ATI Technologies Flexdeburr User manual

Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
ATI Single-Axis, Radially-Compliant
Robotic Deburring Tools
Flexdeburr™
(Model 9150-RS-340)
Product Manual
Document #: 9610-50-1016

Manual, Flexdeburr, RS-340
Document #9610-50-1016-08
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
2
Foreword
CAUTION: This manual describes the function, application, and safety considerations of this
product. This manual must be read and understood before any attempt is made to install or
operate the product, otherwise damage to the product or unsafe conditions may occur.
Information contained in this document is the property of ATI 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 reect and incorporate changes made to the product.
The information contained herein is condential 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 tness 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
Sale, Service and Information about ATI products:
ATI IndustrialAutomation
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]

Manual, Flexdeburr, RS-340
Document #9610-50-1016-08
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
3
Table of Contents
Foreword.......................................................................................................................................... 2
Glossary........................................................................................................................................... 5
1. Safety......................................................................................................................................... 6
1.1 ExplanationofNotications.........................................................................................................6
1.2 General Safety Guidelines............................................................................................................6
1.3 Safety Precautions........................................................................................................................7
2. Product Overview..................................................................................................................... 8
2.1 Tool Collet Systems......................................................................................................................9
2.2 Technical Description ...................................................................................................................9
2.2.1 Environmental Limitations..................................................................................................9
2.2.1.1 Operation............................................................................................................9
2.2.1.2 Storage.............................................................................................................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 Perpendicular Loading .....................................................................................................18
4.2 Normal Operations......................................................................................................................18
4.3 Flexdeburr Working Environment .............................................................................................19
4.2.7 Program the Robot to Incorporate 50% Compliance Travel of the Tool...........................19
4.4 Tool Center Point (TCP) Position and Programming...............................................................20
4.5 Cutter Operation and Bur Selection..........................................................................................22
4.5.1 Bur Selection....................................................................................................................22

Manual, Flexdeburr, RS-340
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5. Maintenance............................................................................................................................ 25
5.1 Pneumatics..................................................................................................................................25
5.2 Lubrication...................................................................................................................................25
5.3 Boot Inspection...........................................................................................................................25
5.4 Bur Inspection.............................................................................................................................25
6. Troubleshooting and Service Procedures ........................................................................... 26
6.1 Troubleshooting..........................................................................................................................26
6.2 Service Procedures.....................................................................................................................27
6.2.1 Bur and Collet Replacement ............................................................................................27
6.2.2 Turbine Motor Replacement.............................................................................................29
6.2.3 Ring Cylinder Assembly Replacement.............................................................................31
7. Serviceable Parts ................................................................................................................... 33
7.1 Accessories Tools, and Optional Replacement Parts .............................................................33
8. Specications ......................................................................................................................... 34
9. Drawings ................................................................................................................................. 35
9.1 RS-340 Geometry and Mounting................................................................................................35
9.2 RS-340 Serviceable Parts Drawing............................................................................................36
10. Terms and Conditions of Sale............................................................................................... 37
10.1 Motor Life and Service Interval Statement................................................................................38
10.1.1 Turbine Motor Products (Flexdeburr (RS) models) ..........................................................38

Manual, Flexdeburr, RS-340
Document #9610-50-1016-08
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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 the air supply lines. Typically refers to
removal of the particulates.
Air Turbine Air motor that drives the spindle.
Bur Cutting tool used to remove the burrs from the work piece. Alternatively
referred to as a rotary le, cutter, or bit.
Burr Any unwanted, raised protrusion on the work piece.
Climb Milling Cutting method where the direction of the cutter rotation and tool motion are
the same.
Chattering Machine vibrations. The cutting tool bounces as it contacts the work surface.
Coalescing Filter Device designed to remove the 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 the response to protrusions on
the or deviations of the work piece.
Conventional Milling Method of cutting where the direction of the tool motion is opposite that of the
tool rotation.
End-Effector Tool used by the robot to perform a particular function
Flexdeburr Product family name for ATI’s line of radially compliant deburring tools.
Main Housing The main cylindrical body of the unit which includes the mounting features.
Positive Stop The tool has contacted a physical limitation and can no longer move.
Qty Quantity.
Regulator Device used to set and control the supplied air pressure to lower acceptable
levels.
Rear Housing Rear cover to the main housing. The body includes a connection port for
compliance and motor air.
RS Single-axis radially-compliant.
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.

