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
4
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
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
5
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
6
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
7
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
9
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
10
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.