SCHUNK FDB 150 User instructions

original manual
Deburring spindle
FDB 150, 300, 340, 660, 900, 1040
Assembly and operating manual
Superior Clamping and Gripping

Imprint
2 02.01|FDB 150, 300, 340, 660, 900, 1040 |en
Imprint
Copyright:
This manual remains the copyrighted property of SCHUNK GmbH & Co. KG. It is solely
supplied to our customers and operators of our products and forms part of the product.
This documentation may not be duplicated or made accessible to third parties, in particu-
lar competitive companies,
without our prior permission.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 0389072
Edition: 02.01 |30/05/2017|en
© SCHUNK GmbH & Co. KG
All rights reserved.
Dear customer,
congratulations on choosing a SCHUNK product. By choosing SCHUNK, you have opted for
the highest precision, top quality and best service.
You are going to increase the process reliability of your production and achieve best
machining results – to the customer's complete satisfaction.
SCHUNK products are inspiring.
Our detailed assembly and operation manual will support you.
Do you have further questions? You may contact us at any time – even after purchase.
Kindest Regards
Yours SCHUNK GmbH & Co. KG
Spann- und Greiftechnik
Bahnhofstr. 106 – 134
D-74348 Lauffen/Neckar
Tel. [phone]
Fax [phone]
[email protected]
www.schunk.com

Table of contents
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3
Table of contents
Glossary ................................................................................................................... 5
1
General .................................................................................................................... 6
1.1
About this manual .................................................................................................... 6
1.1.1
Presentation of Warning Labels.................................................................... 6
1.1.2
Applicable documents................................................................................... 7
1.1.3
Sizes............................................................................................................... 7
1.2
Warranty................................................................................................................... 7
2
Safety....................................................................................................................... 8
2.1
Intended use............................................................................................................. 8
2.2
General Safety Guidelines ........................................................................................ 8
2.3
Safety Precautions.................................................................................................... 9
3
Product Overview.................................................................................................... 11
3.1
Tool Collet Systems ................................................................................................ 12
4
Technical Data......................................................................................................... 13
5
Installation .............................................................................................................. 18
5.1
Inspection of Condition When Delivered............................................................... 18
5.2
Unpacking and Handling......................................................................................... 18
5.3
Mounting ................................................................................................................ 18
5.3.1
Axial Mounting Installation......................................................................... 19
5.4
Pneumatics ............................................................................................................. 20
5.5
Transportation and Protection during Transportation .......................................... 23
5.6
Storage and Preventive Maintenance during Storage........................................... 23
6
Operation................................................................................................................ 24
6.1
General Precautions ............................................................................................... 24
6.2
Working Environment ............................................................................................ 25
6.3
Operational Considerations ................................................................................... 25
6.4
Tool Center Point (TCP) Position and Programming .............................................. 26
6.5
Cutter Operation and Burr Selection ..................................................................... 28
6.5.1
Burr Selection Table .................................................................................... 29
7
Troubleshooting ...................................................................................................... 33
8
Maintenance ........................................................................................................... 35
8.1
Recommended Spare Parts .................................................................................... 35
8.2
Preventive Maintenance ........................................................................................ 36
8.2.1
Inspect Pneumatics Lines and Filter Regulator........................................... 36
8.2.2
Lubrication .................................................................................................. 37

Table of contents
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8.2.3
Spindle Boot Inspection .............................................................................. 37
8.2.4
Burr Inspection............................................................................................ 37
8.3
Service Procedures ................................................................................................. 38
8.3.1
Burr Replacement ....................................................................................... 38
8.3.2
Air Motor Replacement .............................................................................. 39
8.3.3
Pivot Bearing Replacement......................................................................... 51
8.3.4
Ring Cylinder Assembly Replacement......................................................... 59
8.3.5
Spindle Boot Replacement FDB 660 ........................................................... 64
9
Translation of original declaration of incorporation................................................. 67

Glossary
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5
Glossary
Climb Milling
Cutting method where the direction of
cutter rotation and tool motion are the
same.
Adapter plate
Device for attaching the deburring tool
to either a robot flange or a stationary
mounting surface.
Air Filter
Device for removing contamination
from air supply lines. Typically refers to
removal of particulates.
Air Turbine
Air motor that drives the spindle.
Burr
Cutting tool used to remove burs from
the workpiece. Alterna-tively referred
to as a rotary file, cutter, or bit.
Coalescing Filter
Device designed to remove liquid aero-
sols from the supply air lines.
Collet
Gripping device used to hold cutting
tools in the spindle.
Compliance
The ability of the spindle to passively
move in response to protrusions on or
deviations of the work piece.
Conventional Milling
Method of cutting where the direction
of tool motion is opposite that of tool
rotation.
Regulator
Device used to set and control the sup-
plied air pressure to lower acceptable
levels.
Solenoid Valve
Electrically controlled device for
switching air supplies on and off.
Spindle
The rotating portion of the tool assem-
bly.

