SCHUNK AOV User instructions

Translation of Original Operating Manual
Assembly and Operating Manual
AOV
Axially-Compliant Orbital Sander Tool

Imprint
2 01.00 | AOV | Assembly and Operating Manual | en | 1454623
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: 1454623
Version: 01.00|20/01/2021|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
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...................................................................................5
1.1.3 Applicable documents ..............................................................................6
1.1.4 Variants.....................................................................................................6
1.2 Warranty .............................................................................................................. 6
1.3 Scope of delivery .................................................................................................. 6
1.4 Accessories ........................................................................................................... 6
2 Basic safety notes ................................................................................................... 7
2.1 Intended use......................................................................................................... 7
2.2 Not intended use.................................................................................................. 7
2.3 Constructional changes ........................................................................................ 7
2.4 Spare parts ........................................................................................................... 7
2.5 Ambient conditions and operating conditions .....................................................8
2.6 Personnel qualification......................................................................................... 8
2.7 Personal protective equipment............................................................................ 9
2.8 Transport .............................................................................................................. 9
2.9 Malfunctions......................................................................................................... 9
2.10 Disposal .............................................................................................................. 10
2.11 Fundamental dangers......................................................................................... 10
2.11.1 Protection during handling and assembly ..............................................10
2.11.2 Protection during commissioning and operation ...................................11
2.11.3 Protection against dangerous movements.............................................11
2.12 Notes on particular risks..................................................................................... 12
3 Technical data.........................................................................................................13
3.1 Basic data ........................................................................................................... 13
3.2 Ambient conditions and operating conditions ...................................................13
3.3 Compliance force................................................................................................ 14
4 Design and description............................................................................................15
4.1 Design ................................................................................................................. 15
4.2 Description ......................................................................................................... 16
5 Assembly and settings ............................................................................................17
5.1 Assembling and connecting................................................................................ 17
5.2 Connections........................................................................................................ 18
5.2.1 Mechanical connection...........................................................................18
5.2.2 Pneumatic connection............................................................................19
5.3 Mounting the backer pad ................................................................................... 21
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Table of Contents
6 Operation ...............................................................................................................22
7 Troubleshooting .....................................................................................................23
7.1 Uneven machining result.................................................................................... 23
7.2 No compensation possible ................................................................................. 23
7.3 Residues on the workpiece after machining ......................................................23
8 Maintenance ..........................................................................................................24
8.1 Notes .................................................................................................................. 24
8.2 Maintenance interval ......................................................................................... 24
8.3 Lubricating the motor......................................................................................... 24
8.4 Changing the backer pad .................................................................................... 25
8.5 Changing the motor............................................................................................ 26
8.6 Retrofitting the vacuum connection .................................................................. 27
8.7 Disassembly and assembly ................................................................................. 28
8.8 Assembly drawings ............................................................................................. 31
9 Translation of original declaration of incorporation ................................................33
10 Annex to Declaration of Incorporation....................................................................34
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General
1 General
1.1 About this manual
This manual contains important information for a safe and
appropriate use of the product.
This manual is an integral part of the product and must be kept
accessible for the personnel at all times.
Before starting work, the personnel must have read and
understood this operating manual. Prerequisite for safe working is
the observance of all safety instructions in this manual.
Illustrations in this manual are provided for basic understanding
and may differ from the actual product design.
In addition to these instructions, the documents listed under
Applicable documents [}6] are applicable.
1.1.1 Presentation of Warning Labels
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Danger for persons!
Non-observance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons!
Non-observance can lead to irreversible injury and even death.
CAUTION
Dangers for persons!
Non-observance can cause minor injuries.
CAUTION
Material damage!
Information about avoiding material damage.
1.1.2 Definition of Terms
The term "product" replaces the product name on the title page in
this manual.
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General
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1.1.3 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
1.1.4 Variants
This operating manual applies to the following variations:
• AOVwith vacuum
• AOVwithout vacuum
1.2 Warranty
If the product is used as intended, the warranty is valid for 24
months from the ex-works delivery date under the following
conditions:
• Observe the ambient conditions and operating conditions
Parts touching the workpiece and wear parts are not included in
the warranty.
1.3 Scope of delivery
The scope of delivery includes
• Axially-Compliant Orbital Sander Tool AOV in the version
ordered
• Assembly and Operating Manual
• Accessory pack
1.4 Accessories
The following accessories are available for the product, which
must be ordered separately:
• Adapter plate
• Media changer
For information regarding which accessory articles can be used
with the corresponding product variants, see catalog data sheet.

