SCHUNK AGE-U User instructions

Translation of the original manual
Assembly and Operating manual
AGE-U
Universal Compensation Unit

Table of contents
2
01.00 | AGE-U | Assembly and Operating manual | en | 1393226
Table of contents
1 General.................................................................................................................... 5
1.1 About this manual ................................................................................................ 5
1.1.1 Presentation of Warning Labels ...............................................................5
1.1.2 Definition of Terms...................................................................................6
1.1.3 Applicable documents ..............................................................................6
1.2 Warranty .............................................................................................................. 6
1.3 Scope of delivery .................................................................................................. 6
1.4 Accessories ........................................................................................................... 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 Ambient conditions and operating conditions .....................................................8
2.6 Personnel qualification......................................................................................... 8
2.7 Personal protective equipment............................................................................ 9
2.8 Notes on safe operation ....................................................................................... 9
2.9 Malfunctions....................................................................................................... 10
2.10 Disposal .............................................................................................................. 10
2.11 Fundamental dangers......................................................................................... 10
2.11.1 Protection during handling and assembly ..............................................11
2.11.2 Protection during commissioning and operation ...................................11
3 Technical data.........................................................................................................12
3.1 Basic data ........................................................................................................... 12
3.2 Maximum load capacity and compensation resistance .....................................13
4 Design and description............................................................................................16
4.1 Design ................................................................................................................. 16
4.2 Description ......................................................................................................... 17
4.3 Compensation types........................................................................................... 18
4.3.1 Lateral compensation .............................................................................18
4.3.2 Axial compensation ................................................................................18
4.3.3 Torsional compensation .........................................................................19
4.3.4 Angular compensation............................................................................19

Table of contents
01.00 | AGE-U | Assembly and Operating manual | en | 1393226
3
5 Assembly ................................................................................................................20
5.1 Mechanical connection ...................................................................................... 20
5.1.1 Requirements for adapter plates ...........................................................21
5.2 Pneumatic connection........................................................................................ 23
5.3 Assembling and connecting the product............................................................ 23
5.4 Mounting the MMS 22 magnetic switch ............................................................ 27
5.5 Installing the protective cover (optional accessory)........................................... 28
6 Operation ...............................................................................................................30
6.1 Centering ............................................................................................................ 30
6.2 Compensating..................................................................................................... 30
6.3 Joining parts ....................................................................................................... 31
6.4 Picking up parts .................................................................................................. 32
6.5 Monitoring deflection......................................................................................... 34
7 Troubleshooting .....................................................................................................35
8 Maintenance ..........................................................................................................36
8.1 Maintenance intervals........................................................................................ 36
8.2 Removing the product from the robot arm........................................................ 36
8.3 Changing the overload pins, compression springs and workpiece stop.............37
8.4 Assembly drawing............................................................................................... 39
9 Translation of original declaration of incorporation ................................................40
10 Annex to Declaration of Incorporation....................................................................41

Imprint
4
01.00 | AGE-U | Assembly and Operating manual | en | 1393226
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: 1393226
Version: 01.00|27/03/2019|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

General
01.00 | AGE-U | Assembly and Operating manual | en | 1393226
5
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.
NOTICE
Material damage!
Information about avoiding material damage.

General
6
01.00 | AGE-U | Assembly and Operating manual | en | 1393226
1.1.2 Definition of Terms
The term "product" replaces the product name on the title page in
this manual.
1.1.3 Applicable documents
• General terms of business*
• Catalog data sheet of the purchased product *
• Assembly and operating manuals of the accessories *
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
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 specified maintenance and lubrication intervals
• Observe the ambient conditions and operating conditions
Parts touching the workpiece and wear parts are not included in
the warranty.
1.3 Scope of delivery
The scope of delivery includes
• Universal Compensation Unit AGE-U in the version ordered
• Assembly and Operating Manual
• Accessory pack
1.4 Accessories
A wide range of accessories are available for this product
For information regarding which accessory articles can be used
with the corresponding product variants, see catalog data sheet.

Basic safety notes
01.00 | AGE-U | Assembly and Operating manual | en | 1393226
7
2 Basic safety notes
2.1 Intended use
The product is designed to compensate for tolerances and
positioning inaccuracies during handling of workpieces .
• The product may only be used within the scope of its technical
data, Technical data [}12].
• 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.
• The product is intended for installation in a machine/system.
The applicable guidelines must be observed and complied with.
• The product is intended for industrial and industry-oriented use.
• Appropriate use of the product includes compliance with all
instructions in this manual.
2.2 Not intended use
• 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
8
01.00 | AGE-U | Assembly and Operating manual | en | 1393226
2.5 Ambient conditions 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 data [}12].
2.6 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.
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.

