SCHUNK FDB-AC Series User instructions

Original Manual
Assembly and Operating Manual
FDB-AC
Robotic Deburring Tool

Imprint
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02.00 | FDB-AC | Assembly and Operating Manual | en | 389513
Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights
reserved. Any reproduction, processing, distribution (making available to third parties),
translation or other usage - even excerpts - of the manual is especially prohibited and
requires our written approval.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 389513
Version: 02.00|15/08/2019|en
© SCHUNK GmbH & Co. KG
All rights reserved.
Dear Customer,
thank you for trusting our products and our family-owned company, the leading
technology supplier of robots and production machines.
Our team is always available to answer any questions on this product and other solutions.
Ask us questions and challenge us. We will find a solution!
Best regards,
Your SCHUNK team
SCHUNK GmbH & Co. KG
Spann- und Greiftechnik
Bahnhofstr. 106 – 134
D-74348 Lauffen/Neckar
Tel. [phone]
Fax [phone]
[email protected]
schunk.com

Table of Contents
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Table of Contents
1 General.................................................................................................................... 5
1.1 About this manual ................................................................................................ 5
1.1.1 Presentation of Warning Labels ...............................................................5
1.1.2 Applicable documents ..............................................................................6
1.1.3 Variants.....................................................................................................6
1.2 Warranty .............................................................................................................. 6
1.3 Scope of delivery .................................................................................................. 6
2 Basic safety notes ................................................................................................... 7
2.1 Intended use......................................................................................................... 7
2.2 Constructional changes ........................................................................................ 7
2.3 Spare parts ........................................................................................................... 7
2.4 Ambient conditions and operating conditions .....................................................8
2.5 Personnel qualification......................................................................................... 8
2.6 Personal protective equipment............................................................................ 9
2.7 Notes on safe operation ....................................................................................... 9
2.8 Transport ............................................................................................................ 10
2.9 Malfunctions....................................................................................................... 10
2.10 Disposal .............................................................................................................. 10
2.11 Fundamental dangers......................................................................................... 10
2.11.1 Protection during handling and assembly ..............................................11
2.11.2 Protection during commissioning and operation ...................................11
2.12 Notes on particular risks..................................................................................... 12
3 Technical data.........................................................................................................13
3.1 Technical Specifications...................................................................................... 13
3.2 Environmental Limitations ................................................................................. 15
4 Handling, Installation, Storage and Transportation .................................................16
4.1 Inspection of Condition when Delivered ............................................................ 16
4.2 Unpacking and Handling..................................................................................... 16
4.3 Installation.......................................................................................................... 17
4.3.1 Pneumatics FDB-AC 90 ...........................................................................17
4.3.2 Pneumatics FDB-AC 180 .........................................................................18
4.3.3 Mounting, Adapter and Interface Plate..................................................21
4.4 Transportation and Protection during Transportation....................................... 22
4.5 Storage and Preventive Maintenance during Storage........................................ 22
5 Operating Instructions ...........................................................................................23
5.1 General Precautions ........................................................................................... 24
5.2 FDB-AC Working Environment ........................................................................... 25
5.3 Tool Center Point (TCP) Position ........................................................................ 26
5.3.1 TCP FDB-AC 90........................................................................................26

Table of Contents
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5.3.2 TCP FDB-AC 180......................................................................................27
5.4 Operational Considerations................................................................................ 28
5.5 Programming...................................................................................................... 29
6 Maintenance ..........................................................................................................31
6.1 Regular Operational Maintenance ..................................................................... 31
6.1.1 User Serviceable parts FDB-AC 90 ..........................................................32
6.1.2 User Serviceable parts FDB-AC 180 ........................................................33
6.2 Recommended Inspection and Cleaning Procedure ..........................................34
6.3 Lubrication.......................................................................................................... 36
6.4 Replacement of Burrs......................................................................................... 37
6.5 Replacement of Other FDB-AC Parts .................................................................. 38
6.6 Overhaul ............................................................................................................. 38
6.7 Repairs and Spare Parts...................................................................................... 38
7 Drawings.................................................................................................................39
7.1 FDB-AC 90........................................................................................................... 39
7.2 FDB-AC 180......................................................................................................... 40
8 Translation of original declaration of incorporation ................................................41
9 Annex to Declaration of Incorporation....................................................................42

General
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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.

