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]
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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.
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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.

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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

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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
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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

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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.
!

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Figure 2.1—RC-300 Series Geometry and Mounting

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Figure 2.2—RC-300-ER Series Geometry and Mounting

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Figure 2.3—RC-660 Geometry and Mounting

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Figure 2.4—RC-660-ER Geometry and Mounting

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2.3.2 Pneumatics
Connect the RC deburring tool as shown in Figure 2.3.
Figure 2.3—Pneumatic Connections
The air supply should be dry, filtered, and free of oil. A coalescing filter with elements
rated for 5 micron or better is required.
A high-flow air pressure control regulator is required to supply the spindle motor at 6.2-
6.5 bar [90-95 psi]. A second, precision, self-relieving regulator will supply air for the
compliance or centering force.
The compliance force is applied radially and is adjusted until the desired cut is made.
The robot traversing speed will also be adjusted to achieve the desired finish.
Conventional, customer-supplied, pneumatic components are used to control the air
supply to the deburring tool. ATI recommends that the user install a high-flow
pneumatic pressure regulator and a high-flow valve to properly supply a stable air
supply of 6.2-6.5 bar [90-95 psi] to the spindle motor. (ATI Part #9150-FFR-90, or
equivalent. See Section 3.2 for the maximum flow requirements). The RC deburring
tool will not operate properly if supplied air below 6.2 bar.
A second, precision, self-relieving regulator and valve are used to supply the
compliance (centering) mechanism. This pressure corresponds to the side force on the
rotary burr. Very little airflow is required for the compliance mechanism (ATI Part #
9150-PPR-60, or equivalent). This allows a significantly smaller valve to be used.
CAUTION: Pneumatic components used for the motor drive circuit must be capable of
meeting the air consumption requirements (See Technical Specifications, Section 3.2).
Poor performance will result if the correct components are not used.
!

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(Consult the valve and regulator supplier’s literature when selecting these
components.)
If the complete workpiece can be deburred with equal force, a conventional, manual
pressure regulator can be used for compliance. If the burrs to be removed vary from
place to place on the workpiece, and this variation is repeatable for all workpieces of
the same type, it may be necessary to adjust the force using an analog pressure
regulator controlled from the robot. An analog output port in the robot or logic controller
will be needed.
Both solenoid valves are actuated from the robot or program logic controller by means
of a digital output signal.
Function Connection Type Pressure
Motor Inlet
(9150-RC-300 and 340 Series) 3/8" Quick Connect Tube
(Alternate: Remove Supplied Fitting to use
1/8-NPT Port, or use 5/16 (8mm) Tubing
Adapter)
(9150-RC-660 Series)
1/2" Quick Connect Tube
(Alternate: Remove Supplied Fitting to use
3/8-NPT Port, or use 5/16 (8mm) Tubing
Adapter)
6.2–6.5 bar
[90–95 psi]
Compliance (Radial) Force Inlet
(9150-RC-300 and 340 Series) 5/32 (4mm) Quick Connect Tube
(Alternate: Remove Supplied Fitting to use
1/8-NPT Port)
(9150-RC-660 Series)
5/32 (4mm) Quick Connect Tube (Alternate: Remove Supplied Fitting to use
1/8-NPT Port)
1.0–4.1 bar
[15–60 psi]
(Maximum)
Exhaust Vented to Atmosphere through the Housing Not
Applicable
Table 2.1—Pneumatic Connections
It is recommended that flexible plastic tubing be used for the motor air supply and the
compliance force air supply. The installed fittings can be removed to expose tapped
supply ports thus allowing the use of alternate, customer-supplied components. The
turbine air motor is extremely quiet and vents dry air to the environment through the
screen-covered ports on the side of the housing. No mufflers are required. Information
on the sound intensity is provided in Section 3.2. To reduce the sound from the cutting
operation in neighboring working areas, a customer-supplied barrier surrounding the
installation may be installed (Plexiglas or Lexan is preferred, see Section 3.2).
The compliance force, air supply pressure regulator should have a 0-4.1 bar [0–60 psi]
range. When testing for the proper contact force, start with a very low pressure and
increase slowly until the desired cut is achieved.

