SCHUNK FDB User instructions

Translation of Original Operating Manual
Assembly and Operating Manual
FDB
Chamfering spindle

Imprint
2 04.00 | FDB | Assembly and Operating Manual | en | 389072
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: 389072
Version: 04.00|30/08/2022|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 Symbol definition......................................................................................6
1.1.4 Applicable documents ..............................................................................6
1.1.5 Sizes ..........................................................................................................6
1.2 Warranty .............................................................................................................. 6
2 Basic safety notes ................................................................................................... 7
2.1 Intended use......................................................................................................... 7
2.2 Safety Precautions................................................................................................ 7
2.3 General Safety Guidelines .................................................................................... 9
3 Product Overview ...................................................................................................10
3.1 Tool Collet Systems ............................................................................................ 11
4 Technical Data ........................................................................................................12
5 Installation .............................................................................................................16
5.1 Inspection of Condition When Delivered ........................................................... 16
5.2 Unpacking and Handling..................................................................................... 16
5.3 Mounting ............................................................................................................ 16
5.3.1 Axial Mounting Installation.....................................................................17
5.4 Pneumatics ......................................................................................................... 18
6 Operation ...............................................................................................................21
6.1 General Precautions ........................................................................................... 21
6.2 Working Environment ........................................................................................ 22
6.3 Operational Considerations................................................................................ 22
6.4 Lock axis for compensation in one direction (FDB 900 / FDB 1040)...................22
6.5 Tool Center Point (TCP) Position and Programming........................................... 24
6.6 Cutter Operation and Burr Selection.................................................................. 26
6.6.1 Burr Selection Table................................................................................26
7 Troubleshooting .....................................................................................................30
8 Maintenance ..........................................................................................................32
8.1 Recommended Spare Parts ................................................................................ 32
8.2 Preventive Maintenance .................................................................................... 33
8.2.1 Inspect Pneumatics Lines and Filter Regulator.......................................33
8.2.2 Lubrication..............................................................................................33
8.2.3 Spindle Boot Inspection..........................................................................34
8.2.4 Burr Inspection .......................................................................................34
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Table of Contents
8.3 Service Procedures ............................................................................................. 34
8.3.1 Burr Replacement...................................................................................34
8.3.2 Air Motor Replacement ..........................................................................35
8.3.3 Pivot Bearing Replacement ....................................................................45
8.3.4 Ring Cylinder Assembly Replacement ....................................................49
8.3.5 Spindle Boot Replacement FDB 660 .......................................................52
9 Transport and storage.............................................................................................54
9.1 Transportation and Protection during Transportation....................................... 54
9.2 Storage and Preventive Maintenance during Storage........................................ 54
10 Translation of original declaration of incorporation ................................................55
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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.
In addition to these instructions, the documents listed
under }1.1.4 [/6] are applicable.
NOTE: The illustrations in this manual are intended to provide a
basic understanding and may deviate from the actual version.
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 Symbol definition
The following symbols are used in this manual:
■Prerequisite for an action
1. Action 1
2. Action 2
✓Intermediate results
✔Final results
}1.1.3 [/6]: chapter number and [page number] in hyperlinks
1.1.4 Applicable documents
• General terms of business *
• Catalog data sheet of the purchased product *
The documents labeled with an asterisk (*) can be downloaded
from schunk.com.
1.1.5 Sizes
This operating manual applies to the following sizes:
• FDB 150
• FDB 300
• FDB 340
• FDB 900
• FDB 1040
1.2 Warranty
The warranty of the Chamfering spindle FDB 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 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.

Basic safety notes
2 Basic safety notes
2.1 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 [/12].
• The product is intended for industrial and industry-oriented use.
• Appropriate use of the product includes compliance with all
instructions 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
accordance to the EC Machinery Directive.
• the statutory safety and accident-prevention regulations and
the standards and guidelines valid at the usage site are not
observed.
2.2 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
protection.
•Always use hearing protection while working in the
neighborhood 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
protection.
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Basic safety notes
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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
being 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
equipment and void the warranty.
•Do not use spare parts other than original SCHUNK spare
parts.
•Always use original SCHUNK spare parts.
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
motion, stand behind appropriate Plexiglas windows.
•Provide a barrier to prohibit people from approaching the
deburring 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
unless 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
before performing maintenance or repair on the FDB product.

Basic safety notes
2.3 General Safety Guidelines
Prior to purchase, installation, and operation of the FDB, the
customer 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 connections as described in this manual.
All pneumatic fittings and tubing must be capable of withstanding
the repetitive motions of the application without failing. The
routing 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.
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Product Overview
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3 Product Overview
Tool Collet
Side Mounting
Axial
Mounting
Compliance Air
Connection
Motor Air Connection
FDB Deburring Tool
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
suited 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
irregularities while maintaining a constant, settable force. This
allows high feed rates with uniform quality in any orientation. The
tool also requires no oil, allowing clean exhaust air to be vented
directly 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.

