ATI Technologies Flexdeburr 9150-RC-300 Series User manual

Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
ATI Radially-Compliant Robotic Deburring Tools
Flexdeburr™
(Models 9150-RC-300, -340 & -660)
Installation and Operation Manual
US Patent # 6,974,286 B2
9150-RC-340
Document #: 9610-50-1007-11
September 2009

Flexdeburr Installation and Operation Manual
Document: 9610-50-1007-11
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
2
Information contained in this document is the property of ATI Industrial Automation, 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 Industrial Automation 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. Users’ critical evaluation of this
document is welcomed.
©Copyright by ATI Industrial Automation. All rights reserved.
How to Reach Us
Sales, Service and Information about ATI products:
ATI Industrial Automation
1031 Goodworth Drive
Apex, NC 27539 USA
www.ati-ia.com
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Technical support and questions:
Application Engineering
Tel: [phone], Option 2, Option 2
Fax: [phone]
E-mail: [email protected]
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 this product, otherwise damage
to this product or unsafe conditions may occur.
!

Flexdeburr Installation and Operation Manual
Document: 9610-50-1007-11
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
3
Glossary of Terms
The Flexdeburr™ product family is ATI's line of Radially-Compliant (RC) deburring tools. Articulated motion of
the high-speed, air turbine-driven spindle allows for the rapid removal of parting lines and burrs while
following irregular part profiles. The RC product line is available with a multitude of different motors for
demanding applications, with power ratings from 150 to 660 Watts and spindle speeds from 30,000 to 65,000
RPM.
Term Definition
Adapter Plate Device for attaching the deburring tool to either a robot flange or a stationary
mounting surface.
Air Filter Device for removing contamination from air supply lines. Typically refers to
removal of particulates.
Air Turbine Air motor that drives the spindle.
Bur Any unwanted, raised protrusion on the workpiece.
Burr Cutting tool used to remove burs from the workpiece. Alternatively referred to as
a rotary file, cutter, or bit.
Climb Milling Cutting method where the direction of cutter rotation and tool motion are the
same.
Coalescing Filter Device designed to remove liquid aerosols from the supply air lines.
Collet Gripping device used to hold cutting tools in the spindle.
Compliance The ability of the spindle to passively move in response to protrusions on or
deviations of the workpiece.
Conventional Milling Method of cutting where the direction of tool motion is opposite that of tool
rotation.
End-Effector Tool used by the robot to perform a particular function
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.
Spindle The rotating portion of the deburring tool assembly.

Flexdeburr Installation and Operation Manual
Document: 9610-50-1007-11
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
4
Table of Contents
1. General Data ..................................................................................................................................5
1.1 Environmental Limitations......................................................................................................5
1.2 Cutting Tool Holding Systems (Collets).................................................................................5
1.3 Deburring Tool Part Numbers................................................................................................6
2. Handling, Installation, Storage and Transportation...................................................................7
2.1 Inspection of Condition When Delivered................................................................................7
2.2 Unpacking and Handling........................................................................................................7
2.3 Installation..............................................................................................................................7
2.3.1 Mounting, Adapter and Interface Plate......................................................................7
2.3.2 Pneumatics..............................................................................................................12
2.4 Transportation and Protection during Transportation ..........................................................14
2.5 Storage and Preventive Maintenance during Storage.........................................................14
3. Technical Description.................................................................................................................15
3.1 Product Description..............................................................................................................15
3.2 Technical Specifications.......................................................................................................15
4. Operation......................................................................................................................................20
4.1 General Precautions ............................................................................................................20
4.2 Flexdeburr Working Environment.........................................................................................20
4.3 Operational Considerations..................................................................................................21
4.4 Tool Center Point (TCP) Position and Programming...........................................................21
4.5 Cutter Operation and Burr Selection....................................................................................22
4.6 Safety Precautions...............................................................................................................23
5. Maintenance Instructions...........................................................................................................24
5.1 Burr Replacement ................................................................................................................24
5.2 Air Motor Replacement ........................................................................................................24
5.3 Pivot Bearing Replacement..................................................................................................25
5.4 Ring Cylinder Assembly.......................................................................................................26
5.5 Pneumatics...........................................................................................................................27
5.6 Lubrication............................................................................................................................27
6. Recommended Spare Parts........................................................................................................28
7. Troubleshooting and Burr Selection.........................................................................................33
7.1 Troubleshooting Matrix.........................................................................................................33
7.2 Burr Selection Table.............................................................................................................34
8. Terms and Conditions ................................................................................................................37
9. Attachments.................................................................................................................................38

