SCHUNK CDB Assembly And Operating Manual

Assembly and Operating Manual CDB Compliant Deburring Blade Tool

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: 1453534 Version: 01.00 | 23/11/2020 | 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. +49-7133-103-2503 Fax +49-7133-103-2189 [email protected] Please read the operating manual in full and keep it close to the product.

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 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 ........................................................................................ 8 2.4 Spare parts ........................................................................................................... 8 2.5 Ambient conditions and operating conditions ..................................................... 8 2.6 Personnel qualification......................................................................................... 9 2.7 Personal protective equipment.......................................................................... 10 2.8 Transport............................................................................................................ 10 2.9 Malfunctions....................................................................................................... 10 2.10 Disposal .............................................................................................................. 11 2.11 Fundamental dangers......................................................................................... 11 2.11.1 Protection during handling and assembly .............................................. 11 2.11.2 Protection during commissioning and operation................................... 12 2.11.3 Protection against dangerous movements............................................. 12 2.12 Notes on particular risks..................................................................................... 13 3 Technical data......................................................................................................... 14 3.1 Basic data ........................................................................................................... 14 3.2 Compliance force................................................................................................ 15 4 Design and description............................................................................................ 16 4.1 Design................................................................................................................. 16 4.2 Description ......................................................................................................... 17 5 Assembly and settings ............................................................................................ 18 5.1 Assembling and connecting................................................................................ 18 5.2 Connections........................................................................................................ 19 5.2.1 Mechanical connection........................................................................... 19 5.2.2 Pneumatic connection............................................................................ 20 5.3 Attaching the blade holder manually ................................................................. 21 5.4 Mount the tool stand module ............................................................................ 22 5.5 Setting axis fixation ............................................................................................ 24 3 01.00 | CDB | Assembly and Operating Manual | en | 1453534

6 Operation ............................................................................................................... 25 7 Troubleshooting ..................................................................................................... 26 7.1 Tool wears out or breaks.................................................................................... 26 7.2 Tool rattles during deburring ............................................................................. 26 7.3 Uneven deburring result .................................................................................... 26 7.4 Residue on the workpiece after deburring......................................................... 27 7.5 Piston does not move......................................................................................... 27 8 Maintenance .......................................................................................................... 28 8.1 Notes .................................................................................................................. 28 8.2 Maintenance interval ......................................................................................... 28 8.3 Assembly drawings............................................................................................. 29 4 01.00 | CDB | Assembly and Operating Manual | en | 1453534

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. 5 01.00 | CDB | Assembly and Operating Manual | en | 1453534

1.1.2 Definition of Terms The term "product" replaces the product name on the title page in this manual. 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: • CDB with manual tool change • CDB-ATC with Auto Tool Changer 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 • Compliant Deburring Blade Tool CDB in the version ordered • Assembly and Operating Manual 1.4 Accessories The following accessories are available for the product, which must be ordered separately: • Adapter plate • Tool stand module For information regarding which accessory articles can be used with the corresponding product variants, see catalog data sheet.

2 Basic safety notes 2.1 Intended use The product is intended exclusively for machining workpieces with a robot. • The product may only be used within the scope of its technical data, Technical data [} 14]. • 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. 7 01.00 | CDB | Assembly and Operating Manual | en | 1453534

8 01.00 | CDB | Assembly and Operating Manual | en | 1453534 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. 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 [} 14].

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. 9 01.00 | CDB | Assembly and Operating Manual | en | 1453534

10 01.00 | CDB | Assembly and Operating Manual | en | 1453534 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.

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. 11 01.00 | CDB | Assembly and Operating Manual | en | 1453534

12 01.00 | CDB | Assembly and Operating Manual | en | 1453534 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.

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. 13 01.00 | CDB | Assembly and Operating Manual | en | 1453534

3 Technical data 3.1 Basic data Designation CDB CDB-ATC Weight [kg] 1.04 1.09 Compensation angle radial X/Y [°] ± 5.5 Compensation path axial Z [mm] 8 Compliance force [N] (radial) Min. Max. 25 76 Compliance force [N] (axial) Min. Max. 13 67 Nominal operating pressure [bar] Compensation air connection Air connection tool changer 1-4.1 4.1 Pressure medium Compressed air (clean, dry, filtered (≤ 5 µm), oil-free) More technical data is included in the catalog data sheet. Whichever is the latest version.