General
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1.1.2 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 schunk.com
1.1.3 Variants
This operating manual applies to the following variations:
• Robotic Deburring Tool FDB-AC 90
• Robotic Deburring Tool FDB-AC180
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,
Ambient conditions and operating conditions [}8]
• Observe the specified maintenance intervals, Maintenance [}31]
Parts touching the workpiece and wear parts are not included in
the warranty.
1.3 Scope of delivery
The scope of delivery includes
• Robotic Deburring Tool FDB-AC in the version ordered

Basic safety notes
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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, Technical data [}13].
• 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 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.
2.3 Spare parts
Use of unauthorized spare parts
Using unauthorized spare parts can endanger personnel and
damage the product or cause it to malfunction.
• Use only original spare parts or spares authorized by SCHUNK.

Basic safety notes
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2.4 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].
2.5 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
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2.6 Personal protective equipment
Use of personal protective equipment
Personal protective equipment serves to protect staff against
danger which may interfere with their health or safety at work.
• When working on and with the product, observe the
occupational health and safety regulations and wear the
required personal protective equipment.
• Observe the valid safety and accident prevention regulations.
• Wear protective gloves to guard against sharp edges and
corners or rough surfaces.
• Wear heat-resistant protective gloves when handling hot
surfaces.
• Wear protective gloves and safety goggles when handling
hazardous substances.
• Wear close-fitting protective clothing and also wear long hair in
a hairnet when dealing with moving components.
2.7 Notes on safe operation
Incorrect handling of the personnel
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Avoid any manner of working that may interfere with the
function and operational safety of the product.
• Use the product as intended.
• Observe the safety notes and assembly instructions.
• Do not expose the product to any corrosive media. This does
not apply to products that are designed for special
environments.
• Eliminate any malfunction immediately.
• Observe the care and maintenance instructions.
• Observe the current safety, accident prevention and
environmental protection regulations regarding the product's
application field.

Basic safety notes
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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.
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.

Basic safety notes
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2.11.1 Protection during handling and assembly
Incorrect handling and assembly
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Have all work carried out by appropriately qualified personnel.
• For all work, secure the product against accidental operation.
• Observe the relevant accident prevention rules.
• Use suitable assembly and transport equipment and take
precautions to prevent jamming and crushing.
Incorrect lifting of loads
Falling loads may cause serious injuries and even death.
• Stand clear of suspended loads and do not step into their
swiveling range.
• Never move loads without supervision.
• Do not leave suspended loads unattended.
2.11.2 Protection during commissioning and operation
Falling or violently ejected components
Falling and violently ejected components can cause serious injuries
and even death.
• Take appropriate protective measures to secure the danger
zone.
• Never step into the danger zone during operation.

Basic safety notes
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2.12 Notes on particular risks
• Never use or start the tool without first reading and
understanding the Installation and Operation Manual.
• Make sure that the tool is mounted as described in chapter
"Mounting Mounting, Adapter and Interface Plate [}21].
• Never use the tool for other purposes than those explicitly
described in the Installation and Operation Manual.
• Make sure that the pneumatic control equipment is mounted as
described in chapter "Pneumatics FDAB-AC.."
Pneumatics FDB-AC 90 [}17] / Pneumatics FDB-AC 180 [}18]
• Only original spare parts and files/burrs delivered from the tool
manufacturer must be used Repairs and Spare Parts [}38].
• Never stand near the tool while it is started and running. If it is
necessary to approach the tool while in motion, stand behind
appropriate Plexiglass® windows.
• Be aware of rotating parts.
• A barrier to prohibit people from approaching the tool while in
operation must secure the installation.
• Be aware of high sound levels. Always use earplugs while
working near the tool.
• Provide protective equipment to prevent objects from falling or
being ejected, such as processed workpieces, tools, chips,
fragments, rejects.
• The danger zone must be surrounded by a safety fence during
operation.

