SCHUNK MFT User instructions

Original manual
Polishing Spindle
MFT
Assembly and operating manual
Superior Clamping and Gripping

Imprint
2
01.00|MFT |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: 0389545
Edition: 01.00 |15/01/2016|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
01.00|MFT |en
3
Table of contents
Glossary of Terms..................................................................................................... 5
1
About this manual.................................................................................................... 6
1.1
Warnings................................................................................................................... 6
1.2
Applicable documents .............................................................................................. 7
1.3
Variants..................................................................................................................... 7
2
Basic safety notes .................................................................................................... 8
2.1
Intended use............................................................................................................. 8
2.2
Not intended use...................................................................................................... 8
2.3
Environmental and operating conditions................................................................. 8
2.4
Product safety........................................................................................................... 9
2.4.1
Protective equipment ................................................................................... 9
2.4.2
Constructional changes................................................................................. 9
2.5
Personnel qualification............................................................................................. 9
2.6
The use personal protective equipment ................................................................ 10
2.7
Transportation and Protection during Transportation .......................................... 11
2.8
Safety Precautions.................................................................................................. 11
3
Warranty................................................................................................................. 12
4
Scope of delivery ..................................................................................................... 13
5
Technical Specifications........................................................................................... 14
6
Description and function ......................................................................................... 17
6.1
Description ............................................................................................................. 17
6.2
Spindle Operation and Media Selection ................................................................ 18
7
Assembly and Installation........................................................................................ 19
7.1
Mechanical connection .......................................................................................... 19
7.2
Pneumatic Connection ........................................................................................... 19
7.3
Electrical Connections ............................................................................................ 22
7.4
Initial Operation...................................................................................................... 23
7.4.1
Media Considerations ................................................................................. 23
7.4.2
Tool Position and Programming ................................................................. 23
8
Maintenance and repair .......................................................................................... 25
8.1
Routine Operational Maintenance......................................................................... 25
8.2
Media Replacement .............................................................................................. 25
8.3
Boot Replacement .................................................................................................. 26
8.4
Air Motor Replacement.......................................................................................... 27
8.5
Sensor Replacement............................................................................................... 28

Table of contents
4
01.00|MFT |en
8.5.1
Sensor for monitoring: Spindle extracted (Option -F) ................................ 29
8.5.2
Sensor for monitoring: Spindle retracted (Option -R) ................................ 30
8.5.3
Sensor for rotation speed: Tachometer sensor (Option -T) ....................... 30
8.6
Pneumatic -lines/-connections............................................................................... 32
8.7
Lubrication of the polishing spindle ....................................................................... 32
8.8
Storage and Preventive Maintenance during Storage........................................... 33
9
Troubleshooting ...................................................................................................... 34
9.1
Troubleshooting Matrix.......................................................................................... 34
10
Recommended Spare Parts...................................................................................... 35
11
Drawings ................................................................................................................. 36
12
Translation of original declaration of incorporation ................................................. 40

Glossary of Terms
01.00|MFT |en
5
Glossary of Terms
Adapter
Device for attaching the tool to robots
or work surfaces.
Air Filter
Device for removing contamination
from air supply lines. Typically refers to
removal of particulates.
Burr
Any unwanted, raised protrusion on
the workpiece.
Chuck
Gripping device used to hold tools and
media to the spindle.
Compliance
The ability of the spindle to passively
move in response to protrusions on or
deviations of the work piece.
Forward Sensor
The forward sensor is an inductive prox-
imity switch which is ON when the spin-
dle is in the fully extended position indi-
cating there is no contact with the tool.
Gearhead
A gearbox responsible for reducing the
spindle speed of the air motor.
Main Housing
The main cylindrical body of the unit
which includes the mounting features.
Media
Term referring to tools and/or abra-
sives held by the tool during the com-
pletion of a manufacturing process.
Rear Housing
Rear cover to the main housing. This
body includes a connection port for the
compliance air supply and feed-through
seals for optional electrical sensors.
Regulator
Device used to set and control the sup-
plied air pressure to lower acceptable
levels.
Retract Sensor
The retract sensor is an optional induc-
tive proximity switch which is ON when
the spindle is in the fully retracted po-
sition indicating there is no further mo-
tion possible.
Solenoid Valve
Electrically controlled device for
switching air supplies on and off.
Spindle
The rotating portion of the tool assembly.
Tachometer Sensor
The tachometer sensor is an optional in-
ductive proximity switch which monitors
the rotation of a disk mounted behind
the chuck on the spindle. The sensor will
deliver two OFF pulses per spindle rota-
tion. It is recommended that the tacho-
meter sensor be utilized for process de-
velopment but removed from the unit
when in a production environment.
Vane Motor
Air motor that drives the tool spindle.