General
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General
About this manual
This manual contains important information for a safe and appro-
priate use of the product.
This manual is an integral part of the product and must be kept ac-
cessible for the personnel at all times.
Before starting work, the personnel must have read and under-
stood 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
(1.1.2, Page 7) are applicable.
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.
1
1.1
1.1.1

General
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|en
7
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 www.schunk.com.
Sizes
This operating manual applies to the following sizes:
• FDB 150
• FDB 300
• FDB 340
• FDB 660
• FDB 990
• FDB 1040
Warranty
The warranty of the Deburring spindle is valid for 24 months. This
does not apply to the air motor.
The air motor is warranted for a period of 2000 hours or one year
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.
1.1.2
1.1.3
1.2

Safety
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Safety
The safety section describes general safety guidelines to be fol-
lowed with this product. More specific notification are imbedded
within the sections of the manual were they apply.
Intended use
The product is to be used only for the deburring of workpieces.
The product is intended for installation on a robot. The requirements
of the applicable guidelines must be observed and complied with.
• The product may only be used within the scope of its technical
data, (4, Page 13).
• The product is intended for industrial use.
• Appropriate use of the product includes compliance with all in-
structions in this manual.
Use which is not specified as an intended use is for instance when
• the product 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 ac-
cordance to the EC Machinery Directive.
• the statutory safety and accident-prevention regulations and
the standards and guidelines valid at the usage site are not ob-
served.
General Safety Guidelines
Prior to purchase, installation, and operation of the FDB, the cus-
tomer should first read and understand the operating procedures
and information described in this manual. Never use the deburring
tool for any purposes, or in any ways, not explicitly described in
this manual. Follow installation instructions and pneumatic con-
nections as described in this manual.
All pneumatic fittings and tubing must be capable of withstanding
the repetitive motions of the application without failing. The rout-
ing of pneumatic lines must minimize the possibility of
stress/strain, kinking, rupture, etc. Failure of critical pneumatic
lines to function properly may result in equipment damage.
2
2.1
2.2

Safety
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9
Safety Precautions
WARNING
High sound levels can occur during cutting.
Failure to wear hearing protect can cause hearing impairment.
• Never operate the FDB product without wearing hearing pro-
tection.
• Always use hearing protection while working in the neighbor-
hood of the deburring tool.
WARNING
Flying debris can cause injury.
• Always use eye protection while working in the neighborhood
of the deburring tool.
• Never operate the FDB product without wearing eye protec-
tion.
CAUTION
Using burrs rated for less than the speed of the FDB being used
may cause injury or damage equipment.
• Do not use burrs rated for less than the speed of the FDB be-
ing used.
• Always use burrs rated for at least the speed of the FDB being
used.
WARNING
Use of spare parts not supplied by SCHUNK can damage equip-
ment and void the warranty.
• Do not use spare parts other than original SCHUNK spare
parts.
• Always use original SCHUNK spare parts.
2.3

Safety
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WARNING
Flying debris and rotating parts can cause injury.
• Never be present near the deburring tool while it is started or
in operation.
• If it is necessary to approach the deburring tool while in mo-
tion, stand behind appropriate Plexiglas windows.
• Provide a barrier to prohibit people from approaching the de-
burring tool while in operation must secure the installation.
WARNING
Injury or equipment damage can occur with tool not docked and
air on.
• Do not perform maintenance or repair on the FBD product un-
less the tool is safely supported or docked in the tool stand
and air has been turned off.
• Dock the tool safely in the tool stand and turn off the air be-
fore performing maintenance or repair on the FDB product.

Product Overview
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11
Product Overview
FDB Deburring Tool (Size 660 shown)
The FDB Deburring Spindle is a robust, high-speed and lightweight
air turbine-driven deburring unit for deburring aluminum, plastic,
steel, etc. with a robot or CNC machine. The FDB is especially suit-
ed for removal of parting lines and flash from parts. However, its
flexible design allows it to be used in a wide variety of applications.
The FDB’s pneumatically controlled, articulated design allows the
cutting bit to follow the part profile and compensate for surface ir-
regularities while maintaining a constant, settable force. This al-
lows high feed rates with uniform quality in any orientation. The
tool also requires no oil, allowing clean exhaust air to be vented di-
rectly into the work environment.
Compliance is supported by air pressure applied to the shaft of the
unit and is used to perform consistent deburring on irregular part
patterns. The motor’s internal governor maintains high spindle
speeds for optimum surface finish. The FDB also utilizes standard
industrial tungsten-carbide bits which allows for adaptation to
changing assembly lines and part requirements.
The FDB provides for two mounting types, a side mounting and an
axial mounting. The axial mounting utilizes a tapered flange that
requires an adapter plate. Custom adapter plates for both side and
axial mounting are available from SCHUNK.
A tool collet system secures the burr and many collet sizes and of
tools are available to accommodate a wide variety of applications.
3