Flexdeburr Installation and Operation Manual
Document: 9610-50-1007-11
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
5
1. General Data
1.1 Environmental Limitations
Operation:
Installation position: Mounted to robot by means of the side mounting
pattern or rear adapter flange. The flange is specific
to each type of robot. This optional flange is normally
supplied by ATI in a blank form suitable for customer
modification.
Mounted to a table or stand by means of the bench
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.
When not in use, keep the unit in its crate if possible.
Consult Section 2.5 of this manual
Utilities: The tool requires clean, dry, filtered, non-lubricated
air. The use of a coalescing filter and filter elements
rated 5 micron or better is required. The spindle must
be supplied at 6.2–6.5 bar [90–95 psi] and the radial
compliance (centering) air must be supplied from a
regulated source between 1.0–4.1 bar [15–60 psi]
1.2 Cutting Tool Holding Systems (Collets)
All Flexdeburr products utilize removable collets to grip customer supplied cutting tools.
Different collet diameters may be substituted to retain numerous cutter shank diameters. The
collet retaining nut is loosened to open the collet allowing cutting tools to be removed and
inserted. Once the tool is set to the desired depth, spanner wrenches are used to tighten the
collet nut causing the collet to collapse and secure the cutting tool. The air motor design does
not allow the installation of quick-change or drawbar collet systems.
The standard tool holding system for Flexdeburr products is an economical, proprietary, single-
angle collet design utilizing three gripping fingers. This is suitable for most applications where
industry standard shank diameter cutting tools are used and runout tolerances of up to 0.001”
[0.025mm] are acceptable. Special sizes are available upon request but require custom
machining.
Where the cutting tool shank is not a common diameter or higher precision is required, ATI
offers air motors utilizing the ER-11 collet system. The ER-11 collet is a double-angled design
featuring multiple gripping sections. This allows the collet to produce more contact points along
the length of the tool shank. ER-11 collets can achieve runout tolerances below 0.0005”
[0.013mm] and provide a gripping range up to 0.040” [1mm]. This allows a standard 1/4 inch
ER-11 collet to safely and accurately hold a metric 6mm diameter cutter. However, the ER-11

Flexdeburr Installation and Operation Manual
Document: 9610-50-1007-11
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
6
collet system represents a greater initial expense and its wrenches and collet nut are more
delicate.
The two collet systems are not interchangeable. An ER-11 collet cannot be used in a standard
Flexdeburr and the standard Flexdeburr collet cannot be used with an air motor designed for
the ER-11 collet system. Flexdeburr units with “ER” appearing in their part number utilize ER-11
collets.
1.3 Deburring Tool Part Numbers

Flexdeburr Installation and Operation Manual
Document: 9610-50-1007-11
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
7
2. Handling, Installation, Storage and Transportation
2.1 Inspection of Condition When Delivered
Upon receipt, the following should 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 ATI for assistance in evaluation of the product condition.
2.2 Unpacking and Handling
The deburring tool should always be placed inside the accompanying box (crate) during
transportation, storing and handling.
2.3 Installation
2.3.1 Mounting, Adapter and Interface Plate
The side-mounting pattern of the RC deburring tool consists of two dowel pin holes and
a number of threaded holes as can be seen in Figure 2.1. The maximum fastener
length specified must not be exceeded lest the fasteners interfere with the compliant
motion of the air motor spindle. As coil-type thread inserts are used in the aluminum
housing the customer is advised to use lock washers in preference to liquid thread
locker on mounting fasteners.
A blank robot adapter plate is also available to allow axial mounting off the rear of the
deburring tool housing. This plate may be modified by the system integrator or by the
owner/user of the Flexdeburr. ATI can provide custom interface plates and adapters
upon request. An optional bench mount adapter plate allows the deburring tool to be
permanently attached to a bench or other work surface (see Figure 2.2). If the RC
deburring tool is permanently mounted to a work surface, the robot carries the part to
be deburred to the deburring tool.
CAUTION: Lock washers are recommended on all mounting fasteners. Liquid
thread lockers should not be used for the mounting hardware as this may
damage or remove thread inserts during disassembly.
!

Flexdeburr Installation and Operation Manual
Document: 9610-50-1007-11
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
8
Figure 2.1—RC-300 Series Geometry and Mounting

Flexdeburr Installation and Operation Manual
Document: 9610-50-1007-11
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
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Figure 2.2—RC-300-ER Series Geometry and Mounting

Flexdeburr Installation and Operation Manual
Document: 9610-50-1007-11
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]
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Figure 2.3—RC-660 Geometry and Mounting