Floating Compensation Sensor Installation and Commissioning Guide

This article uses the FOUK FD Series Floating Compensation Unit as an example to explain the installation, adjustment, and commissioning of floating compensation sensors. By following this guide, you will understand the function of each pneumatic port and learn how to correctly install sensors to detect the locked and unlocked positions.

Understanding the Pneumatic Ports of the FOUK FD Series

Before installing the sensors, it is important to understand how the pneumatic circuit of the floating compensation unit works.

As shown below, the upper section of the floating compensation unit is mounted to the robot flange, while the lower section is connected to the end-of-arm tool (EOAT).

The FOUK FD Series Floating Compensation Unit features three pneumatic ports:

· Lock Port 

· Unlock Port 

· Position Holding Port 

Each port performs a different function during operation.

Unlock Port

When compressed air is supplied to the Unlock Port, the floating compensation mechanism enters the floating (unlocked) state.

In this condition, the extension body can move freely, allowing the robot tool to compensate for positional deviations during assembly or insertion applications.

Lock Port

When the air supply is switched to the Lock Port, the floating mechanism automatically returns to its center position and becomes locked.

Once locked, the extension body can no longer move freely, providing a rigid connection between the robot and the tool.

Position Holding Port

The Position Holding Port allows the floating compensation unit to maintain its current offset position.

When air is supplied to this port, the extension body holds its current position instead of floating freely. Although the unit remains unlocked, the stored position is maintained without movement.

When the air supply to the Position Holding Port is removed, the floating compensation unit returns to its normal free-floating compensation mode.

Understanding these three pneumatic functions is essential before installing and adjusting the sensors.

Sensor Installation and Adjustment

The following example uses the FOUK FD Series Floating Compensation Unit.

The unit includes two sensor mounting slots:

· Upper sensor slot: Detects the Floating (Unlocked) State 

· Lower sensor slot: Detects the Locked State 

To ensure accurate detection, each sensor must be installed while the floating compensation unit is in the corresponding operating state.

Installing the Locked-State Sensor

1. Supply compressed air to the Lock Port.

2. Confirm that the floating compensation unit has returned to the center position and is fully locked.

3. Insert the sensor into the lower mounting slot.

4. Slowly slide the sensor to the right along the slot.

5. When the sensor detects the internal magnet, the red indicator LED will illuminate.

6. Fine-tune the sensor position so it is centered within the sensing range, then securely tighten the mounting screw.

The locked-state sensor is now correctly installed.

Installing the Floating (Unlocked) State Sensor

1. Supply compressed air to the Unlock Port.

2. Confirm that the floating compensation unit is in the floating (unlocked) state.

3. Insert the sensor into the upper mounting slot.

4. Slowly slide the sensor to the right.

5. The red indicator LED will turn on when the sensor enters the magnetic sensing area.

6. Continue moving the sensor slightly farther to the right until the LED turns off.

The region where the LED changes from ON to OFF represents the effective sensing range.

Adjust the sensor to the middle of this sensing area, then tighten the mounting screw securely.

Sensor Installation Complete

The sensor installation and commissioning process for the FOUK FD Series Floating Compensation Unit is now complete.

After installation, verify that:

· The Locked-State Sensor switches correctly when the Lock Port is pressurized.

· The Floating-State Sensor switches correctly when the Unlock Port is pressurized.

· The floating compensation unit operates smoothly between the Locked, Floating, and Position Holding modes.

Proper sensor adjustment ensures reliable position detection and stable operation in automated robotic applications.