SCHUNK AOV-MC User instructions

Translation of Original Operating Manual
Assembly and Operating Manual
AOV-MC
Media changer for orbital sander

Imprint
2 01.00 | AOV-MC | Assembly and Operating Manual | en | 1461420
Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights
reserved.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 1461420
Version: 01.00|01/02/2021|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. [phone]
Fax [phone]
[email protected]
Please read the operating manual in full and keep it close to the product.

Table of Contents
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
1.1.4 Components .............................................................................................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 Ambient conditions and operating conditions .....................................................8
2.6 Personnel qualification......................................................................................... 8
2.7 Personal protective equipment............................................................................ 9
2.8 Transport .............................................................................................................. 9
2.9 Malfunctions......................................................................................................... 9
2.10 Disposal .............................................................................................................. 10
2.11 Fundamental dangers......................................................................................... 10
2.11.1 Protection during handling and assembly ..............................................10
2.11.2 Protection during commissioning and operation ...................................11
2.11.3 Protection against dangerous movements.............................................11
2.12 Notes on particular risks..................................................................................... 12
3 Technical data.........................................................................................................13
4 Design and description............................................................................................14
4.1 Design ................................................................................................................. 14
4.2 Description ......................................................................................................... 15
5 Assembly ................................................................................................................16
5.1 Installing and connecting.................................................................................... 16
5.2 Mechanical connection ...................................................................................... 17
5.3 Pneumatic connection........................................................................................ 18
5.4 Electrical connection .......................................................................................... 19
6 Start-up ..................................................................................................................20
6.1 Notes on teaching-in .......................................................................................... 20
6.2 Pick up sanding discs .......................................................................................... 20
6.3 Check for presence of sanding discs................................................................... 25
6.4 Remove sanding discs......................................................................................... 27
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Table of Contents
7 Troubleshooting .....................................................................................................30
7.1 Sanding discs are not removed correctly ........................................................... 30
7.2 The sander removes more than one sanding disc.............................................. 30
7.3 The sensor is not issuing a signal........................................................................ 30
7.4 Sanding discs are not removed........................................................................... 31
8 Maintenance ..........................................................................................................32
8.1 Notes .................................................................................................................. 32
8.2 Maintenance interval ......................................................................................... 32
8.3 Disassembly and assembly ................................................................................. 33
8.4 Replace the Velcro disc on the media checker................................................... 35
8.5 Replace needles.................................................................................................. 36
8.6 Assembly drawings ............................................................................................. 37
9 EU Declaration of Conformity AOV-MCH.................................................................40
10 Certificate of Conformity AOV-MF5 / -MF6 .............................................................41
11 Declaration of incorporation AOV-MRA ..................................................................42
12 Annex to Declaration of Incorporation....................................................................43
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General
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.
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General
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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
1.1.4 Components
This manual applies to the following components:
• Media feeder AOV-MF
• Media checker AOV-MCH
• Media remover AOV-MRA
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
Parts touching the workpiece and wear parts are not included in
the warranty.
1.3 Scope of delivery
The scope of delivery includes
• Components of the media changer for orbital sander in the
version ordered
• Assembly and Operating Manual

Basic safety notes
2 Basic safety notes
2.1 Intended use
This product is exclusively intended for the automatic removal and
reinsertion of sanding discs with Velcro fastener and for checking
the correct change procedure for orbital sanders.
• The product may only be used within the scope of its technical
data, Technical data [}13].
• 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 or
for mounting to a robot. 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
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.
• Inappropriate use includes using the product as a hand 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.
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Basic safety notes
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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 [}13].
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
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.
• Wear ear protection and safety goggles during the machining
process.
2.8 Transport
Handling during transport
Incorrect handling during transport can make the product unsafe
and risk the danger of serious injuries and considerable material
damage.
• During transport and handling, secure the product to prevent it
from falling.
• Do not walk under suspended loads.
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.
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Basic safety notes
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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 installations.
• Install the provided protective product in the danger zone
before switching on the product.
• Remove the energy supplies before installation, modification,
maintenance, or adjustment work. Ensure there is no residual
energy in the system.
• Do not move parts by hand while the energy supply is
connected.
• Do not reach into the movement area of the product during
operation.
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.

