ATI Technologies 9150-PCFC-12 User manual

Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
ATI Passive Compliant
Force Control
(Models 9150‑PCFC‑12)
Product Manual
Document #: 9610-50-1036

Manual, Passive Compliant Force Control
Document #9610-50-1036-04
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
2
Foreword
CAUTION: This manual describes the function, application, and safety considerations of this
product. This manual must be read and understood before any attempt is made to install or
operate the product, otherwise damage to the product or unsafe conditions may occur.
Information contained in this document is the property of ATI IndustrialAutomation, Inc (ATI) and shall not be
reproduced in whole or in part without prior written approval of ATI. The information herein is subject to change without
notice. This manual is periodically revised to reflect and incorporate changes made to the product.
The information contained herein is confidential and reserved exclusively for the customers and authorized agents of ATI
Industrial Automation and may not be divulged to any third party without prior written consent from ATI. No warranty
including implied warranties is made with regard to accuracy of this document or fitness of this device for a particular
application. ATI IndustrialAutomation shall not be liable for any errors contained in this document or for any incidental
or consequential damages caused thereby.ATI Industrial Automation also reserves the right to make changes to this
manual at any time without prior notice.
ATI assumes no responsibility for any errors or omissions in this document.
©Copyright (2021) by ATI IndustrialAutomation. All rights reserved.
How to reach us:
Sale, Service and Information about ATI products:
ATI Industrial Automation
1031 Goodworth Drive
Apex, NC 27539 USA
www.ati‑ia.com
Tel: [phone]
Fax: [phone]
Application Engineering
Tel: [phone]
Fax: [phone]
E‑mail: applicationsengineers@ati‑ia.com

Manual, Passive Compliant Force Control
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Table of Contents
Glossary........................................................................................................................................... 5
1. Safety......................................................................................................................................... 6
1.1 Explanation of Notifications.........................................................................................................6
1.2 General Safety Guidelines............................................................................................................6
1.3 Safety Precautions........................................................................................................................6
1.4 PCFC Safe Working Environment................................................................................................6
2. Product Overview..................................................................................................................... 7
2.1 Features and Benefits of the PCFC.............................................................................................7
2.2 Technical Description ...................................................................................................................8
2.2.1 Environmental Limitations..................................................................................................8
2.2.1.1 Operation............................................................................................................8
2.2.1.2 Storage...............................................................................................................8
2.3 Compliance Unit Performance.....................................................................................................9
2.4 Part Numbering Guide................................................................................................................10
3. Installation ...............................................................................................................................11
3.1 Protection During Transportation.............................................................................................. 11
3.2 Inspection of Condition When Delivered.................................................................................. 11
3.3 Unpacking and Handling............................................................................................................ 11
3.4 Storage and Preventive Maintenance During Storage............................................................. 11
3.5 Axial Mount Installation..............................................................................................................12
3.6 Side Mount Installation...............................................................................................................13
3.7 Customer Tooling Installation....................................................................................................14
3.8 Pneumatic Connections .............................................................................................................14
3.9 Electrical Connections................................................................................................................16
3.10 Mating Cable................................................................................................................................16
4. Operation ................................................................................................................................ 17
4.1 Safety Precautions......................................................................................................................17
4.2 Minimum Requirements for Operation......................................................................................18
4.2.1 Air Quality.........................................................................................................................18
4.2.2 No Lubrication..................................................................................................................18
4.2.3 Program the Device to Incorporate 50% Compliance Travel ...........................................18
4.3 Normal Operation LED Behavior ...............................................................................................19
4.3.1 Gravity Compensation......................................................................................................20
4.3.1.1 Gravity Compensation Procedure.....................................................................21

Manual, Passive Compliant Force Control
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4.4 RS485 Serial Console .................................................................................................................22
4.5 Set/Cal Commands......................................................................................................................24
4.6 Filter Parameters.........................................................................................................................25
5. Maintenance............................................................................................................................ 26
5.1 Routine Operational Maintenance.............................................................................................26
5.2 Utilities .........................................................................................................................................26
6. Troubleshooting ..................................................................................................................... 27
7. Parts and Accessories........................................................................................................... 27
7.1 Accessories and Tools ...............................................................................................................27
8. Specifications......................................................................................................................... 27
9. Drawings ................................................................................................................................. 28
10. Terms and Conditions of Sale............................................................................................... 28