Technical data
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3 Technical data
3.1 Technical Specifications
Motor Air motor, vane type
Speed Idle 30.000 RPM, while deburring 18.000–25.000
RPM
Torque 0,4 Nm at lower speeds
Power 250 W at 20,000 RPM
Weight total FDB-AC 90: 0.5 kg
FDB-AC 180: 0.51 kg
Weight, compensation piston
with burr
0.05 kg
Compensation (burr float) Max. ± 4 mm axial and lateral, ±2 mm recommended
Axial force 1 - 25 N, @ supply pressure of 0–3,1 bar
Burr surface speed 7,5 - 10,5 m/s, measured at Ø 8mm
(halfway between center tip and outer rim)
Air consumption ca. 6,65 l/s at 5,17 bar line pressure
Sound pressure level 75 dB(A)
Sound pressure value 87 dB(C)
Rotary burrs 1) 90° coned shape, straight fluting.
2) 90° coned shape, spiraled fluting.
3) C2, C5 Carbide
Other rotary burr/file qualities on request.
Special tools Burr changing tool
Notes about Sound
pressure level
All noise emission measurements were taken at a distance of 3
feet from the FDB-AC and at a height of 5 feet from the floor. The
FDB-AC was mounted on a laboratory test-bench. No barriers or
noise-reduction facilities were used except for exhaust return to
an oil-recovery-unit located beneath the test-bench. A drive
pressure of 75 psi was applied (full FDB-AC drive pressure). No
axial force pressure was applied. The FDB-AC was running at full
idle speed. Because the working environment is not known, this
method was considered the best method for measurements.
The equivalent continuous A-weighted sound pressure level was
measured as 75 dB (A).
The peak C-weighted instantaneous sound pressure value was
measured as 87 dB(C).

Technical data
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Axial contact force, measured with rotary burr pointing downwards
Each FDB-AC goes through a thorough test procedure before it is
shipped. In the figure are theoretical and measured forces relative
to applied axial air pressure. Please note that theoretical
calculations are not necessarily identical to actual data.
Measurements may vary from one product to another, and should
only be treated as nominal.
0
50
100
150
200
250
300
350
400
0 50 00 1000 0 1500 0 2000 0 250 00 3 0000
Roboter torque M, in Nmm
Output power P, inW
Torq ue
Pow er
Rotor velocity, in rpm
Theoretical calculations, FDB-AC output torque and power
Due to pressure losses between the pressure regulator and the
compensation piston, the axial force is lower than theoretical
calculations will predict. The actual force characteristics will
change from installation to installation due to different types of
pneumatic components used.

Technical data
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Drive pressure, in psi
Rotary speed in RPM
0
5 000
1 0000
1 5000
2 0000
2 5000
3 0000
0 14 .5 2 9 43 .5 58 72 .5 87
Spe ed
Idle speed as function of applied drive pressure
We recommend a working speed of 15,000 to 25,000 RPM for
maximum possible output. A speed lower than 15,000 RPM is not
recommended, as it increases the risk of stalling the motor, due to
the higher torque at lower speeds.
3.2 Environmental Limitations
General Area classification: None
Gas group/ignition group: None
Operation Installation position: • Mounted to robot by means of the
Speedeburr adapter and flange. The
flange is specific to each type of robot.
This flange not supplied by SCHUNK .
• Mounted to a table or stand by means
of the Speedeburr adapter (the robot is
carrying the workpiece).
Temperature range: 5°C–35°C
41°F–95°F
Storage Temperature range: 0°C–45°C
32°F–113°F
Conditions The tool should be stored in its crate and in a dry place. The tool
should be kept dry and full of pneumatic oil when stored. Keep
unit in crate if possible. Transportation and Protection during
Transportation [}22]

Handling, Installation, Storage and Transportation
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4 Handling, Installation, Storage and Transportation
4.1 Inspection of Condition when Delivered
Upon receipt, the following must be checked:
• Delivery in accordance with freight documents
• 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.
4.2 Unpacking and Handling
The FDB-AC tool, during transportation, storing and handling,
should always be placed inside the accompanying box (crate).

