ATI Technologies Flexdeburr RC-1000 Series User manual

Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
ATI Radially‑Compliant Robotic Deburring Tools
Flexdeburr™ RC‑1000 Series
(Models 9150‑RC‑900‑ER, 9150‑RC‑900‑ER‑E,
9150‑RC‑1040‑ER, and 9150‑RC‑1040‑ER‑E)
Product Manual
US Patent # 6,974,286 B2
Document #: 9610‑50‑1024

Manual, Flexdeburr, RC‑1000 Series
Document #9610‑50‑1024‑05
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • 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 this product. Failure to do so may result in personnel injury and/or damage to equipment.
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.
©Copyright (2020) by ATI Industrial Automation. 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, Flexdeburr, RC‑1000 Series
Document #9610‑50‑1024‑04
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
3
Table of Contents
Foreword.......................................................................................................................................... 2
Glossary........................................................................................................................................... 5
1. Safety......................................................................................................................................... 6
1.1 Explanation of Notifications.........................................................................................................6
1.2 General Safety Guidelines............................................................................................................7
1.3 Safety Precautions........................................................................................................................7
2. Product Overview..................................................................................................................... 8
2.1 Collet System.................................................................................................................................9
2.2 Technical Description .................................................................................................................10
2.2.1 Environmental Limitations................................................................................................10
2.2.2 Compliance Unit Performance ......................................................................................... 11
3. Installation .............................................................................................................................. 12
3.1 Transportation and Protection during Transportation.............................................................12
3.2 Inspection of Condition When Delivered..................................................................................12
3.3 Unpacking and Handling............................................................................................................12
3.4 Storage and Preventive Maintenance during Storage.............................................................12
3.5 Side Mounting Installation..........................................................................................................13
3.6 Axial Mounting Installation.........................................................................................................14
3.7 Pneumatics..................................................................................................................................15
4. Operation ................................................................................................................................ 17
4.1 Safety Precautions......................................................................................................................17
4.2.1 Air Quality.........................................................................................................................18
4.2.2 No Lubrication..................................................................................................................18
4.2.3 Bur Selection, Design, and Maintenance.........................................................................18
4.2.4 Deburring Tool Approach Path Should be Slow and at an Angle .....................................18
4.2.5 No Axial Loading ..............................................................................................................18
4.2.6 Program the Robot to Incorporate 50% Compliance Travel of the Tool...........................18
4.2 Normal Operation........................................................................................................................18
4.3 Flexdeburr Working Environment .............................................................................................19
4.4 Locking the Tool to Single Axis Compliance............................................................................20
4.5 Tool Center Point (TCP) Position and Programming...............................................................21
4.6 Cutter Operation and Bur Selection..........................................................................................23
4.6.1 Bur Selection....................................................................................................................23

Manual, Flexdeburr, RC‑1000 Series
Document #9610‑50‑1024‑04
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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5. Preventive Maintenance ........................................................................................................ 26
5.1 Pneumatics..................................................................................................................................26
5.2 Lubrication...................................................................................................................................26
5.3 Spindle Boot Inspection.............................................................................................................26
5.4 Bur Inspection.............................................................................................................................26
6. Troubleshooting and Service Procedures ........................................................................... 26
6.1 Troubleshooting..........................................................................................................................27
6.2 Service Procedures.....................................................................................................................28
6.2.1 Bur and Collet Replacement ............................................................................................28
6.2.2 Turbine Motor Replacement.............................................................................................30
6.2.3 Ring Cylinder Assembly Replacement.............................................................................36
6.2.4 Spindle Boot Replacement...............................................................................................37
7. Serviceable Parts ................................................................................................................... 39
7.1 Accessories Tools, and Optional Replacement Parts .............................................................39
8. Specifications......................................................................................................................... 40
9. Drawings ................................................................................................................................. 42
10. Terms and Conditions............................................................................................................ 44
10.1 Motor Life and Service Interval Statement................................................................................45
10.1.1 Turbine Motor Products (Flexdeburr (RC) models)..........................................................45