Product Overview
3.1 Tool Collet Systems
3 Slots
(Front Only)
Single Angle
6 Slots
(Front and Rear)
Double Angle
ER-11
COLLET
STANDARD
COLLET
Tool Collets
All FDB products utilize removable collets to secure customer
supplied 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 removed 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.
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Technical Data
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4 Technical Data
Environmental restrictions
Operation:
Installation position: Mount on the robot with the lateral mounting hole pattern or
the rear adapter flange. The flange varies from robot to robot.
This optional flange is usually supplied by SCHUNK as a blank,
which the customer can adapt according to their requirements.
Mount on a table or bracket using an adapter plate (the
workpiece is fed in by the robot).
Temperature range: 5° C – 35° C
Storage:
Temperature range: 5° C – 35° C
Storage conditions: Store the product in packaging in a dry place. If available, store
the product in its delivery packaging }9.2 [/54].
Equipment: The product requires clean, dry, filtered, oil-free compressed
air. The use of coalescing filters and filter elements with a
nominal value of 5 microns or finer is required. The spindle
must be supplied with 6.2 – 6.5 bar. The radial flexibility
(centered) must be supplied from a regulated source at 1.0 to
1.4 bar.
Technical Specifications
FDB
150 300 340
Motor Compressed air turbine
Idle speed [RPM] 65,000 30,000 40,000
Power 150 W (0.20 hp)
at 65,000 RPM
300 W (0.40 hp)
at 30,000 RPM
340 W (0.46 hp)
at 40,000 RPM
Weight (without adapter) 1.1 kg 1.2 kg 1.2 kg
Compensation range
(radial)
±6.4 mm max.
radial,
±3.2 mm
recommended
±7.5 mm max., ±3
mm recommended
±7.5 mm max., ±3
mm recommended
Deflection force
(measured at the collet)
0.9 – 5.8 N,
at 1 – 4.14 bar
12.7 – 42 N
at 1.0 – 4.1 bar
12.7 – 42 N
at 1.0 – 4.1 bar
Deburring speed Depending on the geometry of the grinder and the 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) 5.6 l/s (6 CFM) 5.6 l/s (6 CFM)
Air consumption
(blocked)
3.78 l/s (8 CFM) 10.2 l/s (21.5 CFM) 10.2 l/s (21.5 CFM)
Noise pressure level * 78 dB(A) (without
milling cutter)
78 dB(A) (without
milling cutter)
78 dB(A) (without
milling cutter)

Technical Data
FDB
150 300 340
Collet diameter
(standard)**
3 mm 6 mm 6 mm
Milling cutter *** Special tools
(included in scope of
delivery)
commercial units
classified for 40,000
RPM or higher
commercial units
classified for 40,000
RPM or higher
Special tools Wrenches, 6.4 mm
and 7 mm
Wrenches (1 pair
included in scope of
delivery)
14.5 mm, 11 mm
Wrenches (1 pair
included in scope of
delivery)
14.5 mm, 11 mm
Technical Specifications
FDB
900 1040
Motor Compressed air turbine
Idle speed [RPM] 25,000 40,000
Power 900 W
at 25,000 RPM
1000 W
at 40,000 RPM
Weight (without adapter) approx. 3.4 kg approx. 3.45 kg
Compensation range
(radial)
±9 mm max. radial, ±5 mm recommended
Deflection force
(measured at the collet)
12.8 – 45.4 N at 1.0 – 4.1 bar
Deburring speed Depending on the geometry of the grinder and the motor
speed
Spindle air pressure 6.2 – 6.5 bar
6.9 bar max
Air consumption (idle) 11.8 l/s (25 CFM)
Air consumption
(blocked)
19 l/s (40 CFM)
Noise pressure level * 78 dB(A) (without milling cutter)
Collet diameter
(standard)**
6 mm (ER-11)
Milling cutter *** commercial units classified for 40,000 RPM or higher
Special tools Wrenches (1 pair included in scope of delivery)
11 mm, unlimited
10 mm, narrow (only for 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 predict
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.
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Technical Data
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** Optional sizes available, }8.1 [/32]
** SCHUNK can supply Burrs,}6.6.1 [/26]
Each FDB deburring tool receives a thorough test procedure
before 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
Compliance Force (N)
Compliance Air Pressure (Bar)
FDB 300/340
Compliance Air Pressure [bar]
Compliance Force [N]

Technical Data
FDB 900/1040
Compliance Force (N)
Centering Air Pressure (bar)
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.
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Installation
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5 Installation
The FDB Deburring Spindle is delivered fully assembled. Optional
equipment such as: mounting adapter plates, burrs, and additional
collets will be separate.
5.1 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.
5.2 Unpacking and Handling
The FDB Deburring Spindle should always be placed inside the
accompanying box (crate) during transportation, storing and
handling.
Pneumatic lines and electrical cables are attached, bundled, and
must be strain-relieved in a manner that allows for freedom of
movement during operation.
5.3 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.
CAUTION
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
surfaces prior to use. Under no circumstances should the unit be
used for manual/hand deburring. Once securely mounted, the unit
should be supplied with clean, dry, non-lubricated air filtered 5
micron or better. The use of a coalescing air filter is recommended
to remove all trace moisture and oil.