Manual, Passive Compliant Force Control
Document #9610-50-1036-04
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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Glossary
Term Denition
Air Filter Device for removing contamination from air supply lines. Typically refers to removal of
particulates.
Coalescing Filter Device that removes liquid aerosols from the supply air lines.
Compliance The ability of the device to passively move in response to protrusions on or deviations of
the work piece.
Interface Plate Adapter plate for attaching the tool to robots or work surfaces.
PCFC Passive Compliant Force Control ‑ A stand‑alone, passive compliance device to be used
with an end‑effector.
Qty Quantity
Regulator Device used to set and control the supplied air pressure to lower acceptable levels.
Solenoid Valve Electrically controlled device for switching air supplies on and off.

Manual, Passive Compliant Force Control
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Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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1. Safety
The safety section describes general safety guidelines to be followed with this product, explanations of the
notifications found in this manual, and safety precautions that apply to the product. Product specific notifications
are imbedded within the sections of this manual (where they apply).
1.1 Explanation of Notifications
These notications are used in all of ATI manuals and are not specic to this product. The user should heed
all notications from the robot manufacturer and/or the manufacturers of other components used in the
installation.
DANGER: Notification of information or instructions that if not followed will result in
death or serious injury. The notification provides information about the nature of the
hazardous situation, the consequences of not avoiding the hazard, and the method for
avoiding the situation.
WARNING: Notification of information or instructions that if not followed could result
in death or serious injury. The notification provides information about the nature of the
hazardous situation, the consequences of not avoiding the hazard, and the method for
avoiding the situation.
CAUTION: Notification of information or instructions that if not followed could result
in moderate injury or will cause damage to equipment. The notification provides
information about the nature of the hazardous situation, the consequences of not
avoiding the hazard, and the method for avoiding the situation.
NOTICE: Notification of specific information or instructions about maintaining, operating,
installing, or setting up the product that if not followed could result in damage to equipment. The
notification can emphasize, but is not limited to: specific grease types, best operating practices,
and maintenance tips.
1.2 General Safety Guidelines
The customer should first read and understand the operating procedures and information described in this
manual. Never use the PCFC for any purpose not explicitly described in this manual. Follow installation
instructions, electrical connections, and pneumatic connections as described in this manual.
All pneumatic fittings and tubing must be capable of withstanding the repetitive motions of the application
without failing. The routing of pneumatic lines must minimize the possibility of stress/strain, kinking,
rupture, etc. Failure of critical pneumatic lines to function properly may result in equipment damage.
1.3 Safety Precautions
CAUTION: Do not use serviceable parts other than original ATI serviceable parts. Use
of serviceable parts not supplied by ATI can damage equipment and void the warranty.
Always use original ATI serviceable parts.
1.4 PCFC Safe Working Environment
As described in previous sections, the PCFC should 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 included 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 polycarbonate to facilitate observation of the
manufacturing process.
During system or tool maintenance, make sure the PCFC and equipment are stopped before entering the cell.
Never be present in the cell when the device is running when installing and testing.
Be aware of moving parts. Use eye‑protection while working around the device.