Manual, Flexdeburr, RC‑1000 Series
Document #9610‑50‑1024‑05
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Glossary
Term Denition
Adapter Plate Device for attaching the deburring tool to either a robot ange or a stationary
mounting surface.
Air Filter Device for removing contamination from air supply lines. Typically refers to removal of
particulates.
Burr Any unwanted, raised protrusion on the work piece.
Bur Cutting tool used to remove burrs from the work piece. Alternatively referred to as a
rotary le, 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 work piece.
Conventional Milling Method of cutting where the direction of tool motion is opposite that of tool rotation.
Deburr To remove the burrs from (a piece of machined work)
End‑Effector Tool used by the robot to perform a particular function
Flexdeburr Product family name for ATI’s line of Radially‑Compliant (RC) deburring tools.
Main Housing The main cylindrical body of the unit which includes the mounting features.
RC Radially‑Compliant.
Rear Housing Rear cover to the main housing. This body includes a connection port for the
compliance air supply.
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.
Turbine Air motor that drives the spindle.
‑E Euro models.

Manual, Flexdeburr, RC‑1000 Series
Document #9610‑50‑1024‑05
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • 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.

Manual, Flexdeburr, RC‑1000 Series
Document #9610‑50‑1024‑05
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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1.2 General Safety Guidelines
Prior to purchase, installation, and operation of the Flexdeburr product, the customer should first read and
understand the operating procedures and information described in this manual. Never use the deburring tool
for any purposes, or in any ways, not explicitly described in this manual. Follow installation instructions 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
WARNING: Never operate the Flexdeburr product without wearing hearing protection.
High sound levels can occur during cutting. Failure to wear hearing protection can
cause hearing impairment. Always use hearing protection while working in the
neighborhood of the deburring tool.
WARNING: Never operate the Flexdeburr product without wearing eye protection.
Flying debris can cause injury. Always use eye protection while working in the
neighborhood of the deburring tool.
CAUTION: Do not use burs rated for less than the speed of the RC deburring tool
being used. Using these too may cause injury or damage equipment. Always use burs
rated for at least the speed of the RC deburring tool being used.
CAUTION: Do not use spare parts other than original ATI spare parts. Use of spare
parts not supplied by ATI can damage equipment and void the warranty. Always use
original ATI spare parts.
CAUTION: Never be present near the deburring tool while it is started or in operation.
Flying debris and rotating parts can cause injury. If it is necessary to approach the
deburring tool while in motion, stand behind appropriate Plexiglas windows. Provide a
barrier to prohibit people from approaching the deburring tool.
CAUTION: Do not perform maintenance or repair on the Flexdeburr product unless the
tool is safely supported or placed in the tool stand and air has been turned off. Injury
or equipment damage can occur with tool not placed in a tool stand and air remaining
on. Place the tool safely in the tool stand and turn off the air before performing
maintenance or repair on the Flexdeburr product.
NOTICE: Turbine motors are not serviceable at this time. Refer to Section 10—Terms and
Conditions. To maximize the life of turbine motor products the customer should follow closely the
normal operation procedures outlined in the product manual. The air must be totally lube free
and filtered to remove particulates and moisture. Exposing the turbine motors to oil in the air
supply results in premature failure.