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2.4 Transportation and Protection during Transportation
The RC deburring tool is packaged in a crate designed to secure and protect it during
transportation. Always use the crate when transporting the deburring tool in order to minimize
the risk of damage.
2.5 Storage and Preventive Maintenance during Storage
The deburring tool should be stored in its crate when it is not in use. The deburring tool should
also be stored in a dry place.
For long-term storage, the deburring tool should be thoroughly cleaned of any burrs or debris. It
should not be disassembled. Place the deburring tool inside a sealed, plastic bag inside the
crate.

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3. Technical Description
3.1 Product Description
Attached at the end of this document you will find the RC deburring tool product description.
3.2 Technical Specifications
Main specifications for the RC deburring tools:
Parameter Rating
Motor Air Turbine
Idle Speed (RPM) RC-300 Series: 30,000
RC-340 Series: 40,000
RC-660 Series: 40,000
Torque (Max.) RC-300 Series: 0.09 N-m (0.8 lb-in)
RC-340 Series: 0.08 N-m (0.7 lb-in)
RC-660 Series: 0.16 N-m (1.4 lb-in)
Power RC-300 Series: 300 Watts (0.40 hp) @ 30,000 RPM
RC-340 Series: 340 Watts (0.46 hp) @ 40,000 RPM
RC-660 Series: 660 Watts (0.88 hp) @ 40,000 RPM
Weight (without Adapters) RC-300 Series: 1.2 kg (2.6 lb)
RC-340 Series: 1.2 kg (2.6 lb)
RC-660 Series: 2.2 kg (4.9 lb)
Compensation (Radial) RC-300 Series: +/- 7.5mm max., +/- 3mm recommended
RC-340 Series: +/- 7.5mm max., +/- 3mm recommended
RC-660 Series: +/- 9mm max., +/- 4.5mm recommended
Compliance Force RC-300 Series: 12.7-42 N (2.8–9.5 lb) @ 1.0-4.1 bar (15–60 psi)
(Measured at Collet) RC-340 Series: 12.7-42 N (2.8–9.5 lb) @ 1.0-4.1 bar (15–60 psi)
RC-660 Series: 12.8-45.4 N (2.8–10.2 lb) @ 1.0-4.1 bar (15–60
psi)
Burr Surface Speed Dependent on cutter geometry and motor
Spindle Air Pressure 6.2-6.5 bar (90–95 psi) (All Models) [6.9 bar (100 psi) max]
Air Consumption (Idle) RC-300 Series: 2.8 l/s (6 CFM)
RC-340 Series: 2.8 l/s (6 CFM)
RC-660 Series: 5.4 l/s (11.5 CFM)
Air Consumption (Stall) RC-300 Series: 10.2 l/s (21.5 CFM)
RC-340 Series: 10.2 l/s (21.5 CFM)
RC-660 Series: 17.9 l/s (38 CFM)
Sound Pressure Level Less than 70 dB(A) (All Models, without Cutter)
Collet Size (Standard)** 1/4" (All Models), -E Models Supplied with 6mm Collets
Rotary Burrs ++ Commercial Units Rated 40,000 RPM or Higher
Special Tools Open End Wrenches (1 Pair Supplied)
9/16" (14.5mm), 7/16" (11mm)
10mm Narrow (Only for use with ER11 Collets, -ER Models)
Specifications applied to a series of models cover the basic “inch” designs, metric -E models, and
-ER models with the ER-11 collet system.
** Optional Sizes Available, See Section 6
++ ATI Can Supply Burrs, See Section 7.2

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All noise emission measurements were taken under no load idle conditions without a cutting
tool. Because the working environment is unknown, it is impossible to predict the noise that will
occur during a deburring operation.
Each RC deburring tool receives a thorough test procedure before it is shipped.
Below are measured forces relative to applied compliance (centering) air pressure.
Measurements may vary from one product to another, and should only be treated as nominal.
RC-300/340 Series Radial Contact Force
0
5
10
15
20
25
30
35
40
45
1.0 2.0 3.0 4.0
Centering Air Pressure (bar)
Radial Force (N
)
RC-300/340 Series Radial Contact Force
0
1
2
3
4
5
6
7
8
9
10
10 20 30 40 50 60 70
Centering Air Pressure (PSI)
Radial Force (lbf)
Figure 3.1—RC-300/340 Series Radial Compliance Force Curves
(Measured at the Spindle Tip)