Manual, Passive Compliant Force Control
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2. Product Overview
ATI's PCFC device is a robust, stand‑alone, passive compliance device to be used with an end‑effector.
Figure 2.1—Product Overview
Rear Cover Plate
Sensor Cable
Connection (M12)
LEDs
Extend Compliance Fitting
Retract Compliance Fitting
Purge Air Fitting
Compliance Slide
Sensor
Block
Note: Tool shown with
blank cover plates. Customer
will machine bolt pattern
for tooling and mounting.
2.1 Features and Benefits of the PCFC
• Floating axial compliance
Remotely‑adjusted air pressure controls and maintains the constant axial force on the device. The
axially‑compliant motion of the device allows the customer's tool to compensate for deviations in
the part profile along the robot path and provide constant contact force with the workpiece.
• Mounting options
The PCFC provides a rear cover plate that can be machined for axial mounting of its housing and a
flat on the side of the housing for side mounting.
• Easy programming of the robot
The axial motion of the PCFC allows fast and simple programming of the robot. This movement
also compensates for changes in part tolerances, part misalignment, and robot path variation.
• Gravity Compensation
This feature allows the tool to automatically adjust the compliance force as the tool’s orientation
changes with respect to gravity.

Manual, Passive Compliant Force Control
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2.2 Technical Description
A technical overview of the product is provided in the following tables and graphs. For additional technical
specifications, refer to Section 8—Specifications.
2.2.1 Environmental Limitations
2.2.1.1 Operation
Table 2.1—Operation
Installation position Mounted to machining center by means various,
customer‑supplied end‑effector.
Temperature range 5° C–35° C
41° F–95° F
Utilities
The device requires the following:
• Clean, dry, ltered, and non‑lubricated air (refer
to Section 4.2.2—No Lubrication).
• A coalescing lter and lter elements that are
rated 5 micron or better.
• The axial force/compliance air must be supplied
up to 4.1 bar (60 PSI) maximum from a
regulated source
2.2.1.2 Storage
Table 2.2—Storage
Temperature range 0° C–45° C
32° F–113° F
Conditions
The device should be stored in its crate and in a dry
place.
When not in use, keep the unit in its crate. Consult
Section 3.4—Storage and Preventive Maintenance
During Storage of this manual.

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2.3 Compliance Unit Performance
The force created by the compliance mechanism varies linearly with air pressure as shown in Figure 2.2.
This does not account for friction or the weight of the carriage and attached tooling. Measurements may
vary from one product to another and should only be treated as nominal. The effect of friction will vary
based on the application, and a minimum compliance force is required to overcome the friction and allow
the compliance mechanism to move properly. This minimum force is typically 2‑4 lbf, but it may be higher
or lower based on a variety of factors.
Figure 2.2—Compliance Force
0102030405060
0
10
20
30
40
50
60
OperatingPressure(PSI)
ComplianceForce(lbf)
PistonAC
onfiguration
onfiguration
onfiguration
PistonBC
PistonC C
PCFC Pressure vs. Compliance Force
If using the Gravity Compensation functionality of the PCFC, refer to section Section 4.3.1—Gravity
Compensation for instructions on how to select the correct pressure for your desired compliance force. If
not using Gravity Compensation, refer to Figure 2.2 and factor in the weight of the attached tooling plus
an additional 2.2 pounds for the carriage inside the PCFC. If the PCFC is pointed upward, this weight will
reduce the net compliance force, requiring a higher operating pressure to achieve the desired compliance
force. If the PCFC is pointed downward, it will increase the net compliance force, requiring a lower
operating pressure (or a higher pressure applied to the retract compliance fitting) to achieve the desired
compliance force.

Manual, Passive Compliant Force Control
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2.4 Part Numbering Guide
Figure 2.3—Part Numbering Guide
9150- -12 - - -
= ATI Version, Orange
= Euro Version, Black
Sensing Option
= Default
Hall Effect Position Sensing
= No Sensing
(Note 3)
Piston Configuration
A= 1 Piston
B= 2 Pistons
C= 3 Pistons
(Note 2)
Base Part Number
= Default
(Note 1)
Notes:
1.
Although this is a 9150 (Material Removal) base part number, the PCFC
acts like a compensator. It is a double acting, single axis compensator
product that is also featured under the ATI Compensator product line.
2.
Compliance force range is dictated by the piston selection.
A = 19 lbf (84.5 N)
B = 38.6 lbf (171.7 N)
C = 59.1 lbf (242.9 N)
3. Position Sensing Option (-S1) is the default product configuration.
Sensing outputs relative positon along the 12mm stroke path via (3) LED's.
Filename: 9645-50-1001, Rev03
9150
PCFC
S1
(Blank)
PCFC-12 Part Number Guide
(Blank)
E

