not intended use if the product is used, for example, as a
pressing tool, stamping tool, lifting gear, guide for tools, cutting
tool, clamping device or a drilling tool.
• Any utilization that exceeds or differs from the appropriate use
is regarded as misuse.
2.3 Constructional changes
Implementation of structural changes
By conversions, changes, and reworking, e.g. additional threads,
holes, or safety devices can impair the functioning or safety of the
product or damage it.
• Structural changes should only be made with the written
approval of SCHUNK.
2.4 Spare parts
Use of unauthorized spare parts
Using unauthorized spare parts can endanger personnel and
damage the product or cause it to malfunction.
• Use only original spare parts or spares authorized by SCHUNK.

Basic safety notes
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2.5 Recommended Spare Parts
For repair and spare parts please contact SCHUNK. For an
exploded drawing showing all the components of the MFT, see
Drawings [}31].
2.6 Environmental and operating conditions
Required ambient conditions and operating conditions
Incorrect ambient and operating conditions can make the product
unsafe, leading to the risk of serious injuries, considerable material
damage and/or a significant reduction to the product's life span.
• Make sure that the product is used only in the context of its
defined application parameters, Technical Specifications
[}11].
• The Polishing Spindle MFTshould only be used in an automated
cell/chamber.
• The work cell must be secured by means of barriers to prohibit
personnel from entering the cell. A lockable door should be in-
cluded as a part of 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
manufacturing process.
• Be aware of high sound levels. While the Polishing Spindle MFT
air motor is not loud, the cutting action associated with many
processes frequently is. Always use hearing protection while
working in the neighborhood of the production cell.
2.7 Personnel qualification
Inadequate qualifications of the personnel
If the personnel working with the product is not sufficiently
qualified, the result may be serious injuries and significant
property damage.
• All work may only be performed by qualified personnel.
• Before working with the product, the personnel must have read
and understood the complete assembly and operating manual.
• Observe the national safety regulations and rules and general
safety instructions.

Basic safety notes
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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 dangers and know the relevant standards and
regulations.
Qualified personnel Due to its technical training, knowledge and experience, qualified
personnel is able to perform the delegated tasks, recognize and
avoid possible dangers and knows the relevant standards and
regulations.
Instructed person Instructed persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behaviour.
Service personnel of
the manufacturer
Due to its technical training, knowledge and experience, service
personnel of the manufacturer is able to perform the delegated
tasks and to recognize and avoid possible dangers.
2.8 Personal protective equipment
Use of personal protective equipment
Personal protective equipment serves to protect staff against
danger which may interfere with their health or safety at work.
• When working on and with the product, observe the
occupational health and safety regulations and wear the
required personal protective equipment.
• Observe the valid safety and accident prevention regulations.
• Wear protective gloves to guard against sharp edges and
corners or rough surfaces.
• Wear heat-resistant protective gloves when handling hot
surfaces.
• Wear protective gloves and safety goggles when handling
hazardous substances.
• Wear close-fitting protective clothing and also wear long hair in
a hairnet when dealing with moving components.
2.9 Transportation and Protection during Transportation
The MFT is packaged in a crate designed to secure and protect it
during transportation. Always use the crate when transporting the
MFT in order to minimize the risk of damage.

Basic safety notes
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2.10 Safety Precautions
• Never use or start the MFT without first reading and
understanding the operating procedures described in this
manual.
• Make sure that the MFT is mounted as described in this manual.
• Never use the MFT for any purposes or in any ways not
explicitly described in this manual.
• Make sure that the pneumatic control equipment is connected
as described.
• Only original spare parts supplied by SCHUNK must be used.
• Install a barrier to prohibit people from approaching the MFT
while in operation.
• Never be present near the MFT while it is started or running. If
it is necessary to approach the MFTwhile in motion, stand
behind appropriate Plexiglas windows.
• Be aware of rotating parts.
• Abrasive media must be rated for at least 5,600 1/min.
• Use eye protection.
• Be aware of high sound levels during cutting. Always use
hearing protection while working in the neighborhood of the
MFT.
• During system or tool maintenance, make sure the MFT and
equipment are stopped before entering the cell. Never be
present in the cell when the tool is running when installing and
testing.

Technical Specifications
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3 Technical Specifications
Main specifications for the axially compliant tool:
Operating temperature [°C] 5 - 35
Storage Temperature [°C] 0 - 45
Pressure medium clean, dry, filtered, lubricated or
not lubricated air.
To achieve the optimum engine
life, it is recommended to
lubricate the air.
The use of a coalescing filter and
filter elements rated 5 micron or
better is recommended.
Air consumtion [l/s] at 6.2 bar 9
Motor Air motor, vane type
Idle Speed [1/min] 5.600
Working Speed
(max. power) [1/min]
2.600
Power at 2.600 1/min [W] 390
Continuous torque (max. power)
[Nm]
1.4
Starting torque (starting/stall)
[Nm]
2.7
Weight total [kg]
(w/o adapter)
3.3
Compensation axial (max.) [mm] 15
7 - 8 recommended
Compliance force @ supply
pressure of 0.34–4.1 bar [N]
14 - 74
Sspindle air pressure (max.)
[bar]
6.2
Air consumption (max.) [l/s] approximately 9
Oil consumption
(recommended)
approximately 3–4 drops of oil
per minute (1 drop = 15mm3) by
oil fog at max. air consumption
Fast Tightening Chuck size 3/8 "
Abrasive media Customer-supplied
Sound Pressure Level [dBA]
No-Load at a Distance of 1.5
meters from Tool
< 75 *