Manual, Flexdeburr, RS-340
Document #9610-50-1016-08
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1. Safety
The safety section describes general safety guidelines to be followed with this product, explanations of the
notications found in this manual, and safety precautions that apply to the product. More specic notications are
imbedded within the sections of the manual where they apply.
1.1 ExplanationofNotications
The following notications are specic to the product(s) covered by this manual. It is expected that the user
heed all notications from the robot manufacturer and/or the manufacturers of other components used in the
installation.
DANGER: Notication of information or instructions that if not followed will result in
death or serious injury. The notication provides information about the nature of the
hazardous situation, the consequences of not avoiding the hazard, and the method for
avoiding the situation.
WARNING: Notication of information or instructions that if not followed could result
in death or serious injury. The notication provides information about the nature of the
hazardous situation, the consequences of not avoiding the hazard, and the method for
avoiding the situation.
CAUTION: Notication of information or instructions that if not followed could result
in moderate injury or will cause damage to equipment. The notication provides
information about the nature of the hazardous situation, the consequences of not
avoiding the hazard, and the method for avoiding the situation.
NOTICE: Notication of specic information or instructions about maintaining, operating,
installing, or setting up the product that if not followed could result in damage to equipment. The
notication can emphasize, but is not limited to: specic grease types, best operating practices,
and maintenance tips.
1.2 General Safety Guidelines
Prior to purchase, installation, and operation of the Flexdeburr product, the customer should rst 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 ttings and tubing must be capable of withstanding the repetitive motions of the application
without failing. The routing of the pneumatic lines must minimize the possibility of stress/strain, kinking,
rupture, etc. Failure of the critical pneumatic lines to function properly may result in the equipment damage.

Manual, Flexdeburr, RS-340
Document #9610-50-1016-08
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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1.3 Safety Precautions
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: 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 of Sale. 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 ltered to remove particulates and moisture. Exposing the turbine motors to oil in
the air supply results in premature failure.

Manual, Flexdeburr, RS-340
Document #9610-50-1016-08
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2. Product Overview
The single-axis radially-compliant (RS) Deburring tool, also known as Flexdeburr, is robust, high-speed and
lightweight air turbine-driven deburring units for deburring aluminum, plastic, steel, etc. with a robot or CNC
machine. The RS deburring tool is especially suited for removal of parting lines and ash from the parts. However,
its exible design allows it to be used in a wide variety of applications.
The RS deburring tool’s pneumatically controlled, articulated design allows the cutting bit to follow the part prole
and compensate for surface irregularities while maintaining a constant, settable force. This allows high feed rates
with uniform quality in any orientation. The tool 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 motors internal governor maintains high spindle speeds for optimum surface
nish. The RS deburring tool also utilizes standard industrial tungsten-carbide bits which allows for adaptation to
changing assembly lines and part requirements.
The RS-340 provides for (2) mounting types, 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 ange 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.
The RS-340 is equipped with a 1/2" (12 mm on the Euro models) push-to connect tting to supply the motor air and
a 5/32" (4 mm) Push-to Connect tting to supply the compliance air.
A tool collet system secures the bur tool. Many collet sizes and a various selection of tools are available to
accommodate a wide variety of applications.
Figure 2.1—RS-340 Deburring Tool
Tool Collet System
Side Mounting
Motor Air
Connection
Compliance Air
Connection
Axial
Mounting

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2.1 Tool Collet Systems
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 the quick-change or drawbar collet systems.
The standard tool holding system for Flexdeburr products is an economical, proprietary, single-angle collet
design utilizing (3) gripping ngers. This is suitable for most applications where industry standard shank
diameter cutting tools are used and runout tolerances of up to 0.001” (0.025 mm) are acceptable. Special
sizes are available upon request but require custom machining.
2.2 Technical Description
A technical overview of the product is provided in the following tables and graphs. For additional technical
specications, refer to Section8—Specications.
2.2.1 Environmental Limitations
2.2.1.1 Operation
Table 2.1—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. Refer to Section 9.1—RS-340 Geometry
and Mounting.
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).

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2.2.1.2 Storage
Table 2.2—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 3.7—Storage and Preventive
Maintenance during Storage of this manual.

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2.2.2 Compliance Unit Performance
The variation of the compliance force with applied air pressure are illustrated in the following
graph. 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 the 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—RS-340 Compliance Force Curves (Measured at the Spindle Collet)
1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00 3.25 3.50 3.75 4.00
9
13
18
22
27
31
36
40
2
3
4
5
6
7
8
9
15 20 25 30 35 40 45 50 55 60
Compliance Air Pressure (bar)
Axial Force (N)Axial Force (lbs)
Compliance Air Pressure (psi)

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3. Installation
The RS-340 Deburring Tool is delivered fully assembled. Optional equipment such as mounting adapter plates, burr
tools, additional collets will be separate.
3.1 Transportation and Protection during Transportation
The RS deburring tool arrives in packaging to secure and protect it during transportation. Always use this
packaging 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 is in accordance with freight documents.
• Packaging is in good condition.
If there is damage to any of the packaging, or if any of the goods have been exposed to abnormal handling,
unpack those parts 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 packaging 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 packaging 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 its packaging.