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3. Installation
The compliance housing incorporates a rear mounting pattern to which an interface plate can be installed (Refer to
Section 3.5—Axial Mount Installation.) An interface plate for side mounting to fixed surface is available (Refer to
Section 3.6—Side Mount Installation.)
The device must be rigidly mounted prior to use. Under no circumstances should the device be used for manual/
hand operations. Once securely mounted, the device shall be supplied with clean, non‑lubricated air filtered (5)
micron or better. The use of a coalescing filter is recommended to remove trace moisture from the air supply.
Air line fittings supplying the PCFC should be installed with care using a minimum of tape or liquid sealant.
To prevent contaminant damage to the device, all air lines should be blown down to remove debris prior to
connection of the PCFC.
CAUTION: Thread locker applied to fasteners must not be used more than once. Fasteners
might become loose and cause equipment damage. Always apply new thread locker when
reusing fasteners.
3.1 Protection During Transportation
The PCFC arrives in packaging that secures and protects the device during transportation. Always use this
packaging when transporting the PCFC in order to minimize the risk of damage.
3.2 Inspection of Condition When Delivered
Upon receipt, the following should be checked:
• delivery in accordance with freight documents
• packaging is in good condition
If there is damage to any of the packaging, or if any of the goods have been exposed to abnormal handling,
unpack those parts for a closer inspection. Contact ATI for assistance.
3.3 Unpacking and Handling
Always place the PCFC inside the accompanying packaging, while transportation, storing, and handling.
3.4 Storage and Preventive Maintenance During Storage
For short‑term storage, the device should be stored in its accompanying packaging and in a dry place.
For long‑term storage, the PCFC should be thoroughly cleaned of any dust or debris. Never disassemble the
units. Place the device inside a sealed, plastic bag and place the bagged device inside the crate.

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3.5 Axial Mount Installation
A blank rear cover plate is provided to allow axial mounting off the rear of the PCFC housing. This plate
must be modified by the system integrator or by the owner/user of the PCFC. Machining must allow for
fasteners to be counter‑sunk flush or below flush of rear cover plate surface that mounts to PCFC body.
Figure 3.1—Axial Installation
Rear Cover Plate
(2) Dowel Pin
(4) M6 Socket Head Cap Screw
[Torque to 89 in-lbs (10 Nm)]

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3.6 Side Mount Installation
The side mount pattern of the PCFC consists of (2) dowel pin holes and (4) threaded holes as shown
in Figure 3.2. If the PCFC is mounted to a fixed surface, the robot carries the part to the end‑effector
attached to the PCFC.
Figure 3.2—Side Mount
Optional Side Mount
(9005-50-6148 Shown)
(4) M6 Socket Head Cap Screw
(Included with Bench Mount Kit)
[Torque to 89 in-lbs (10 Nm)]

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3.7 Customer Tooling Installation
The inner slide cover plate must be machined to interface with customer tooling. This plate must be
modified by the system integrator or by the owner/user of the PCFC.
Figure 3.3—Customer Tooling Mounting
Inner Slide
Cover Plate
(2) Dowel Pin
(6) M4 Socket Head
Cap Screw
[Torque to 25 in-lbs (2.82 Nm)]
3.8 Pneumatic Connections
Connect the PCFC as shown on the Pneumatic Diagram (9630‑50‑PCFC‑PNEUMATIC) found on
the ATI website.
WARNING: All pneumatic fittings and tubing must be capable of withstanding the
repetitive motions of the application without failing. The routing of pneumatic lines must
minimize the possibility of over stressing, pullout, or kinking the lines. Failure to do
so can cause some critical pneumatic lines not to function properly and may result in
damage to the equipment.
NOTICE: It is recommended that the customer use a coalescing filter and filter elements
rated 5 micron or better to remove trace moisture. Water damage of the air device or damage
associated with debris in the air lines is not covered under warranty.
Depending on whether the PCFC is changing orientation during operation or held still, the required
pneumatic components vary.
a. Regardless of orientation, one regulator is needed for the PurgeAir Fitting. Set this regulator to 30
PSI (2.1 bar) to prevent ingress of dust or other particulates.
b. If mounting the PCFC on a robot or other moving machinery which will change the orientation of
the PCFC, then two electronically controlled regulators are required.