Basic safety notes
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.
2.11.3 Protection against dangerous movements
Unexpected movements
Residual energy in the system may cause serious injuries while
working with the product.
• Switch off the energy supply, ensure that no residual energy
remains and secure against inadvertent reactivation.
• Never rely solely on the response of the monitoring function to
avert danger. Until the installed monitors become effective, it
must be assumed that the drive movement is faulty, with its
action being dependent on the control unit and the current
operating condition of the drive. Perform maintenance work,
modifications, and attachments outside the danger zone
defined by the movement range.
• To avoid accidents and/or material damage, human access to
the movement range of the machine must be restricted. Limit/
prevent accidental access for people in this area due through
technical safety measures. The protective cover and protective
fence must be rigid enough to withstand the maximum possible
movement energy. EMERGENCY STOP switches must be easily
and quickly accessible. Before starting up the machine or
automated system, check that the EMERGENCY STOP system is
working. Prevent operation of the machine if this protective
equipment does not function correctly.
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Basic safety notes
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2.12 Notes on particular risks
DANGER
Risk of fatal injury from suspended loads!
Falling loads can cause serious injuries and even death.
•Stand clear of suspended loads and do not step within their
swiveling range.
•Never move loads without supervision.
•Do not leave suspended loads unattended.
•Wear suitable protective equipment.
WARNING
Risk of injury from objects falling and being ejected!
Falling and ejected objects during operation can lead to serious
injury or death.
•Take appropriate protective measures to secure the danger
zone.
WARNING
Risk of injury due to unexpected movements!
If the power supply is switched on or residual energy remains in
the system, components can move unexpectedly and cause
serious injuries.
•Before starting any work on the product: Switch off the power
supply and secure against restarting.
•Make sure, that no residual energy remains in the system.
CAUTION
Risk of injury from flying chips and dirt particles
During operation, flying chips and dirt particles can cause eye
injuries.
•Always wear appropriate personal protective equipment,
particularly protective goggles.
•Take suitable protective measures to secure the danger zone.

Technical data
3 Technical data
Designation AOV-MC
Nominal operating pressure [bar] 4.1-6.2
Pressure medium Compressed air (clean,
dry, filtered (≤ 5 µm),
oil-free)
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Design and description
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4 Design and description
4.1 Design
Media feeder
1 Alignment rail
2 Media retaining gasket
3 Media storage
4 Through holes for mounting
Media remover
1 Needle gripper
2 Plate with Through holes for mounting
3 "Retract needle" air connection
4 "Extend needle" air connection
5 Needle stroke adjustment

Design and description
Media checker
1 Through holes for mounting
2 Media detection piston
3 Sensor connection
4.2 Description
Automatic sanding disc changer for mounting and removing
sanding discs and checking the change procedure
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Assembly
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5 Assembly
5.1 Installing and connecting
WARNING
Risk of injury from needles!
The needles on the media remover can cause cuts.
•Avoid contact.
•Wear suitable protective equipment.
1. Mount the components of the product,
Mechanical connection [}17].
2. Load the media feeder in small stacks with 15-25 sanding discs.
The media must be inserted with the Velcro side facing
upwards.
3. Connect media remover to compressed air supply,
Pneumatic connection [}18].
4. Connect media checker, Electrical connection [}19].
5. Teach-in components, Start-up [}20].

Assembly
5.2 Mechanical connection
Evenness of the
mounting surface
The values apply to the whole mounting surface to which the
product is mounted.
Requirements for evenness of the mounting surface (Dimensions in mm)
Edge length Permissible unevenness
< 100 < 0.02
> 100 < 0.05
The media checker and the media feeder can be mounted in all
orientations. The media remover must be mounted in such a way
that the media used can fall down by gravity.
Item Mounting AOV-MC
MCH MF MRA
1 Through hole for mounting M6
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Assembly
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5.3 Pneumatic connection
NOTE
• Observe the requirements for the compressed air supply,
Technical data [}13].
• Use a 5/2 directional control valve to control the two air
connections.
1 "Retract needle" air connection
2 "Extend needle" air connection
Item Mounting AOV-MRA
1 Hose connection [mm] 4
2 Hose connection [mm] 4

Assembly
5.4 Electrical connection
Proximity switch on the media checker
• Type of switching: PNP
• Switching function: Closer
• Connector: M8
Pin Wire strand Designation
1 Brown +10 to 30 VDC
3 Blue GND
4 Black Output
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Start-up
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6 Start-up
6.1 Notes on teaching-in
• While teaching the robot, make sure that the orbital sander is
positioned so that it is perpendicular to the appropriate surface
of each component of the media changer.
• Determine the disposal process for the sanding discs removed
by the media changer. The media remover should be positioned
so that the removed media falls by gravity into a designated
container.
• SCHUNK recommends defining a common starting position
"HOME" for each individual process in order to facilitate the
transition between the individual processes.
• Before regular operation, the removal of a freshly used sanding
disc must be tested. The friction of a sanding process of 15
seconds or more can cause the Velcro to bind more strongly
than a manually applied sanding disc.
6.2 Pick up sanding discs
• Load media feeder In doing so, observe the following:
✓Removing the debris shield can help with teaching-in, as the
sanding disc stack is visible.
✓Loading several small stacks (approx. 15-25 sanding discs) is
better than loading all sanding discs at once.
✓Stack sanding discs with a curved shape on top of each
other in an offset pattern to avoid snagging.
✓Carefully bend the sanding disc stack by hand so that the
discs are level.
■The sander is in the starting position "HOME".
■The operating pressure for extending the sander should be set
to 4.1bar.
1. Move the sander over the feeder.
✓The distance between the backer pad and the media feeder
should be approx. 0.6cm (view A).
✓The nearest edge of the backer pad should be at a distance
b of approx. 1.2-2.5cm from the alignment rail (view B).