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. Supply pressure [bar] Axial compliance force [N] Axial compliance force as a function of operating pressure Supply pressure [bar] Radial compliance force [N] Radial compliance force as a function of operating pressure 15 01.00 | CDB | Assembly and Operating Manual | en | 1453534

16 01.00 | CDB | Assembly and Operating Manual | en | 1453534 4 Design and description 4.1 Design Variant: Manual tool change Compliant Deburring Blade Tool  with manual tool change 1 Axial Connection 2 Compensation air connection 3 Housing 4 Collet 5 Axis fixation set screw Variant: Auto Tool Changer Compliant Deburring Blade Tool with Auto Tool Changer 1 Axial Connection 2 Compensation air connection 3 Housing 4 Tool lock/unlock air connection 5 Auto Tool Changer for blade holder 6 Axis fixation set screw

4.2 Description Compliant tool for deburring with the robot and proven deburring tools 17 01.00 | CDB | Assembly and Operating Manual | en | 1453534

18 01.00 | CDB | Assembly and Operating Manual | en | 1453534 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. 1. Check the evenness of the mounting surface, Mechanical connection [} 19]. 2. Connect compressed air supply line to the main air connection, Pneumatic connection [} 20]. 3. Screw the product to the machine/system, Mechanical connection [} 19]. ✓ If necessary, use appropriate connection elements (adapter plates). 4. Manual tool change variant: Fasten the blade holder in the collet, Attaching the blade holder manually [} 21]. Auto Tool Changer variant:Mount the tool stand module in the tool stand, Mount the tool stand module [} 22]. 5. If necessary, adjust the axis fixation set screw, Setting axis fixation [} 24].

5.2 Connections 5.2.1 Mechanical connection Evenness of the mounting surface The values apply to the whole mounting surface to which the product is mounted. Requirements for evenness of the mounting surface (Dimensions in mm) Edge length Permissible unevenness < 100 < 0.02 > 100 < 0.05 Item Mounting CDB 1 Adapter plate provided by customer (available from SCHUNK on request) * 2 Mounting screw 3 Clamping collar * The catalog data sheet contains more information. The latest version is always applicable. 19 01.00 | CDB | Assembly and Operating Manual | en | 1453534

20 01.00 | CDB | Assembly and Operating Manual | en | 1453534 5.2.2 Pneumatic connection NOTE • Observe the requirements for the compressed air supply, Technical data [} 14]. • Use a regulator with venting for better regulation of the compressed air. NOTE Supply the tool lock air connection with compressed air continuously during use. 1 Compensation air connection 2 Tool lock air connection 3 Tool unlock air connection Item Mounting CDB CDB-ATC 1 Compensation air connection [mm] 4 4 2 Tool air connection [mm] (lock/unlock) - 3 3

5.3 Attaching the blade holder manually 1. Pull the manual clamping collar for tool change (1) towards the product. ✓ The locking ball unlocks. 2. Push the blade holder (2) into the product and adjust the desired length. ✓ The latch on the blade holder points in the direction of the locking ball. 3. Loosen the manual clamping collar (1). 4. Make sure that the blade holder (2) is correctly engaged. 21 01.00 | CDB | Assembly and Operating Manual | en | 1453534

22 01.00 | CDB | Assembly and Operating Manual | en | 1453534 5.4 Mount the tool stand module 1. Remove the end cap (1) from the extruded aluminum rail (4). 2. Push the tool stand module (2) with the T-slot into the extruded aluminum rail (4) to the desired position. 3. Tighten the tool stand module (2) with the fastening screw (3). ✓ Max. tightening torque: 10 Nm. 4. Place the end cap (1) onto the extruded aluminum rail (4).

NOTE A latch is used to fasten the blade holder in the tool stand module. For this reason, a sufficient distance must be maintained from the stand module above and below so that the blade holder can snap into the tool stand module. The blade holder must also protrude sufficiently from the collet of the product. The robot controller must be adjusted accordingly to this distance. ■ Use the teach mode of the robot controller. 1. Connect the tool lock/unlock air connections (2) to the system. 2. Manually actuate compressed air to unlock the tool stand module. 3. Place the blade holder (1) manually in the tool stand module in such a way that at least three catches in the latch mechanism (3) can grip the blade holder. 4. Manually actuate compressed air to lock the tool stand module. 5. If necessary, place further tool stand modules in the tool stand. ✓ Maintain a minimum distance of 25 mm between each module. 23 01.00 | CDB | Assembly and Operating Manual | en | 1453534