Basic safety notes
01.00 | AGE-U | Assembly and Operating manual | en | 1393226
9
2.7 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.
2.8 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
function and operational safety of the product.
• Use the product as intended.
• Observe the safety notes and assembly instructions.
• Do not expose the product to any corrosive media. This does
not apply to products that are designed for special
environments.
• Eliminate any malfunction immediately.
• Observe the care and maintenance instructions.
• Observe the current safety, accident prevention and
environmental protection regulations regarding the product's
application field.

Basic safety notes
10
01.00 | AGE-U | Assembly and Operating manual | en | 1393226
2.9 Malfunctions
Behavior in case of malfunctions
• Immediately remove the product from operation and report the
malfunction to the responsible departments/persons.
• Order appropriately trained personnel to rectify the
malfunction.
• Do not recommission the product until the malfunction has
been rectified.
• 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 disposal.
2.11 Fundamental dangers
General
• Observe safety distances.
• Never deactivate safety devices.
• Before commissioning the product, take appropriate protective
measures to secure the danger zone.
• Disconnect power sources before installation, modification,
maintenance, or calibration. Ensure that no residual energy
remains in the system.
• If the energy supply is connected, do not move any parts by
hand.
• Do not reach into the open mechanism or movement area of
the product during operation.

Basic safety notes
01.00 | AGE-U | Assembly and Operating manual | en | 1393226
11
2.11.1 Protection during handling and assembly
Incorrect handling and assembly
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Have all work carried out by appropriately qualified personnel.
• For all work, secure the product against accidental operation.
• Observe the relevant accident prevention 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
Falling or violently ejected components
Falling and violently ejected components can cause serious injuries
and even death.
• Take appropriate protective measures to secure the danger
zone.
• Never step into the danger zone during operation.

Technical data
12
01.00 | AGE-U | Assembly and Operating manual | en | 1393226
3 Technical data
3.1 Basic data
Designation AGE-U
Value Further information
Weight [kg] 0.6 Incl. sensor
Max. payload [kg] 5.0 "Max. static moment"
Compensation path in
direction of axes [mm]
X/Y-axis
Z-axis
± 2.7
6.1
Simultaneously low axial
compensation *
Rotation about the axes [°]
X/Y-axis
Z-axis
± 3
± 8
*
Max. static moment [Nm]
X/Y-axis
Z-axis
2.26
1.13
For zero deflection at 3 g
robot acceleration.
Spring force [N] in
Z-direction
max.
min.
92.1
35.6
Total with supply pressure
of 0 bar and min./max. axial
compensation.
Pressure medium Compressed air, compressed air quality
according to ISO 8573-1:7 4 4
Minimal operating
pressure [bar]
0.3
Operating pressure [bar]
for adjusting rigidity
max.
min.
2.1
0.3
The use of flexibility at an
operating pressure > 2.1 bar
shortens the life of the
product.
Locking operating
pressure [bar]
max.
min.
6.9
4.1
Rated life Cycles,
maximum number [mil.]
1
* Compensation possible in all directions simultaneously but
without maximum compensation in this case.
More technical data is included in the catalog data sheet.
Whichever is the latest version.

Technical data
01.00 | AGE-U | Assembly and Operating manual | en | 1393226
13
3.2 Maximum load capacity and compensation resistance
The breakaway torque is the time at which the product begins to
compensate due to the payload. The payload is comprised of the
weights and accelerations of customer tools and workpieces. The
higher the payload, the lower the breakaway torque. To increase
the breakaway torque, either the payload must be reduced or the
supply pressure must be increased.
The curves of the breakaway force differ according to the direction
and acceleration of the applied forces.
Axial breakaway force in relation to the supply pressure
Breakaway force
Supply pressure
Linear (proportional) curve
Angular breakaway torque about X/Y-axis
Breakaway torque
Supply pressure
Regressive curve

Technical data
14
01.00 | AGE-U | Assembly and Operating manual | en | 1393226
Rotational breakaway torque about Z-axis
Breakaway torque
Supply pressure
Progressive curve
If the applied load is too large (equal to or greater than the
breakaway torque), an angular deflection may occur, that is,
undesirable tilting about the X- or Y-axis. To avoid this deflection,
it can be estimated. In this case, the X/Y moment, supply pressure,
payload and distance to the center of gravity must be observed.
Estimating the X/Y moment
Angular displacement as a function of X/Y moment
M = F x A
M Maximum moment [lb(f)in]
F Sum of applied forces
A Distance between tool plate of the compensation unit and
center of gravity of the applied load

Technical data
01.00 | AGE-U | Assembly and Operating manual | en | 1393226
15
CAUTION
Observe load limits!
Estimated rigidity values are close to the upper load limits of the
product and therefore do not provide a reliable basis.
•Calculate angular displacement with tolerance margin for
variable values such as acceleration and velocity.
•Limit payload so as not to restrict the acceleration or
deceleration of the product during motion.