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ATI recommends the use of our regulator kit (ATI Part # 9005‑50‑6133) which was designed for this
purpose. If the customer is supplying their own regulators, they must meet the following criteria:
1. The regulators must be controlled by an analog signal (either 0…5VDC, 0…10VDC, or 4…20 mA). By
default, the PCFC is set to the 0…5VDC output setting. If using a regulator which requires a 0…10VDC
or 4…20mA control signal, refer to Section 4.5 RS485 Serial Console to change this setting.
2. The regulators must supply a pressure range of approximately 1‑60 PSI (0.1‑4.1 bar). A reduced pressure
range will limit and may negatively impact the performance of the PCFC’s Gravity Compensation
functionality. ***Change to new paragraph style for WARNING and run script again‑DELETE THIS***
The regulator range must not exceed 70 PSI (4.8 bar). Over pressurization may risk damaging the PCFC.
3. The regulators must be self‑relieving.
One of the electronic regulators will be controlled by the PCFC, via the VO/IO_REG+ signal (See Table
3.2). That regulator must connect to the Retract Compliance Fitting. The second electronic regulator
should be controlled by the robot or PLC, and it will connect to the Forward Compliance Fitting. See
Section 4.3.1—Gravity Compensation for instructions on how to determine the correct pressure setting.
c. If mounting the PCFC in a rigid manner or if the PCFC will be kept in a single orientation during
the full process, only a single self‑relieving regulator is required for the compliance mechanism. It
may be manually or electronically controlled, depending on the customer’s preference and the needs
of the specific application. If the PCFC is mounted upright or horizontally, connect the regulator to
the forward compliance fitting to supply a positive process force. If the PCFC is holding the tool
in a hanging position, connect the regulator to either the forward compliance fitting or the retract
compliance fitting in order to either increase or decrease the process force which will include the
weight of the tool. This regulator may be set between 0‑60 PSI (0‑4.1 bar). Connect some flexible
tube to the other compliance fitting and route it away from debris will be generated to prevent
ingress that could damage the compliance mechanism. Do not use a plug or restrict air from flowing
to that connection.
Table 3.1—Pneumatic Connections
Function Connection Type Pressure
Compliance (Axial) Force Inlet (2) 3/8 (10 mm) Tube Up to 60 psi (4.1 bar)
maximum
Purge Air 5/32 (4 mm) Tube 30 psi (2 bar)
The device must be plumbed using flexible tubing.
When testing for the proper contact force, start with a very low force and increase slowly until the desired
process result is achieved. Typical applications will need a minimum of 2‑4 pounds of compliance force
to overcome the internal friction of the compliance mechanism. This may vary higher or lower based on a
variety of factors.

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3.9 Electrical Connections
Refer to the following for electrical connection pinouts. Cable shielding is required. A cable is available for
purchase separately from the PCFC part number. Refer to Section 3.10—Mating Cable.
Figure 3.4—M12 8-Pin Connector Wiring (Face View Shown)
Table 3.2—M12 8-Pin Connector Wiring
Pin Signal name Description Voltage/Current
1 V+ Power (Positive) 24VDC+/‑20%
2V‑ Power (GND) 0V
3VO‑/IO‑ Analog Output Reference 0V
4Cal+ Initiate Calibration Input Pulse (24VDC+/‑20%)
5VO/IO_REG+ Analog output (Regulator) 0‑5V, 0‑10V, 4‑20mA1
6VO/IO_POS+ Analog output (Position) 0‑5V, 0‑10V, 4‑20mA1
7RS485+ Serial Data NA
8RS485‑ Serial Data NA
Note:
1. Default value for a new unit is 0‑5V.
3.10 Mating Cable
ATI Offers a shielded mating cable to interface to the M12 Connector found on the unit. Refer to the
following part number for ordering:
9150‑C‑0521108‑U‑00‑10