Product Overview
12 02.01|FDB 150, 300, 340, 660, 900, 1040 |en
Tool Collet Systems
Tool Collets
All FDB products utilize removable collets to secure customer sup-
plied cutting tools. Different collet diameters may be substituted
to retain numerous cutter shank diameters. The collet retaining
nut is loosened to open the collet allowing cutting tools to be re-
moved and inserted. Once the tool is set to the desired depth,
spanner wrenches are used to tighten the collet nut causing the
collet to collapse and secure the cutting tool. The air motor design
does not allow the installation of spindle brakes or quick-change
(drawbar) collet systems.
3.1

Technical Data
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13
Technical Data
Enviromental Limitations
Operation:
Installation position:
Mounted to robot by means of the side mounting pattern or
rear adapter flange. The flange is specific to each type of robot.
This optional flange is normally supplied by SCHUNK in a blank
for customer modification.
Mounted to a table or stand by means of the bench adapter
(the robot is carrying the workpiece).
Temperature range:
5° C – 35° C
Storage:
Temperature range:
5° C - 35° C
Conditions:
The tool should be stored in its crate and in a dry place. When not
in use, keep the unit in its crate if possible (

5.6, Page 23).
Utilities:
The tool requires clean, dry, filtered, non-lubricated air. The
use of a coalescing filter and filter elements rated 5 micron or
better is required. The spindle must be supplied at 6.2–6.5 bar
and the radial compliance (centering) air must be supplied
from a regulated source between 1.0–4.1 bar
4

Technical Data
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Technical Specifications
FDB
150
300
340
Motor
Air Turbine
Idle Speed (RPM)
65,000
30,000
40,000
Power
150 W (0.20 hp)
@ 65,000 RPM
300 W (0.40 hp)
@ 30,000 RPM
340 W (0.46 hp)
@ 40,000 RPM
Weight (without Adapters)
1.1 kg
1.2 kg
1.2 kg
Compensation
(Radial)
± 5 mm max. radial,
± 2.5 mm recom-
mended
± 7.5 mm max.,
± 3 mm recom-
mended
± 7.5 mm max.,
± 3 mm recommend-
ed
Compliance Force
(Measured at Collet)
3.1–6.7 N,
@ 1.4 - 4.14 bar
12.7-42 N
@ 1.0-4.1 bar
12.7-42 N
@ 1.0-4.1 bar
Burr Surface Speed
Dependent on cutter geometry and motor speed
Spindle Air Pressure
6.2 bar maximum
6.2 - 6.5 bar
[6.9 bar max]
6.2 - 6.5 bar
[6.9 bar max]
Air Consumption (Idle)
1.42 l/s (3 CFM)
2.8 l/s (6 CFM)
2.8 l/s (6 CFM)
Air Consumption (Stall)
3.78 l/s (8 CFM)
10.2 l/s (21.5 CFM)
10.2 l/s (21.5 CFM)
Sound Pressure Level *
Less than 67 dB(A)
(without cutter)
Less than 70 dB(A)
(without cutter)
Less than 70 dB(A)
(without cutter)
Collet Size (Standard)**
3 mm
6 mm
6 mm
Rotary Burrs ***
Special tools
(supplied)
Commercial Units
Rated 40,000 RPM
or Higher
Commercial Units
Rated 40,000 RPM
or Higher
Special Tools
Open end Wrenches
6.4 mm and 7 mm
Open end Wrenches
(1 pair supplied)
14.5 mm, 11 mm
Open end Wrenches
(1 pair supplied)
14.5 mm, 11mm