24 01.00 | CDB | Assembly and Operating Manual | en | 1453534 5.5 Setting axis fixation CAUTION Risk of damage to the product! A load along the Y-axis when using axis fixation will damage the compensation mechanism. • When using a single-axis lock, only apply loads in the X direction. • The product must always be vertical in relation to the edge of the workpiece. Orient the robot appropriately depending on the geometry of the workpiece. A = Unlocked; B = Locked 1. Adjust the screw to the desired position: ✓ Unlocked = 360° compensation ✓ Locked = Compensation only in X-axis 2. Manually check ease of movement and possible directions of movement for correct function.

If the tool quickly approaches the workpiece vertically, this will lead to premature wear of the tool and possibly damage the product. • Set process parameters precisely. • Test the operating direction of the blade before operation. ■ Product was completely assembled. 1. Adjust the robot control system so that the product approaches the workpiece slowly and at a shallow angle. Depending on the tool, also provide enough space and distance so that it is still possible to orient the cutting tool to the workpiece contour. 2. Adjust feed rate. 3. Ensure that the distance to the workpiece and the orientation of the cutting tool are correctly set before each new operation. 4. Plan the robot path so that 50% of the compensation function of the product is used at the theoretical tool edge. This allows the product to use its flexibility to machine areas evenly despite different initial geometries without losing contact with the workpiece. If this is not possible, several machining passes may be necessary. 5. When using the axis fixation, always set the free compensation axis of the product perpendicular to the edge of the workpiece. 25 01.00 | CDB | Assembly and Operating Manual | en | 1453534

7 Troubleshooting 7.1 Tool wears out or breaks Possible cause Corrective action Tool is not suitable for the workpiece. Select the tool that matches the properties of the workpiece. Coat tool if necessary. Too much material is being removed. Check process parameters, reduce infeed, reduce air pressure for compensation, perform machining in several passes., Operation [} 25]. The load on the tool is too great because the product is moving too slowly. Increase feed rate. Compensation mechanism at the stop. Readjust the offset, Operation [} 25]. High force on initial contact with workpiece. Change the feed rate and/or angle when approaching the workpiece. 7.2 Tool rattles during deburring Possible cause Corrective action Feed rate not set correctly. Check process parameters, reduce infeed, reduce air pressure for compensation, perform machining in several passes., Operation [} 25]. Compliance pressure too low. Too much material is being removed. Tool is not suitable for the workpiece. Select the tool that matches the properties of the workpiece. Tool is worn out. Change tool 7.3 Uneven deburring result Possible cause Corrective action Product is leaking. Contact the SCHUNK contact person. The pressure valve is defective. Change pressure valve.

Possible cause Corrective action Feed rate not set correctly. Readjust feed rate. Tool is worn out. Change tool Tool is not suitable for the workpiece. Select the tool that matches the properties of the workpiece. Too much material is being removed. Check process parameters, reduce infeed, reduce air pressure for compensation, perform machining in several passes., Operation [} 25]. Workpiece is approached too fast or at an incorrect angle. 7.5 Piston does not move Possible cause Corrective action Product is leaking. Contact the SCHUNK contact person. Piston is dirty. Compressed air is not clean. Check filter, clean compressed air. 27 01.00 | CDB | Assembly and Operating Manual | en | 1453534

8 Maintenance CAUTION Material damage due to incorrect assembly and disassembly! Incorrect disassembly and reassembly may cause damage to the product and/or accessories. • SCHUNK recommends having the product and/or accessories checked and repaired by SCHUNK if necessary. 8.1 Notes Original spare parts Use only original spare parts of SCHUNK when replacing spare and wear parts. 8.2 Maintenance interval Maintenance interval Maintenance work weekly Clean all parts thoroughly, check for damage and wear as required Send damaged products to SCHUNK for repair.

Variant: Auto Tool Changer Variant: Manual tool change 29 01.00 | CDB | Assembly and Operating Manual | en | 1453534

SCHUNK GmbH & Co. KG Clamping and gripping technology Bahnhofstr. 106 - 134 D-74348 Lauffen/Neckar Tel. +49-7133-103-0 Fax +49-7133-103-2399 [email protected] schunk.com Folgen Sie uns I Follow us 11-2020     © 2020 SCHUNK GmbH & Co. KG          01.00 | CDB | Assembly and Operating Manual | en | 1453534