About this manual
6
01.00|MFT |en
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 unders-
tood 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 of
the product and may differ from the actual product design.
In addition to these instructions, the documents listed under
(1.2, Page 7) are applicable.
Warnings
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Danger for persons.
Non-compliance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons.
Ignoring a safety note like this 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

About this manual
01.00|MFT |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.de.schunk.com.
Variants
This operating manual applies for the following variations
•Polishing Spindle-MFT
•Polishing Spindle-MFTNL
1.2
1.3

Basic safety notes
8
01.00|MFT |en
Basic safety notes
Intended use
The Polishing Spindle MFT is intended to perform robotic and non-
robotic material finishing operations.
The product is intended for installation in a machine/system. The
requirements of the applicable guidelines must be observed and
complied with.
The product may be used only in the context of its defined applica-
tion parameters (5, Page 14).
The product is designed for industrial use.
To use this product as intended, it is also essential to observe the
technical data and installation and operation notes in this manual.
Not intended use
It is not intended use if the product is used, for example, as a
pressing tool, stamping tool, lifting gear, guide for tools, cutting
tool, clamping device or a drilling tool.
•Any utilization that exceeds or differs from the appropriate use
is regarded as misuse.
Environmental and operating conditions
Requirements for the ambient and operating conditions
Due to incorrect ambient and operating conditions, dangers may
arise from the product, which can cause serious injury and sub-
stantial property damage.
•Make sure that the product is used only in the context of its de-
fined application parameters, (5, Page 14).
•The Polishing Spindle MFTshould only be used in an automated
cell/chamber.
•The work cell must be secured by means of barriers to prohibit
personnel from entering the cell. A lockable door should be in-
cluded as a part of the barrier in order to facilitate access to the
cell for authorized personnel only. The barrier could consist
partly or fully of Plexiglas to facilitate observation of the manu-
facturing process.
2
2.1
2.2
2.3

Basic safety notes
01.00|MFT |en
9
•Be aware of high sound levels. While the Polishing Spindle MFT
air motor is not loud, the cutting action associated with many
processes frequently is. Always use hearing protection while
working in the neighborhood of the production cell.
Product safety
Dangers arise from the product, if:
•the product is not used in accordance with its intended pur-
pose.
•the product is not installed or maintained properly.
•the safety and installation notes are not observed.
Avoid any manner of working that may interfere with the function
and operational safety of the product.
Wear protective equipment.
NOTE
More information is contained in the relevant chapters.
Protective equipment
Provide protective equipment per EC Machinery Directive.
Constructional changes
Making constructional changes
Attachements and modifications, constructional changes and subse-
quent work, e.g. additional threads, drill holes and safety devices, can
compromise the operation and safety or damage the product.
•Constructional changes may be only done with permission from
SCHUNK.
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 be only 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.
2.4
2.4.1
2.4.2
2.5

Basic safety notes
10
01.00|MFT |en
The following personal qualifications are necessary for the various
activities related to the product:
Due to their technical training, knowledge and experience, trained
electrician are able to work on electrical systems, recognize and
avoid possible dangers and know the relevant standards and regu-
lations.
Pneumatics specialists have been trained for this particular area of
responsibility and know the relevant standards and regulations.
Hydraulic specialists have been trained for this particular area of
responsibility and knows the relevant standards and regulations.
Due to their technical training, knowledge and experience, quali-
fied personnel is able to perform the delegated tasks, recognize
and avoid possible dangers and knows the relevant standards and
regulations.
Instructed persons were instructed by the operator about the de-
legated tasks and possible dangers due to improper behaviour.
Due to their technical training, knowledge and experience, service
personnel of the manufacturer is able to perform the delegated
tasks and to recognize and avoid possible dangers.
The use personal protective equipment
Using personal protective equipment
If no personal protective gear is worn while working with the prod-
uct, the safety and health of the personnel may be compromised.
•Observe the health and safety regulations and wear the neces-
sary personal protective equipment while working with the
product.
•Observe the applicable safety accident prevention regulations.
•Use protective gloves for sharp edges, sharp corners and rough
surfaces.
•Use protective gloves for hot surfaces.
•Use protective gloves and googles when handling hazardous
substances.
•Wear tight protective clothing for moving components.
Trained electrician
Pneumatics specialist
Hydraulic specialist
Qualified personnel
Instructed person
Service personnel of
the manufacturer
2.6