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4. Operation
These operating instructions are intended to help system integrators program, start up, and complete a robotic cell
containing the device. The system integrator should be familiar with the task in general and should have extensive
knowledge relating to robots and automation incorporating robots.
4.1 Safety Precautions
DANGER: Never use the PCFC for purposes other than automated processes. Never
use the PCFC as a hand‑held machine.
WARNING: All personnel, who are involved in the operation of the PCFC product,
should have a thorough understanding of the operating procedures. Failure to follow
these procedures or neglecting safety precautions can create hazardous situations that
may injure personnel or damage the deburring installation and the PCFC product.
WARNING: Never operate the ATI product without wearing eye protection. Flying
debris can cause injury. Always use eye protection while working in the proximity
of the device.
CAUTION: Do not use replacement parts other than original ATI replacement parts.
Use of replacement parts not supplied by ATI can damage equipment and void the
warranty. Always use original ATI replacement parts.

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4.2 Minimum Requirements for Operation
The following sections describes the minimum requirements for operating the PCFC.
4.2.1 Air Quality
The air supply should be clean, dry, filtered, and non‑lubricated.A coalescing filter that has
elements rated for 5 micron or better is required.
Air quality can affect tool performance substantially. Particulates can block airflow or
impede motion.
4.2.2 No Lubrication
The compliance device cannot have any oil in the air supply. Oil can clog compliance device and
limit compliance range.
4.2.3 Program the Device to Incorporate 50% Compliance Travel
Program the device to have compliance at 50% travel when on the nominal path.
As the part's edge deviates from the perfect path, the device can use compliance to follow along
high and low spots without losing contact or hitting the positive stop and gouging.
Do not "bottom out" the compliance and hit the positive stop.
Repeated impacts on the positive stop can damage the compliance mechanism.
Figure 4.1—50% Travel

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4.3 Normal Operation LED Behavior
Figure 4.2—LEDs
Full Extend
(> 95%
Extension)
Start of
Travel
(Extension
> 70% and
<= 95%)
Safe Travel
Zone
(Extension
>= 30% and
<= 70%)
End of Travel
(Extension
>= 5% and
< 30%)
Robot Crash
(< 5%
Extension)
LED 1
LED 2
LED 3

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4.3.1 Gravity Compensation
The PCFC sensor kit supports gravity compensation. This feature allows the tool to automatically
adjust the compliance force as the tool’s orientation changes with respect to gravity. A sensor built
into the tool tracks the tool’s movements and notes when the tool rotates about X or Y. As this
change occurs, a signal is sent to a programmable regulator to adjust the air pressure being sent to
the retract air‑port. This increase or decrease in air pressure allows the tool to compensate for the
changing forces applied to the workpiece by the weight of the tool. It is important to note that if a
user is planning to use gravity compensation, the weight of the tooling cannot exceed 50% of the
PCFC’s maximum compliance force. This is because when the PCFC is pointed straight down, the
force of the retract pressure must equal two times the weight of the tooling in order to properly bias
out the weight over the entire range of motion.
Without gravity compensation, it is possible to maintain consistent force between a workpiece and
tool through the various tool orientations necessary in complex motions, but it can be very difficult
and time consuming. In standard operation, the force applied would be subject to the orientation
of the tool. When the workpiece is “above” the tool, the pistons push the tool “up” toward the
workpiece while gravity counteracts the pistons and pulls the tool “away” from the workpiece.
However, when the tool rotates and the workpiece is now “below” the tool, the pistons still push
with the same amount of force toward the workpiece, but now that force combines with the effect
of gravity which pulls the tool “toward” the workpiece, creating a large increase on force applied
to the workpiece. This range in force (compliance force +/‑ weight of tool) can be severe and as
varied as the tools that are fixed to the PCFC. Varying force can lead to inconsistent results and
poor process performance.