Manual, Flexdeburr, RC‑1000 Series
Document #9610‑50‑1024‑05
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
8
2. Product Overview
The Radially‑Compliant (RC) deburring tool, also known as Flexdeburr, is a robust, high‑speed and lightweight
turbine‑driven deburring units for deburring aluminum, plastic, steel, etc. with a robot or CNC machine. The RC
deburring tool is especially suited for removal of parting lines and flash from parts. However, its flexible design
allows it to be used in a wide variety of applications.
The RC deburring tool’s pneumatically controlled, articulated design allows the bur to follow the part profile and
compensate for surface irregularities while maintaining and setting a constant force. As a result, high feed rates
with uniform quality in any orientation is achievable. The tool also requires no oil, allowing clean exhaust air to be
vented directly into the work environment.
Compliance is supported by air pressure applied to the shaft of the unit and is used to perform consistent deburring
on irregular part patterns. The motor’s internal governor maintains high spindle speeds for optimum surface finish.
The RC deburring tool also utilizes standard industrial tungsten‑carbide bits that allows for adaptation to changing
assembly lines and part requirements.
The RC deburring tool provides for (2) mounting methods, a side mounting and an axial mounting. The side
mounting provides (2) locating dowel pins and (4) threaded holes. The axial mounting utilizes a tapered flange that
requires an adapter plate. Custom adapter plates for both side and axial mounting are available from ATI. Refer to
Section 9—Drawings for more information.
Table 2.1—Deburring Tools
Model Description
Motor Air Tube
Size for the
Push‑To‑Connect
Fitting
Compliance Air
Tube Size for the
Push‑to‑Connect
Fitting
9150‑RC‑900‑ER 900 Watt, radially compliant tool 1/2” 5/32”
9150‑RC‑900‑ER‑E 900 Watt, radially compliant tool, Euro 12 mm 4 mm
9150‑RC‑1040‑ER 1040 Watt, radially compliant tool 1/2” 5/32”
9150‑RC‑1040‑ER‑E 1040 Watt, radially compliant tool, Euro 12 mm 4 mm
Figure 2.1—Deburring Tool
Side Mounting
Axial Mounting
Compliance Air
Connection
Motor Air
Connection
Tool Collet Nut

Manual, Flexdeburr, RC‑1000 Series
Document #9610‑50‑1024‑05
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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2.1 Collet System
A collet system secures the bur and many collet sizes are available to accommodate a wide variety
of applications.
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 turbine motor design does not allow the installation of spindle brakes or Tool Changer (drawbar)
collet systems.
The ATI RC‑1000 deburring tools use an ER‑11 collet system to hold cutting tools. The ER collet is a
commercial, double‑angle design offering greater tool gripping force, less tool runout and an extended grip
range. The collets are available from many sources in many different gripping diameters. ER‑11 collets can
achieve runout tolerances below 0.0005” [0.013 mm] and provide a gripping range up to 0.040” [1 mm].
These tolerances and gripping range allow a standard 1/4 inch ER‑11 collet to safely and accurately hold a
metric 6 mm diameter bur. Euro (or ‑E) versions are provided with a 6 mm metric collet.

Manual, Flexdeburr, RC‑1000 Series
Document #9610‑50‑1024‑05
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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2.2 Technical Description
The technical overview of the product is provided in the following tables and graph. For additional technical
specifications, refer to Section 8—Specifications.
2.2.1 Environmental Limitations
2.2.1.1 Operation
Table 2.2—Operation
Installation position
Mounted to robot by means of the side mounting
pattern or rear adapter ange. Refer to Section 3.5—
Side Mounting Installation and Section 3.6—Axial
Mounting Installation. The ange is specic to
each type of robot. This optional ange is normally
supplied by ATI in a blank form suitable for customer
modication.
Mounted to a table or stand by means of the bench
adapter (the robot is carrying the work piece).
Temperature range 5° C–35° C
41° F–95° F
Utilities
The tool requires the following:
• Clean, dry, ltered, non‑lubricated air
• A coalescing lter and lter elements rated
5 micron or better
• The motor spindle must be supplied air at
6.2 bar (90 psi)
• The radial compliance (centering) air must be
supplied from a regulated source between
1.0–4.1 bar (15–60 psi)
2.2.1.2 Storage
Table 2.3—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 3.4—Storage and Preventive
Maintenance during Storage of this manual.