Basic safety notes
2 Basic safety notes
2.1 Intended use
The product is intended exclusively for polishing and grinding
workpieces with a robot.
• The product may only be used within the scope of its technical
data, Technical data [}13].
• When implementing and operating components in safety-
related parts of the control systems, the basic safety principles
in accordance with DIN EN ISO 13849-2 apply. The proven safety
principles in accordance with DIN EN ISO 13849-2 also apply to
categories 1, 2, 3 and 4.
• The product is intended for installation in a machine/system or
for mounting to a robot. The applicable guidelines must be
observed and complied with.
• The product is intended for industrial and industry-oriented use.
• Appropriate use of the product includes compliance with all
instructions in this manual.
2.2 Not intended use
It is not intended use if the product is used, for example, as a
pressing tool, stamping tool, lifting gear, guide for tools, cutting
tool, clamping device or a drilling tool.
• Inappropriate use includes using the product as a hand tool.
• Any utilization that exceeds or differs from the appropriate use
is regarded as misuse.
2.3 Constructional changes
Implementation of structural changes
By conversions, changes, and reworking, e.g. additional threads,
holes, or safety devices can impair the functioning or safety of the
product or damage it.
• Structural changes should only be made with the written
approval of SCHUNK.
2.4 Spare parts
Use of unauthorized spare parts
Using unauthorized spare parts can endanger personnel and
damage the product or cause it to malfunction.
• Use only original spare parts or spares authorized by SCHUNK.
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Basic safety notes
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2.5 Ambient conditions and operating conditions
Required ambient conditions and operating conditions
Incorrect ambient and operating conditions can make the product
unsafe, leading to the risk of serious injuries, considerable material
damage and/or a significant reduction to the product's life span.
• Make sure that the product is used only in the context of its
defined application parameters, Technical data [}13].
2.6 Personnel qualification
Inadequate qualifications of the personnel
If the personnel working with the product is not sufficiently
qualified, the result may be serious injuries and significant
property damage.
• All work may only be performed by qualified personnel.
• Before working with the product, the personnel must have read
and understood the complete assembly and operating manual.
• Observe the national safety regulations and rules and general
safety instructions.
The following personal qualifications are necessary for the various
activities related to the product:
Trained electrician Due to their technical training, knowledge and experience, trained
electricians are able to work on electrical systems, recognize and
avoid possible dangers and know the relevant standards and
regulations.
Qualified personnel Due to its technical training, knowledge and experience, qualified
personnel is able to perform the delegated tasks, recognize and
avoid possible dangers and knows the relevant standards and
regulations.
Instructed person Instructed persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behaviour.
Service personnel of
the manufacturer
Due to its technical training, knowledge and experience, service
personnel of the manufacturer is able to perform the delegated
tasks and to recognize and avoid possible dangers.

Basic safety notes
2.7 Personal protective equipment
Use of personal protective equipment
Personal protective equipment serves to protect staff against
danger which may interfere with their health or safety at work.
• When working on and with the product, observe the
occupational health and safety regulations and wear the
required personal protective equipment.
• Observe the valid safety and accident prevention regulations.
• Wear protective gloves to guard against sharp edges and
corners or rough surfaces.
• Wear heat-resistant protective gloves when handling hot
surfaces.
• Wear protective gloves and safety goggles when handling
hazardous substances.
• Wear close-fitting protective clothing and also wear long hair in
a hairnet when dealing with moving components.
• Wear ear protection and safety goggles during the machining
process.
2.8 Transport
Handling during transport
Incorrect handling during transport can make the product unsafe
and risk the danger of serious injuries and considerable material
damage.
• During transport and handling, secure the product to prevent it
from falling.
• Do not walk under suspended loads.
2.9 Malfunctions
Behavior in case of malfunctions
• Immediately remove the product from operation and report the
malfunction to the responsible departments/persons.
• Order appropriately trained personnel to rectify the
malfunction.
• Do not recommission the product until the malfunction has
been rectified.
• Test the product after a malfunction to establish whether it still
functions properly and no increased risks have arisen.
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Basic safety notes
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2.10 Disposal
Handling of disposal
The incorrect handling of disposal may impair the product's safety
and cause serious injuries as well as considerable material and
environmental harm.
• Follow local regulations on dispatching product components for
recycling or proper disposal.
2.11 Fundamental dangers
General
• Observe safety distances.
• Never deactivate safety installations.
• Install the provided protective product in the danger zone
before switching on the product.
• Remove the energy supplies before installation, modification,
maintenance, or adjustment work. Ensure there is no residual
energy in the system.
• Do not move parts by hand while the energy supply is
connected.
• Do not reach into the movement area of the product during
operation.
2.11.1 Protection during handling and assembly
Incorrect handling and assembly
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Have all work carried out by appropriately qualified personnel.
• For all work, secure the product against accidental operation.
• Observe the relevant accident prevention rules.
• Use suitable assembly and transport equipment and take
precautions to prevent jamming and crushing.
Incorrect lifting of loads
Falling loads may cause serious injuries and even death.
• Stand clear of suspended loads and do not step into their
swiveling range.
• Never move loads without supervision.
• Do not leave suspended loads unattended.