Design and description
16
01.00 | AGE-U | Assembly and Operating manual | en | 1393226
4 Design and description
4.1 Design
Design and Sectional view
1 Screw for mounting on robot 10 Piston
2 Groove for sensor 11 Washer, beveled
3 Piston cover 12 Overload pin
4 Compression spring 13 Workpiece stop
5 Housing, tool side 14 Piston rod
6 Tool plate 15 O-ring
7 Housing, robot side 16 O-ring
8 Air-relief valve 17 Compressed air connection
9 Bore hole for alignment pin

Design and description
01.00 | AGE-U | Assembly and Operating manual | en | 1393226
17
4.2 Description
Application The product is used in automatic assembly applications to
compensate for inaccurate positioning. The product allows for
lateral compensation as well as pressure, torsional and angular
compensation. This increases the versatility and reliability of a
robot or an automated assembly system. For further information
about the different compensation types see, Compensation types
[}18].
Functional principle The robot-side housing(7) is attached to the customer robot arm
using four screws(1) that are accessible from the tool plate(6).
The customer tool, such as a gripper, is attached to the tool
plate(6), Assembly [}20]
The housing(5) is secured by overload pins(11) and beveled
washers(10). Conical compression springs(4) between the
housing(5) and the piston cover(3) provide a minimal
compensation resistance. The chamber can be pressurized with
compressed air to increase this resistance or the rigidity of the
product. The compressed air causes the piston(19) and the piston
rod(13)connected to it to contact the round workpiece stop(12).
While a defined pressure is applied, the spherical contact between
the round workpiece stop(12) and the piston rod(13) enables soft
compensation similar to a ball joint.
Lubrication To improve performance and maximize the life of the product,
lubricate the overload pins(11), the beveled washers(11), the
round workpiece stop(12) and the piston rod(13) with high-
pressure grease, Maintenance intervals [}36].
Piston position
monitoring
The position of the piston(9) is monitored by a sensor in locked
position. When the product is returned to centered home position
with the aid of compressed air, the piston extends fully and the
sensor switches to "ON" position. During compensation, the piston
is pushed back and the sensor switches to "OFF" position. To
ensure that the sensor functions properly, observe the minimum
operating pressure, Technical data [}12]

Design and description
18
01.00 | AGE-U | Assembly and Operating manual | en | 1393226
4.3 Compensation types
4.3.1 Lateral compensation
During lateral compensation, the tool-side housing moves away
from centered home position along the X and Y axes.
During compensation, the product contracts by a maximum of
1.1mm along the Z-axis due to the cone on the overload pin.
Lateral compensation
Y1Compensation in direction of Y-axis: ± 2.7mm
X1Compensation in direction of X-axis: ± 2.7mm
4.3.2 Axial compensation
During pressure compensation, the tool-side housing moves along
the Z axis in the direction of the robot-side housing.
Pressure compensation
Z1Compensation in direction of Z-axis: 6.1mm

Design and description
01.00 | AGE-U | Assembly and Operating manual | en | 1393226
19
4.3.3 Torsional compensation
During torsional compensation, the tool-side housing rotates
relative to the robot-side housing about the Z-axis.
During compensation, the product contracts minimally along the Z
axis due to the cone on the overload pin.
Torsional compensation
R1Compensation about Z-axis: ±8°
4.3.4 Angular compensation
During angular compensation, the tool-side housing is tilted about
the X or Y-axis.
Angular compensation
W1Compensation along X or Y-axis: ±3°

Assembly
20
01.00 | AGE-U | Assembly and Operating manual | en | 1393226
5 Assembly
5.1 Mechanical connection
Dimensions of connections on the product
Mounting AGE-U
Threadlocker adhesive Loctite 242
Robot-side connection
Mounting screw
(4 Piece)
M6 x 10, Strength class8.8
Tightening torque [Nm] 9
ISO-Flange ISO 9409-1-50-4-M6
Bore hole for alignment pin Ø 6H7
Tool-side connection
Threads for mounting screws M6
ISO-Flange ISO 9409-1-50-4-M6
Mounting screw, supplied by
customer
(4 Piece)
M6 x 10, Strength class 12.9
Screw according to standard
DIN EN ISO 4762 or 6912
Tightening torque [Nm] 10.2 or 6.7
Bore hole for alignment pin Ø 6H7