Manual, Flexdeburr, RC‑1000 Series
Document #9610‑50‑1024‑05
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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2.2.2 Compliance Unit Performance
The graph in Figure 2.2 illustrates the variation of compliance force with applied air pressure in the
vertical orientation with the collet pointed toward the ground. Measurements may vary from one
product to another and should only be treated as nominal.
The actual force characteristics are dependent on mounting orientation and condition of the unit. In
applications, where the deburring tool is mounted horizontally, additional compliance air pressure
is required to overcome the weight of the motor. Compliance pressure is also dependent upon the
material of the work piece, type of bur tool, and the amount of material that is removed.
The turbine motor attempts 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.
Figure 2.2—RC‑1000 Series Radial Compliance Force (Measured at the Spindle Tip)
0123456
0
20
40
60
80
100
120
0
5
10
15
20
25
30
010 20 30 40 50 60 70 80 90
ComplianceAirPressure(Bar)
RadialComplianceForce(N)
RadialCompliance Force(lbf)
ComplianceAirPressure(PSI)
RC-1000 Series Radial Compliance Force

Manual, Flexdeburr, RC‑1000 Series
Document #9610‑50‑1024‑05
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3. Installation
The deburring tool is delivered fully assembled. Optional equipment such as mounting adapter plates, burs, and
additional collets will be separate.
3.1 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.
3.2 Inspection of Condition When Delivered
Upon receipt, the following should be checked:
• Delivery in accordance with freight documents
• Packaging 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 that may have been damaged for a closer inspection. If necessary, notify ATI for
assistance in evaluation of the product condition.
3.3 Unpacking and Handling
The deburring tool should always be placed inside the accompanying box (crate) during transportation,
storing and handling.
Pneumatic lines and electrical cables are attached, bundled, and must be strain‑relieved in a manner that
allows for freedom of movement during operation.
3.4 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.

Manual, Flexdeburr, RC‑1000 Series
Document #9610‑50‑1024‑05
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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3.5 Side Mounting Installation
CAUTION: The length of the fasteners should not interfere with the compliant
motion of the turbine motor spindle. Refer to Section 9—Drawings for the maximum
fastener length. Do not use fasteners that exceed the maximum length; otherwise,
damage will occur.
CAUTION: Lock washers are recommended on all mounting fasteners. Liquid thread
lockers should not be used for the mounting fasteners as this may damage or remove
thread inserts during disassembly.
The side mounting pattern of the RC deburring tool consists of (2) dowel pin holes and (4) of threaded holes
as shown in Figure 3.1. If the RC deburring tool is permanently mounted to a work surface, the robot carries
the part to be deburred to the deburring tool.
Figure 3.1—Bench (Side) Installation
Bench Top Interface
(4) M6 Socket Head Cap Screws
Side Mounting on
Front Housing Assembly

Manual, Flexdeburr, RC‑1000 Series
Document #9610‑50‑1024‑05
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3.6 Axial Mounting Installation
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 3.2).
Figure 3.2—Axial Installation
Clamping Collar
Clamping Collar
Blank Interface
Plate
Axial Mounting Flange on Rear Housing Assembly
(2) M5 Socket Head Cap Screws

Manual, Flexdeburr, RC‑1000 Series
Document #9610‑50‑1024‑05
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3.7 Pneumatics
Connect the RC deburring tool as shown in Figure 3.3.
Figure 3.3—Pneumatic Connections
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 equipment.
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 bar (90 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.
CAUTION: Pneumatic components used for the motor drive circuit must be capable
of meeting the air consumption requirements (See Section 8—Specifications ). Poor
performance will result if the correct components are not used.
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 (ATI Part
#9150‑FFR‑90, or equivalent. See Section 8—Specifications for the maximum flow requirements) and
a high‑flow valve to properly supply a stable air supply of 6.2 bar (90 psi) to the spindle motor. The RC
deburring tool will not operate properly if supplied air below 6.2 bar (90 psi).
A second, precision, self‑relieving regulator (ATI Part # 9150‑PPR‑60, or equivalent) is used to supply the
compliance (centering) mechanism. This pressure corresponds to the side force on the rotary bur. Because
very little air flow is required for the compliance mechanism, a significantly smaller valve can be used
(Consult the valve and regulator supplier’s literature when selecting these components).