Technical Specifications
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* Because the working environment is unknown, it is impossible
to predict the noise that will occur during an operation. The
tool may also excite resonant frequencies on equipment to
which it is mounted creating higher sound pressure levels than
the unit by itself.
The following charts show measured forces relative to applied
compliance air pressure. Measurements may vary from one
product to another, and should only be treated as nominal.
Air Pressure (bar)
Compliance Force (N)
Horizontal Compliance Force Curves
The force characteristics shown graphically above are for
horizontal, rigidly-mounted installations. The weight of the motor,
chuck, and abrasive media must be added to this if the motor is
mounted vertically with the spindle down or subtracted with the
spindle pointed up. Units mounted at angles between horizontal
and vertical provide a compliance force that must be calculated
based on the specific mounting geometry or orientation.
The air motor operating speed will change according to load
applied to it developing the power required for the specific task
being attempted. The idle speed of the motor will be its maximum
as no load is applied. This will drop to a lower operating speed
where it will develop the maximum torque. If the torque required
exceeds the maximum available, the motor will stall.

Technical Specifications
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13
Torque (Nm)
1/min
Motor Torque Curves
1/min
Power (kW)
Motor Power Curves

Description and function
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4 Description and function
4.1 Description
CAUTION
•Never use the Polishing Spindle MFT for purposes other than
automated processes.
•Never use the Polishing Spindle MFT Never use the
While the Polishing Spindle MFT provides axial travel, it is not
designed to eliminate tool chatter which will be experienced in full
contact operations, such as countersinking. Rigid tools, such as
milling machines, are required for such applications. It may be
dangerous to operate the Polishing Spindle MFT 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 Polishing Spindle MFT is not designed to support radial loads.
The use of radially used tools (round brushes and grinding rollers)
with the unit is not permitted. This can lead to jamming of the
round guides and prevent axial movement. In addition, the motor
is loaded in an inadmissible manner, which can significantly reduce
the service life.
Reduce the feed rate when the work piece and the tool are making
initial contact. Making the contact movement between the tool
and the work piece too fast may in some situations result in a
collision. Collisions may create hazardous situations for both
personnel and equipment.
When performing maintenance, always remember to tighten all
the fasteners. When replacing media always secure it correctly and
insure that the chuck is tightened Routine Operational
Maintenance [}22].
The air motor of the Polishing Spindle MFTis equipped with an
integral speed reduction gearbox. The life of this gearbox will be
reduced.
NOTE
Never use the Polishing Spindle MFT in a manner to produce
radial loads. Avoid using the Polishing Spindle MFT dfor
countersinking or drilling.

Description and function
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4.2 Spindle Operation and Media Selection
When used with flexible abrasive media, the Polishing Spindle MFT
will perform best when the rotating media approaches the burr in
a direction that will fold the burr back on itself. This will allow the
media to remove material rapidly without excessive force and
without the creation of a secondary burr. This will decrease the
cycle time for the operation while extending the life of the tool
and the consumable media. The MFT spindle rotates clockwise
when viewed from behind.
The selection of such media is highly dependent upon the work
piece material and geometry, and the amount of material to be
removed. It is not practical to present all the possibilities in this
document.

Assembly and settings
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5 Assembly and settings
5.1 Mechanical connection
The product is designed for side mounting.
SCHUNK offers a side interface plate kit for bench mounting.
The product must be rigidly mounted prior to use.
Under no circumstances should the product be used for manual/
hand operations.
5.2 Pneumatic Connection
Notes on compressed
air supply
Air line fittings supplying the Polishing Spindle MFT should be
installed with care using a minimum of tape or liquid sealant.
To prevent contaminant damage to the air motor, all air lines
should be blown down to remove debris prior to connection of the
Polishing Spindle MFT.
Water damage of the air motor or damage associated with debris
in the air lines is not covered under warranty.
Once mounted, the Polishing Spindle MFT should be supplied with
clean, filtered and optionally lubricated compressed air.
Connection Connect the Polishing Spindle MFT as shown in the following
figure.
Supply air:
clean, dry,
6.9 bar min.
Filter Lubricator
High-Flow Regulator
6.2 Bar
Spindle Air
Solenoid Valve
(2-Way)
Spindle
Motor
Vent to
Atmosphere
Compliance
Cylinders
Compliance air
solenoid valve
(4-Way)
Precision
Regulator
0-4.2 Bar
Pneumatic Connections