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RC-660 Series Radial Contact Force
0
5
10
15
20
25
30
35
40
45
50
1.0 2.0 3.0 4.0
Centering Air Pressure (Bar)
Radial Force (N)
RC-660 Series Radial Contact Force
0
1
2
3
4
5
6
7
8
9
10
11
10 20 30 40 50 60 70
Centering Air Pressure (PSI)
Radial Force (lbf)
Figure 3.2—RC-660 Series Radial Compliance Force Curves
(Measured at the Spindle Tip)
The actual force characteristics will vary slightly from installation to installation due to mounting
orientation and condition of the unit.
The air turbine will attempt to maintain its full rated speed even under loaded conditions.
However, when extremely heavy cuts are taken, the motor may eventually stall. Therefore,
multiple, light passes are preferred over slow, heavy cuts. Typical motor performance is shown
in the figures below.

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RC-300/340 Series Performance Curve
(RC-300 Stops at 30,000 RPM)
(Watts & Torque at 6.2 Bar)
0
100
200
300
0 10,000 20,000 30,000 40,000
RPM
Watts
0.00
0.02
0.04
0.06
0.08
0.10
0.12
0.14
Torque (Nm)
Watts
Torque
RC-300/340 Series Performance Curve
(RC-300 Stops at 30,000 RPM)
(Horsepower & Torque at 90 PSI)
0.00
0.10
0.20
0.30
0.40
0.50
0 10,000 20,000 30,000 40,000
RPM
hp
0.00
0.20
0.40
0.60
0.80
1.00
Torque (lb-in)
Horsepower
Torque
Figure 3.3—RC-300/340 Series Motor Performance Curves

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RC-660 Series Performance Curve
(Watts & Torque at 6.2 Bar)
0
100
200
300
400
500
600
700
800
0 10,000 20,000 30,000 40,000
RPM
Watts
0.00
0.10
0.20
0.30
0.40
Torque (Nm)
Watts
Torque
RC-660 Series Performance Curve
(Horsepower & Torque at 90 PSI)
0.00
0.20
0.40
0.60
0.80
1.00
0 10,000 20,000 30,000 40,000
RPM
hp
0.00
1.00
2.00
3.00
4.00
Torque (lb-in)
Horsepower
Torque
Figure 3.4—RC-660 Series Motor Performance Curves

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4. Operation
These operating instructions are intended to help system integrators program, start up, and complete
a robotic deburring cell containing a deburring tool. The system integrator should be familiar with the
task of deburring, in general, and should have extensive knowledge relating to robots and automation
incorporating robots.
4.1 General Precautions
It is important that all personnel involved in operation of the RC deburring tool have a thorough
understanding of the operating procedures. Failure to follow these or neglecting safety
precautions can create hazardous situations, which may, in the worst case, injure personnel or
damage the deburring installation and the RC deburring tool.
The RC deburring tool must only be used for robotic deburring applications. The Flexdeburr is a
deburring tool only.
Countersinking and other axial metal-forming processes should not be performed by the
Flexdeburr. It may be dangerous to operate the RC deburring tool for these purposes. If a
failure occurs due to forces caused by improper use, hazardous situations for both personnel
and equipment could be created. The RC deburring tool is intended to perform deburring only.
The deburring tool should not be used to deburr materials that are prone to fracture. A
fracturing workpiece may result in pieces of material damaging surrounding working
environment and personnel. Material removed correctly should be in the form of chips.
Reduce the robot velocity when the workpiece and the RC deburring tool are making initial
contact. Making the contact movement between the deburring tool and the workpiece too fast
may in some situations result in a collision. Collisions may create hazardous situations for both
personnel and equipment.
Use lock washers with the mounting fasteners. When performing maintenance, always
remember to tighten nuts and bolts. When replacing burrs, always attach the burr correctly.
Please consult Section 5.3.
4.2 Flexdeburr Working Environment
As described in previous sections, the RC deburring tool should only be used in conjunction
with a robot in a secured work 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 Plexiglas to
facilitate observation of the deburring operations.
During system or deburring tool maintenance, make sure the RC deburring tool and robot are
stopped before entering the robot cell. When installing and testing, never be present in the cell
when the Deburring tool is running.
DANGER: Never use the Flexdeburr for purposes other than robotic deburring.
DANGER: Never use the Flexdeburr as a hand-held machine.