Manual, Flexdeburr, RC‑1000 Series
Document #9610‑50‑1024‑05
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If the complete work piece 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 work piece, and this
variation is repeatable for all work pieces 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.
Solenoid valves are actuated from the robot or program logic controller by means of a digital output signal.
Table 3.1—Pneumatic Connections
Function Connection Type Pressure
Motor Inlet
9150‑RC‑900‑ER and
9150‑RC‑1040‑ER
1/2" Quick Connect Tube (U.S. Model)
Alternates:
Remove the ATI Supplied Fitting and use the
3/8‑NPT Port in the Motor Body 6.2 bar
90 psi
9150‑RC‑900‑ER‑E and
9150‑RC‑1040‑ER‑E
12 mm Quick Connect Tube (‑E Euro Model)
Alternates:
Remove the ATI Supplied Fitting and use the
3/8‑NPT Port in the Motor Body
Compliance (Radial) Force Inlet
9150‑RC‑900‑ER,
9150‑RC‑900‑ER‑E,
9150‑RC‑1040‑ER, and
9150‑RC‑1040‑ER‑E
5/32” (4 mm) 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
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 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 8—Specifications. 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 8—Specifications).
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 about 1 bar [15 psi] of pressure and increase the pressure slowly until
the desired cut is achieved.

Manual, Flexdeburr, RC‑1000 Series
Document #9610‑50‑1024‑05
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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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 and
have extensive knowledge about automation applications that incorporate robots.
4.1 Safety Precautions
DANGER: Never use the Flexdeburr for purposes other than robotic deburring. If used
in any other way, serious injury or damage to equipment may occur.
WARNING: All personnel, who are involved in operation of the RC deburring tool,
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 RC deburring tool.
WARNING: Never operate the Flexdeburrproduct without wearing hearing protection.
High sound levels can occur during cutting. Failure to wear hearing protection can
cause hearing impairment. Always use hearing protection while working in proximity of
the deburring tool.
WARNING: Never operate the Flexdeburr product without wearing eye protection.
Flying debris can cause injury. Always use eye protection while working in the proximity
of the deburring tool.
CAUTION: Do not use burs rated for less than the speed of the RC deburring tool
being used. Using lower rated burs may cause injury or damage equipment. Always
use burs rated for at least the speed of the RC deburring tool being used.
CAUTION: Do not use spare parts other than original ATI spare parts. Use of spare
parts not supplied by ATI can damage equipment and void the warranty. Always use
original ATI spare parts.
CAUTION: Never be present near the deburring tool while it is started or in operation.
Flying debris and rotating parts can cause injury. If it is necessary to approach the
deburring tool while in motion, stand behind appropriate Plexiglas windows. Provide a
barrier to prohibit people from approaching the deburring tool while in operation.
CAUTION: Never use or start the deburring tool without first reading and understanding
the operating procedures described in this manual. Never use the deburring tool for any
purposes, or in any ways, not explicitly described in this document. Using the deburring
tool without fully understanding the installation and operating procedures may cause
injury to personnel or damage to equipment. Mount the deburring tool and connect the
pneumatic control equipment as described in this manual. Operate the deburring tool
as described in the manual.