Assembly and settings
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17
The air supply should be clean, dry, filtered, and optionally
lubricated.Technical Specifications [}11].
A high-flow air pressure control regulator is required to supply the
spindle motor at 6.2 bar. A second, precision, self-relieving
regulator will supply air for the compliance or centering force.
The compliance force is applied axially and is adjusted until the
desired finishing result is achieved. The robot traversing speed will
also be adjusted to achieve the desired finish.
Conventional, customer-supplied, pneumatic components are
used to control the air supply to the 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 of 6.2 bar
to the spindle motor. (See Section Technical Specifications [}11]
for the maximum flow requirements.) While the spindle motor can
be operated below 6.2 bar, it will not develop full power or speed.
Very little airflow is required for the compliance mechanism.
The air supply solenoid valve must be controlled through robot or
controller.
CAUTION
Pneumatic components used for the motor drive circuit must be
capable of meeting the air consumption requirements Technical
Specifications [}11]. Poor performance will result if the correct
components are not used. Lubricators must be located as close to
the unit as possible with performance rapidly deteriorating when
the distance exceeds 5 meters.
Function Connection Type Pressure
Motor Inlet G 1/4" 6.2 bar
Compliance (Axial)
Force
G 1/8" 0.34–4.1 bar (max.)
Exhaust G 1/4"(High-flow
Muffler Supplied)
Not Applicable

Assembly and settings
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The Polishing Spindle MFT must be plumbed using flexible tubing.
The inside diameter of the tubing should be as large as practical to
minimize pressure drop to the spindle motor [10mm minimum].
The air motor runs quiet and vents dry exhaust air to the
environment through the pre-mounted silencer on the rear of the
unit when using oil-free air or a slightly oily exhaust air when
operating with oiled air. The customer may choose to replace the
muffler with tubing to carry exhaust away from the work area.
Such tubing must be as large and flexible as possible to minimize
pressure drops and allow unrestricted axial motion respectively.
To reduce the sound level in neighboring working areas, a
customer-supplied barrier surrounding the installation may be
installed (Plexiglas or Lexan is preferred Technical Specifications
[}11].
The compliance force air supply pressure regulator should be
adjusted between 0.34 – 4.1 bar. When testing for the proper
contact force, start with a very low pressure and increase slowly
until the desired process result is achieved.

Assembly and settings
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19
5.3 Electrical Connections
The Polishing Spindle MFT tool can be equipped with up to three
sensors to monitor spindle position and speed. These include the
Forward, Retract, and Tachometer sensors. Each sensor is a PNP type
proximity switch using three wire electrical hook-up.
The Forward and Tachometer sensors are a standard 8mm
threaded body 3-pin type. These sensors each have a three-wire
cable with open strands, which are led out of the back of the
Polishing Spindle MFT. The Retract sensor is a flat proximity switch
whose short cable is terminated with a male threaded 8mm
connector. This connection may be extended using any industry
standard 8 mm 3-pin cable.
The electrical connections for 3-pin proximity sensors are color-
coded and adhere to industry-standards. The blue sensor wires are
connected to 0V and the brown wires are connected to a positive
voltage source between 10V and 30VDC. With the PNP sensors
used on Polishing Spindle MFT, the black wire is the output signal,
when the switch closes (turns on). Thus, the sensor "sources"
power to the load or monitoring circuit.
Brown
Blue
Black
Brown
Blue
Black
Load
Load
Face View of Male Connector
Typical PNP Proximity Switch Schematic Typical Male PNP Connector Pin Out
(Face View of Male 8mm Connector)
See Maintenance and repair [}22] of this manual for further
information on setting and using these sensors.

Assembly and settings
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5.4 Initial Operation
These operating instructions are intended to help system
integrators program, start up, and complete an installation
containing an axially compliant tool. The system integrator should
be familiar with the task in general and should have extensive
knowledge of programming and automation.
Important Note Regarding Operation:
The air motor is supported by two guide rods attached to the front
plate of the deburring tool. To prevent binding of the compliance,
one of these guide rods is rigidly attached to the front plate. The
second guide rod and the compliance piston rods are free to float
in the front plate. This allows the motor assembly to achieve free
compliant motion while resisting the motor’s torque.
DO NOT attempt to change the floating nature of the rods by
adding washers or additional thread locker. These actions will
prevent the rods from floating, which will result in binding of the
tool’s compliance.
5.4.1 Media Considerations
For instructions on how to replace the media, see Routine
Operational Maintenance [}22]
In most applications, no cooling or lubrication of the part or tool is
necessary nor is it desirable. For some materials and situations,
the addition of coolants or compressed air may aid the cutting
process. Any application of coolant must be exercised with care to
prevent fluids from entering the tool or its chuck.
Select media and media holders that position the work piece as
close to the Polishing Spindle MFT as possible.