Installation
Air line fittings supplying the FDB 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 FDB.
CAUTION
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 air motor or damage associated
with the debris in the air lines is not covered under warranty.
5.3.1 Axial Mounting Installation
Clamping Collar
Blank
Interface Plate
Clamping Collar (2x) M5 Socket Head Cap Screws
Axial Mounting Flange on rear Housing Assembly
Axial Installation
A blank robot adapter plate is also available to allow axial
mounting 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.
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Installation
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5.4 Pneumatics
Spindle Air
Solenoid Valve
(2-way)
Spindle
Motor
Vent to
Atmosphere
Compliance
(centering cylinders)
Complinace Air
Solenoid Valve
(4-way)
Precision Regulator
0-4.2 bar
Supply Air:
clean, dry,
non-lubricated
6.9 bar min.
Filter
High-Flow Regulator
6.2 bar
Pneumatic connections FDB-150 and FDB-300/-340
Spindle Air
Solenoid Valve
(2-way)
High-Flow Regulator
6.2 bar
Spindle
Motor
Vent to
Atmosphere
Compliance
(centering)
Cylinders
Precision Regukator
0-4.2 bar
Filter
Supply Air:
clean, dry,
non-lubricated
6.9 bar min.
Pneumatic connections FDB-900 and FDB-1040

Installation
CAUTION
All pneumatic fittings and tubing must be capable of
withstanding the repetitive motions of the application without
failing. The routing of pneumatic lines must minimize the
possibility of over stressing, pullout, or kinking the lines.
Failure to do so can cause some critical pneumatic lines not to
function properly and may result in damage to equipment.
The air supply should be dry, filtered, and free of oil. A coalescing
filter with elements rated for 5 micron or better is required.
A high-flow air pressure control regulator is required to supply the
spindle motor . A second, precision, self-relieving regulator will
supply air for the compliance or centering force.
The compliance force is applied radially and is adjusted until the
desired cut is made. The robot traversing speed will also be
adjusted to achieve the desired finish.
CAUTION
Pneumatic components used for the motor drive circuit must be
capable of meeting the air consumption
requirements }4 [/12].
Poor performance will result if the correct components are not
used.
Conventional, customer-supplied, pneumatic components are
used to control the air supply to the deburring 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 to the spindle motor }4 [/12] for the maximum flow
requirement. The FDB will not operate properly if supplied air is
below 6.2 bar.
A second, precision, self-relieving regulator is used to supply the
compliance (centering) mechanism. This pressure corresponds to
the side force on the rotary burr. Very little airflow is required for
the compliance mechanism.
If the complete workpiece can be deburred with equal force, a
conventional, manual pressure regulator can be used for
compliance. If the burrs to be removed vary from place to place on
the work piece, and this variation is repeatable for all work pieces
of the same type, it may be necessary to adjust the force using an
analog pressure regulator controlled from the robot. An analog
output port in the robot or logic controller will be needed.
Solenoid valves are actuated from the robot or program logic
controller by means of a digital output signal.
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Installation
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Pneumatic connections
Function Connection type Pressure
Motor inlet
FDB 150 1/8" NPT connection 6.2 bar
FDB 300
FDB 340
3/8" quick connector hose
Alternative:
Remove the supplied SCHUNK
connection in order to use the 1/8 NPT
connection (or use the 5/16 [8 mm] hose
adapter)
6.2 – 6.5 bar
FDB 900
FDB 1040
12 mm
Alternative:
Remove the supplied SCHUNK
connection in order to use the 3/8 NPT
connection in the motor body, or use the
12 mm to 10 mm hose adapter
6.2 – 6.5 bar
Inlet for compensation force (radial)
FDB 150 1/8" NPT connection 1.4 – 4.2 bar
(maximum)
FDB 300
FDB 340
FDB 900
FDB 1040
5/32" (4 mm) hose
Alternative:
Remove the supplied connection in order
to use the 1/8" NPT connection
1.4 – 4.1 bar
(maximum)
Exhaust
air
Emitted to the environment via the
housing.
N/A
It is recommended that flexible plastic tubing be used for the
motor air supply and the compliance force air supply. The installed
fittings can be removed to expose tapped supply ports thus
allowing the use of alternate, customer-supplied components. The
turbine air motor is extremely quiet and vents dry air to the
environment through the screen-covered ports on the side of the
housing. No mufflers are required. Information on the sound
intensity is provided in }4 [/12]. To reduce the sound from the
cutting operation in neighboring working areas, a customer-
supplied barrier surrounding the installation may be installed
(Plexiglas® or Lexan™ is preferred, }4 [/12]).
The compliance force, air supply pressure regulator should have a
(FDB 150: 1.4 - 4.2 bar / FDB 300-1040: 0-4.1 bar) range. When
testing for the proper contact force, start with a very low pressure
and increase slowly until the desired cut is achieved.