Manual, Flexdeburr, RC‑1000 Series
Document #9610‑50‑1024‑05
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
18
4.2 Normal Operation
The following sections describe the normal operating conditions for RC deburring tools.
4.2.1 Air Quality
The air supply should be dry, filtered, and free of oil. A coalescing filter with elements rated for 5
micron or better is required. The air must be supplied at 6.2 bar (90 psi).
Air quality affects tool performance more than almost any other factor. Particulate can block airflow
or impede vane motion. If deburring tools Do not receive proper air pressure, the tool stalls. Any
water in the system damages the housing and blades.
4.2.2 No Lubrication
Lubrication of any kind is strictly prohibited.
Turbine motors cannot have any oil in the motor air supply. Oil damages the speed regulator and
causes the motor speed to fluctuate out of tolerance.
4.2.3 Bur Selection, Design, and Maintenance
Use a carbide media.
RC tools have higher operating speeds and the media must be rated to at least the RC idle speed.
Check media quality regularly to ensure it is not dull or worn. Using worn media causes a poor
surface finish and increased wear on the bearings that results in premature tool failure.
Do not use shank extensions because the large moment loads combined with the high speed
can be dangerous.
Brushes are not recommended because the maximum rated speed of the brush is less than the
operating speed of the deburring tool. Operating the brush above its maximum rated speed can be
unsafe due to unbalanced loading. Additionally, even balanced brushes can result in an excessive load
on the motor and reduced motor life.
Do not use a tool that results in axial loading on the RC tool.
4.2.4 Deburring Tool Approach Path Should be Slow and at an Angle
The deburring tool should approach the workpiece slowly and at an angle.
When beginning a deburring pass, try to minimize the initial impact on the work piece by slowly
approaching the tool at an angle while maintaining a slightly parallel path with the surface.
If the tool quickly approaches perpendicularly to the workpiece, the result is gouging and
premature wear of the tool bearings and cutting bit. Additionally, collisions could result and create
a hazardous situation for both personnel and equipment.
4.2.5 No Axial Loading
Do not apply axial loads that are parallel to the axis of the tool’s rotation.
Do not deburr shallow edges where the cutter contacts the parent material below the edge; otherwise,
axial loading is applied on the tool and bearings and results in premature failing of the unit.
When deburring holes, interpolate the perimeter. Do not use a countersink tool; otherwise, axial
loading occurs and causes premature wear on the bearings.
4.2.6 Program the Robot to Incorporate 50% Compliance Travel of the Tool
Program the robot to have the tool’s compliance at 50% travel when on the nominal path.
As the part’s edge deviates from the perfect path, the cutting bit 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 create slop in the compliance and reduce
recentering repeatability.

Manual, Flexdeburr, RC‑1000 Series
Document #9610‑50‑1024‑05
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
19
4.3 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.
Be aware of rotating parts. Use eye‑protection while working around the deburring tool.
Be aware of high sound levels. While the Flexdeburr air motor is not loud, the cutting action associated
with deburring frequently is loud. Always use hearing protection while working in the neighborhood of the
deburring cell.
The deburring tool should not be used to deburr materials that are prone to fracture. A fracturing work
piece may result in pieces of material damaging surrounding working environment and personnel. Material
removed correctly should be in the form of chips.

Manual, Flexdeburr, RC‑1000 Series
Document #9610‑50‑1024‑05
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
20
4.4 Locking the Tool to Single Axis Compliance
The deburring tool can be locked to be compliant in single axis. Included are (4) M4 x 16 button head socket
cap screws to lock the tool.
CAUTION: Do not use improper length screws for locking the tool axis. Improper length
screws can cause damage to equipment and/or personnel. Use only M4 x 16 mm
button head socket cap screws to lock axis.
Tools required: 2.5 mm and 3 mm hex key, torque wrench
Supplies required: Loctite 7649 primer and Loctite 222
1. Remove and/or lock‑out the spindle motor air supply for safety.
2. Using a 3 mm hex key, remove the (4) M5 x 6 mm button head socket cap screws from around the center
of the tool body.
Figure 4.1—Remove M5 Button Head Socket Cap Screws
Tool Body
(4) M5 x 6 mm Button Head
Socket Cap Screws
3. Apply Loctite 7649 primer and Loctite 222 to the (4) M4 x 16 mm button head socket cap screws.
4. Using a 2.5 mm hex key, install the (4) M4 x 16 mm button head socket cap screws into the screw
holes that the (4) M5 x 6 mm button head socket cap screws were removed from. Tighten to
25 in‑lbs (2.82 Nm).
Figure 4.2—Install M4 Button Head Socket Cap Screws
Tool Body
(4) M4 x 16 mm Button Head
Socket Cap Screws
Compliance
after Lock
is Applied.
5. Restore the air supply.