Handling, Installation, Storage and Transportation
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4.3 Installation
4.3.1 Pneumatics FDB-AC 90
(Option 1) on/off
valve actuated
from robot
controller
Mist
lubrication Filter
Air supply
5 bar
Vane
motor Exhauset
FFP
FDB-AC
Axial force from deburring process
External pressure
regular
0 - 3 psi
(Option 2) on/off
valve actuated
from robot
controller
(Option 2) on/off
valve actuated
from robot
controller
Connect the FDB-AC 90 as shown in the figure.
Two connection methods are shown.
• Option 1 uses one solenoid valve to control both motor drive air
supply and axial force air supply.
• Option 2 uses two solenoid valves to independently control the
two air supplies.

Handling, Installation, Storage and Transportation
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4.3.2 Pneumatics FDB-AC 180
Electric on/off valve
actuated from robot
controller
Mist
lubrication Filter
Air supply
5 bar
Vane
motor
Vent
FFS
AFFS
FDB-AC
Axial force from deburring process
External pressure
control valve
0-3 bar
Pneumatic Connection
Connect the FDB-AC 180 as shown in the figure.
A special Speedeburr adapter is available as extra equipment, to
enable standard air nipples to be coupled to the Straight FDB-AC.
Air silencers can be coupled to the exhaust ports of the adapter, to
take away the noise when exhaust air enters the atmosphere. The
drive air to the vane motor should be mist lubricated by use of
conventional pneumatic equipment.
An external pressure control valve, for example mounted on the
industrial robot’s upper arm, will control the axial force on the
rotary tungsten carbide file.
The axial force is adjusted until a chamfer with the correct width is
produced, for a given path speed.
NOTE
Poor performance will result if the correct components are not
used.
Pneumatic components used for the motor drive circuit must be
able to meet the air consumption requirements
Technical Specifications [}13]

Handling, Installation, Storage and Transportation
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Conventional pneumatic components (not supplied with the FDB-
AC tool) are used to control the air supply to the FDB-AC. SCHUNK
recommends that the user install a pneumatic pressure regulator
in order to achieve a stable air supply and to reduce the air supply
to the maximum of 90 psi.
The solenoid-operated valve(s) are actuated from the robot
controller by means of a digital output signal.
The external pressure regulator is used to control the air supply to
the axial force compliance mechanism, thus enabling control of
the axial force on the rotary burr. If the complete workpiece can
be deburred with equal axial force, a conventional manual
pressure regulator can be used. If the burrs to be removed are
varying from place to place on the workpiece, and this variation is
repeatable for all workpieces of the same type, it may be
necessary to adjust the axial force by using an analog pressure
regulator controlled from the robot controller. An analog output
port in the robot controller will be needed.
Function Thread Type Pressure
Motor inlet 1/8" 3,1 - 5,2 bar
maximum 6,2
Axial (contact)
force inlet
M5 0 - 3,1 bar,
maximum 3,1 bar
Control functions M5 Optional
Exhaust 1/4" Not Applicable
It is recommended that 3/8” plastic tube be used for the motor air
supply inlet, and 5/32” tube for the axial force air supply inlet.
Note that a M5 connection is used for the axial force air supply
inlet, and a 1/8" connection for the motor air supply inlet. Use two
silencers directly mounted on the two 1/4" exhaust outlets
Technical Specifications [}13].
If more noise suppression in desired, install silencers on the
exhaust line further away from the Speedeburr adapter. An oil
recovery unit may be installed on the exhaust line to avoid the
mist lubrication droplets from entering the atmosphere around
the robot installation. Additionally, to reduce the sound in
neighboring working areas, a barrier
FDB-AC Working Environment [}25] surrounding the installation
may be installed (Plexiglas or Lexan is preferred).

Handling, Installation, Storage and Transportation
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The axial force air supply pressure regulator should have a 0–45
psi range. When testing for the proper contact force start with a
very low pressure and increase slowly until the desired chamfer is
achieved (typically 3 psi for aluminum and more for steel
workpieces).
Before start-up make sure the air lubrication system is filled with
oil. Lubrication [}36]
CAUTION
Lack of lubrication will cause destruction of the motor within a
relatively short time.
If the lubrication is not working properly, you can hear the motor
running slower than normal, and the speed may be varying.
•Install the lubrication equipment near the robot base
(maximum 16 feet away from the FDB-AC) for proper
operation. Lubrication [}36]