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

Technical data
3 Technical data
3.1 Basic data
Designation AOV
Weight [kg] 2.68
Compensation path axial Z [mm] 12.7
Compliance force [N] (Extend)
Min.
Max.
13.3
66.7
Compliance force [N] (Retract)
Min.
Max.
6.7
33.4
Orbit pattern [mm] 5
Nominal operating pressure [bar]
Compensation
Spindle
1-4.1
6.2
Pressure medium Compressed air (clean, dry,
filtered (≤ 5 µm), oiled)
Max. air consumption [l/s] 9.5
Oil consumption [drops/h] 2-3
Motor operating data
Motor Vane motor (pneumatic)
Idle speed [1/min] 10,000
3.2 Ambient conditions and operating conditions
Designation AOV
Ambient temperature [°C]
Min.
Max.
+5
+35
Noise emission [dB(A)] ≤ 85
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Technical data
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3.3 Compliance force
NOTE
The compliance force may vary from product to product and
should be treated as a guide value only. The actual force
characteristics depend on the installation position and the
condition of the product. The compliance pressure should be
selected depending on the material of the workpiece, the type of
tool and the amount of material to be removed.
NOTE
The specified compliance force only corresponds to the actual
values when the product is mounted horizontally and the motor is
switched off.
Compliance force
(retract)
Supply pressure [bar]
Compliance force (retract) [N]
Compliance force (retract) as a function of the operating pressure
Compliance force
(extend)
Supply pressure [bar]
Compliance force (extend) [N]
Compliance force (extend) as a function of the operating pressure

Design and description
4 Design and description
4.1 Design
AOV with vacuum
1 Compensation air connection
2 Internal thread for mounting the grinding disc
3 Vacuum shroud
4 Bellows
5 Vacuum connector
6 Exhaust air opening
7 Motor air connection
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Design and description
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AOV without vacuum
1 Compensation air connection
2 Internal thread for mounting the grinding disc
3 Shroud
4 Bellows
5 Exhaust air opening
6 Motor air connection
4.2 Description
Pneumatic orbital sander tool with axial compensation for grinding
and polishing workpiece surfaces

Assembly and settings
5 Assembly and settings
5.1 Assembling and connecting
WARNING
Risk of injury due to unexpected movements!
If the power supply is switched on or residual energy remains in
the system, components can move unexpectedly and cause
serious injuries.
•Before starting any work on the product: Switch off the power
supply and secure against restarting.
•Make sure, that no residual energy remains in the system.
CAUTION
Risk of injury from flying chips and dirt particles
During operation, flying chips and dirt particles can cause eye
injuries.
•Always wear appropriate personal protective equipment,
particularly protective goggles.
•Take suitable protective measures to secure the danger zone.
1. Check the evenness of the mounting surface,
Mechanical connection [}18].
2. Connectcompressed air supply,
Pneumatic connection [}19].
3. Attach the product to the robot,
Mechanical connection [}18].
✓If necessary, use appropriate connection elements (adapter
plates).
4. Mounting the backer pad, Mounting the backer pad [}21].
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Assembly and settings
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5.2 Connections
5.2.1 Mechanical connection
Check the flatness of
the bolting surface
The values refer to the mounting surface to which the attachments
provided are mounted (e.g. grippers, rotary modules).
Requirements for the flatness of the bolting surface (dimensions in mm)
Edge lengths Permissible unevenness
< 100 < 0.02
> 100 < 0.05
The product can be assembled from two sides.
Item Mounting AOV
Side A
1 Mounting screw* -
2 Clamping collar*
3 Adapter plateaxial*
Side B
4 Mounting screw* M6
Max. depth of engagement [mm] 9.1
5 Adapter plate radial* -
6 Centering pin[mm] 6
* Mounting material is not included in the scope of delivery.
(available from SCHUNK on request)

Assembly and settings
5.2.2 Pneumatic connection
CAUTION
Damage to the air hoses possible!
The hoses connected to the air connection spindle can be
damaged if the mounting is too tight.
•Allow hoses to hang flexibly so as not to impair the
compensating movements of the motor.
NOTE
• Observe the requirements for the compressed air supply,
Technical data [}13].
•For compensation air connection: For better regulation of the
compressed air, use a self-relieving regulator with air bleed.
•For air connection spindle: For better regulation of the
compressed air, use a 2-way valve and a pressure regulator set
at max. 6.2bar.
1 Motor air connection
2 Compensation air connection (extension)
3 Compensation air connection (retraction)
Item Mounting AOV
1 Hose connection[mm] 10
Thread G1/4
2
3
Hose connection[mm] 4
Thread G1/8
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Assembly and settings
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Pneumatics wiring
diagram
NOTE
Depending on the application, only one of the retract and extend
air connections may be necessary.
Air connection
6.2 bar
Filter
Oil fog
lubricator
2/2 directional control valve
Vane-type air motor
Product
Exhaust
air /
silencer
Compressed air line
(Retract)
Compressed air line
(Extend)
External regulator (1-4.1 bar)
External regulator (1-4.1 bar)
Display
Display
Compensation
Pneumatic wiring diagram