Technical Data
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15
Technical Specifications
FDB
660
990
1040
Motor
Air Turbine
Idle Speed (RPM)
40.000
25.000
40.000
Power
660 W
@ 40,000 RPM
900 W
@ 25,000 RPM
1000 W
@ 40,000 RPM
Weight (without Adapters)
approx 2.2 kg
approx 3.4 kg
approx 3.4 kg
Compensation
(Radial)
± 9 mm max. radial,
± 4.5 mm recom-
mended
± 8 mm max. radial,
± 4 mm recom-
mended
± 8 mm max. radial,
± 4 mm recom-
mended
Compliance Force
(Measured at Collet)
12.8-45.4 N @ 1.0-
4.1 bar
12.8-45.4 N @ 1.0-
4.1 bar
12.8-45.4 N @ 1.0-
4.1 bar
Burr Surface Speed
Dependent on cutter geometry and motor speed
Spindle Air Pressure
6.2 - 6.5 bar
6.9 bar max
6.2 - 6.5 bar
6.9 bar max
6.2 - 6.5 bar
6.9 bar max
Air Consumption (Idle)
5.4 l/s (11.5 CFM)
8.5 l/s (18 CFM)
19 l/s (18 CFM)
Air Consumption (Stall)
17.9 l/s (38 CFM)
40 CFM
40 CFM
Sound Pressure Level *
Less than 70 dB(A) (without cutter)
Collet Size (Standard)**
6 mm (ER-11)
Rotary Burrs ***
Commercial Units Rated 40,000 RPM or Higher
Special Tools
Open end Wrenches (1 pair supplied)
11 mm Open end
10 mm narrow (Only for use with ER11 collets)
*
All noise emission measurements were taken under no load idle conditions without
a cutting tool. Because the working environment is unknown it is impossible to pre-
dict the noise that will occur during a deburring operation. The FDB may also excite
resonant frequencies on equipment to which it is mounted creating higher sound
pressure levels than the unit by itself.
**
Optional sizes available, (8.1, Page 35)
**
SCHUNK can supply Burrs,(

6.5.1, Page 29)

Technical Data
16 02.01|FDB 150, 300, 340, 660, 900, 1040 |en
Each FDB deburring tool receives a thorough test procedure be-
fore it is shipped.
The following chart shows measured forces relative to applied
compliance (centering) air pressure. Measurements may vary from
one product to another, and should only be treated as nominal.
FDB 150
FDB 300/340

Technical Data
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17
The actual force characteristics will vary slightly from installation
to installation due to mounting orientation and condition of the
unit. The air turbine will attempt to maintain its full rated speed
even under loaded conditions. However, when extremely heavy
cuts are taken the motor may eventually stall. Therefore, multiple
light passes are preferred over slow, heavy cuts.
FDB 660
FDB 990/1040

Installation
18 02.01|FDB 150, 300, 340, 660, 900, 1040 |en
Installation
The FDB Deburring Spindle is delivered fully assembled. Optional
equipment such as: mounting adapter plates, burrs, and additional
collets will be separate.
Inspection of Condition When Delivered
Upon receipt, the following should be checked:
• Delivery in accordance with freight document
• 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.
Unpacking and Handling
The FDB Deburring Spindle should always be placed inside the ac-
companying box (crate) during transportation, storing and han-
dling.
Pneumatic lines and electrical cables are attached, bundled, and
must be strain-relieved in a manner that allows for freedom of
movement during operation.
Mounting
The FDB is capable of rear (axial) or side (radial) mounting.
SCHUNK offers a blank rear interface plate kit for rear mounting
and a simple foot bracket for bench mounting.
NOTICE
When using the side mounting pattern, the mounting screws
must not exceed maximum depth from the mounting surface
into the housing.
If screws extend past the maximum depth, they can interfere
with the free compliance of the tool. Use proper length screws
with the side mounting pattern, refer to the catalogue for further
details of the mounting features and requirements.
The FDB must be rigidly mounted using either of its mounting sur-
faces prior to use. Under no circumstances should the unit be used
5
5.1
5.2
5.3

Installation
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, 340, 660, 900, 1040 |en
19
for manual/hand deburring. Once securely mounted, the unit
should be supplied with clean, dry, non-lubricated air filtered 5 mi-
cron or better. The use of a coalescing air filter is recommended to
remove all trace moisture and oil.
Air line fittings supplying the FDB should be installed with care us-
ing a minimum of tape or liquid sealant. To prevent contaminant
damage to the air motor, all air lines should be blown down to re-
move debris prior to connection of the FDB.
NOTICE
The FDB must be supplied with clean, dry, non-lubricated air
filtered five micron or better. The use of a coalescing filter is
recommended.
Water and oil damage of the a
ir motor or damage associated with
the debris in the air lines is not covered under warranty.
Axial Mounting Installation
Axial Installation
A blank robot adapter plate is also available to allow axial mount-
ing off the rear of the deburring tool housing. This plate may be
modified by the system integrator or by the owner/user of the
FDB. SCHUINK can provide custom interface plates and adapters
upon request. An optional bench mount adapter plate allows the
FDB to be permanently attached to a bench or other work surface .
If the FDB is permanently mounted to a work surface, the robot
carries the part to be deburred to the FDB.
5.3.1

Installation
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Pneumatics
Pneumatic Connections FDB-150 and FDB-300/-340
Pneumatic Connections FBD-660, FDB-990, FDB-1040
5.4