Basic safety notes
01.00|MFT |en
11
Transportation and Protection during Transportation
The MFT is packaged in a crate designed to secure and protect it
during transportation. Always use the crate when transporting the
MFT in order to minimize the risk of damage.
Safety Precautions
•Never use or start the MFT without first reading and under-
standing the operating procedures described in this manual.
•Make sure that the MFT is mounted as described in this manual.
•Never use the MFT for any purposes or in any ways not explicit-
ly described in this manual.
•Make sure that the pneumatic control equipment is connected
as described.
•Only original spare parts supplied by SCHUNK must be used.
•Install a barrier to prohibit people from approaching the MFT
while in operation.
•Never be present near the MFT while it is started or running. If
it is necessary to approach the MFTwhile in motion, stand be-
hind appropriate Plexiglas windows.
•Be aware of rotating parts.
•Abrasive media must be rated for at least 5,600 1/min.
•Use eye protection.
•Be aware of high sound levels during cutting. Always use hear-
ing protection while working in the neighborhood of the MFT.
•During system or tool maintenance, make sure the MFT and
equipment are stopped before entering the cell. Never be
present in the cell when the tool is running when installing and
testing.
2.7
2.8

Warranty
12
01.00|MFT |en
Warranty
The warranty of the Polishing Spindle MFT is valid for 24 months.
This does not apply to the air motor.
The air motor is warranted for a period of 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.
3

Scope of delivery
01.00|MFT |en
13
Scope of delivery
The scope of delivery includes
•Polishing Spindle MFT in the ordered model
4

Technical Specifications
14
01.00|MFT |en
Technical Specifications
Main specifications for the axially compliant tool:
Operating temperature [°C]
5 - 35
Storage Temperature [°C]
0 - 45
Pressure medium
MFT-390:
clean, dry, filtered, lubricated air.
MFT-390-NL:
clean, dry, filtered, not lubri-
cated air.
The use of a coalescing filter and
filter elements rated 5 micron or
better is recommended.
Air consumtion [l/s] at 6.2 bar
9
Motor
Air motor, vane type
Idle Speed [1/min]
5,600
Working Speed
(max. power) [1/min]
2,600
Power at 2,600 1/min [W]
390
Continuous torque (max. power)
[Nm]
1.4 Nm
Starting torque (starting/stall)
2.7 Nm
Weight total (w/o adapter)
3.3 kg
Compensation axial (max.) [mm]
15
7–8 recommended
Compliance force @ supply
pressure of 0.34–4.1 bar [N]
14–74
Sspindle air pressure (max.)
[bar]
6.2
Air consumption (max.) [l/s]
approximately 9
Oil consumption
(not valid for MFT 390-NL)
Approx. 3–4 drops of oil per
minute (1 drop = 15mm3) by oil
fog at max. air consumption
Ffast Tightening Chuck size
3/8 "
Abrasive media
Customer-supplied
Sound Pressure Level [dBA]
No-Load at a Distance of 1.5
meters from Tool
< 75 *
5

Technical Specifications
01.00|MFT |en
15
*
Because the working environment is unknown, it is impossible
to predict the noise that will occur during an operation. The
tool may also excite resonant frequencies on equipment to
which it is mounted creating higher sound pressure levels than
the unit by itself.
The following charts show measured forces relative to applied
compliance air pressure. Measurements may vary from one prod-
uct to another, and should only be treated as nominal.
Horizontal Compliance Force Curves
The force characteristics shown graphically above are for horizon-
tal, rigidly-mounted installations. The weight of the motor, chuck,
and abrasive media must be added to this if the motor is mounted
vertically with the spindle down or subtracted with the spindle
pointed up. Units mounted at angles between horizontal and ver-
tical provide a compliance force that must be calculated based on
the specific mounting geometry or orientation.
The air motor operating speed will change according to load ap-
plied to it developing the power required for the specific task be-
ing attempted. The idle speed of the motor will be its maximum as
no load is applied. This will drop to a lower operating speed where
it will develop the maximum torque. If the torque required ex-
ceeds the maximum available, the motor will stall.

Technical Specifications
16
01.00|MFT |en
Motor Torque Curves
Motor Power Curves

Description and function
01.00|MFT |en
17
Description and function
Description
NOTICE
•Never use the MFT for purposes other than automated
processes.
•Never use the MFT as a hand-held machine.
While the Polishing Spindle MFT provides axial travel, it is not de-
signed to eliminate tool chatter which will be experienced in full
contact operations, such as countersinking. Rigid tools, such as
milling machines, are required for such applications. It may be
dangerous to operate the MFT for these purposes. If a failure oc-
curs due to forces caused by improper use, hazardous situations
for both personnel and equipment could be created.
The Polishing Spindle MFT is not designed to support radial loads.
The use of radial media (wheel brushes and sanding drums) in the
unit is discouraged as this will lead to binding in the linear slides
preventing axial motion.
Reduce the feed rate when the work piece and the tool are making
initial contact. Making the contact movement between the tool
and the work piece too fast may in some situations result in a colli-
sion. Collisions may create hazardous situations for both personnel
and equipment.
When performing maintenance, always remember to tighten all
the fasteners. When replacing media always secure it correctly and
insure that the chuck is tightened (8.1, Page 25).
The air motor of the Polishing Spindle MFT is equipped with an
integral speed reduction gearbox. The life of this gearbox will be
reduced if the media extends a long distance from the tip of the
spindle. Whenever possible, select media and mounting adapters
for media that are short and position the work as close to the Po-
lishing Spindle MFT as possible.
NOTE
Never use the MFT in a manner to produce radial loads. Avoid us-
ing the MFT for countersinking or drilling.
6
6.1

Description and function
18
01.00|MFT |en
Spindle Operation and Media Selection
When used with flexible abrasive media, the Polishing Spindle MFT
will perform best when the rotating media approaches the burr in
a direction that will fold the burr back on itself. This will allow the
media to remove material rapidly without excessive force and
without the creation of a secondary burr. This will decrease the
cycle time for the operation while extending the life of the tool
and the consumable media. The MFT spindle rotates clockwise
when viewed from behind.
The selection of such media is highly dependent upon the work
piece material and geometry, and the amount of material to be
removed. It is not practical to present all the possibilities in this
document.
6.2

Assembly and Installation
01.00|MFT |en
19
Assembly and Installation
Mechanical connection
The tool is designed for side mounting.
SCHUNK offers a side interface plate kit for bench mounting.
The tool must be rigidly mounted prior to use.
Under no circumstances should the unit be used for manual/hand
operations.
Pneumatic Connection
Air line fittings supplying the Polishing Spindle MFT should be in-
stalled 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 MFT.
Water damage of the air motor or damage associated with debris
in the air lines is not covered under warranty.
MFT-390
Once mounted, the Polishing Spindle MFT should be supplied with
clean, lubricated, filtered air.
MFT-390-NL
Once mounted, the Polishing Spindle MFT should be supplied with
dry, not lubricated air.
7
7.1
7.2
Notes on compressed
air supply

Assembly and Installation
20
01.00|MFT |en
Connect the Polishing Spindle MFT as shown in the following figure.
Pneumatic Connections
The air supply should be dry, air filtered, and lubricated (5,
Page 14).
A high-flow air pressure control regulator is required to supply the
spindle motor at 6.2 bar. A second, precision, self-relieving regula-
tor will supply air for the compliance or centering force.
The compliance force is applied axially and is adjusted until the de-
sired finishing result is achieved. The robot traversing speed will
also be adjusted to achieve the desired finish.
Conventional, customer-supplied, pneumatic components are
used to control the air supply to the tool. SCHUNK recommends
that the user install a high-flow pneumatic pressure regulator and
a high-flow valve to properly supply a stable air supply of 6.2 bar
to the spindle motor. See Section (5, Page 14)for the maximum
flow requirements.) While the spindle motor can be operated be-
low 6.2 bar, it will not develop full power or speed. Very little air-
flow is required for the compliance mechanism.
The air supply solenoid valve must be controlled through robot or
controller.
Connection