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3.5 Side Mounting Installation
CAUTION: The length of the fasteners should not interfer 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 RS deburring tool consists of (2) dowel pin holes and (4) of threaded holes
as shown in the following gure. An optional bench mount adapter plate allows the deburring tool to be
permanently attached to a bench or other work surface. If the RS 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
Side Mounting
on Front Housing
Assembly
(4) M5 Socket Head
Cap Screws
Lock Washer
Benchtop Interface
Plate Assembly

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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 modied by the system integrator or by the owner/user of the Flexdeburr. ATI
can provide custom interface plates and adapters upon request. If the RS deburring tool is permanently
mounted to a work surface, the robot carries the part to be deburred to the deburring tool.
Figure 3.2—Axial Installation
(2) M5 Socket
Head Cap Screws
Clamping Collar
Blank Interface
Plate
Axial Mounting Flange
on Rear Housing
Assembly

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3.7 Pneumatics
Connect the RS deburring tool as shown in the following gure.
CAUTION: Do not use lubricated air with the Flexdeburr. Oil in the air stream will
result in premature failure of the turbine motor and is not covered under warranty. It
is recommended that the customer use a coalescing lter and lter elements that are
rated 5 micron or better.
Figure 3.3—Pneumatic Connections
WARNING: All pneumatic ttings and tubing must be capable of withstanding the
repetitive motions of the application without failing. The routing of the 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, ltered, and free of oil. A coalescing lter with elements rated for 5 micron or
better is required.
A high-ow 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’s traversing
speed will also be adjusted to achieve the desired nish.
CAUTION: Pneumatic components used for the motor drive circuit must be capable
of meeting the air consumption requirements (see Section8—Specications). 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-ow pneumatic pressure regulator (ATI Part #9150-FFR-
90, or equivalent. See Section8—Specications for the maximum ow requirements) and a high-ow valve
to properly supply a stable air supply of the 6.2 bar (90–95 psi) to the spindle motor. The RS deburring tool
will not operate properly, if the supplied air is below 6.2 bar (90 psi).

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A second, precision, self-relieving regulator (ATI Part # 9150-P16-B-G, or equivalent) is used to supply the
compliance (centering) mechanism. This pressure corresponds to the side force on the bur. Because very
little air ow is required for the compliance mechanism, a signicantly smaller valve can be used. (Consult
the valve and regulator supplier’s literature when selecting these components).
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-RS-340
3/8" quick connect tube
Alternates:
Use 5/16” (8 mm) tubing adapter
or
Remove the supplied tting to use 1/4 NPT
port in the motor body
6.2 bar
(90 psi)
Compliance (Radial) Force
Inlet
9150-RS-340-ER & -E
5/32” (4 mm) quick connect tube
Alternate:
Remove the supplied tting 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 exible plastic tubing be used for the motor air supply and the compliance force
air supply. The installed ttings 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 mufers are required.
Information on the sound intensity is provided in Section8—Specications. To reduce the sound from the
cutting operation in the neighboring working areas, a customer-supplied barrier surrounding the installation
may be installed (Plexiglas or Lexan is preferred, see Section8—Specications).
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.

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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 RS 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 RS 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 RS 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 RS deburring tool being used.
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 rst 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, RS-340
Document #9610-50-1016-08
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
18
4.2 Normal Operations
The following sections describes the normal operating conditions for RS deburring tools.
4.2.1 Air Quality
The air supply should be dry, ltered, and free of oil. A coalescing lter 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 airow
or impede vane motion. If deburring tools do receive proper air pressure, the tool stalls. Any water in
the system damages the housing and blades.
4.2.2 No Lubrication
No lubrication is required.
Turbine motors cannot have any oil in the motor air supply. Oil damages the speed regulator and
causes the motor speed to uctuate out of tolerance.
4.2.3 Bur Selection, Design, and Maintenance
Use a carbide media.
RS tools have higher operating speeds and the media must be rated to RS idle speed at a minimum.
Check media quality regularly to ensure it is not dull or worn. Using worn media causes a poor
surface nish 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 requires axial loading on the RS 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 bur. 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 Perpendicular Loading
Do not apply radial loads that are perpendicular to the axis of pivot. Always keep the tool pivoting
perpendicular to the deburring surface. Loading the tool along the pivot axis will damage the pivot
pins and cause premature failure.

Manual, Flexdeburr, RS-340
Document #9610-50-1016-08
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
19
4.2.7 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 bur 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.
4.3 Flexdeburr Working Environment
As described in previous sections, the RS 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 RS 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, RS-340
Document #9610-50-1016-08
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
20
4.4 Tool Center Point (TCP) Position and Programming
The following gure shows the RS deburring tool dimensions. The Flexdeburr provides radial compliance
and performs best when the cuts taken are not excessively deep. The deburring tool spindle must never be
running while programming the robot. During teaching, the compliance air must be on and supplied above a
minimum of 0.35 bar (5 psi).
Two programming methods are suggested but others are possible. In the rst method, a dowel pin of suitable
diameter is inserted in place of a bur (simulating the cutter shank diameter) when teaching the robot path.
For 6 mm collets, this will mean a 6 mm diameter pin of suitable length. The dowel pin should extend
sufciently from the collet to reach the surface on the bur where cutting is desired (refer to the following
gure). The diameter of the bur should not exceed that of the dowel pin by more than the compliance of the
RS deburring tool.
Another programming method is to teach the path using the centerline of the bur as a guide, following the
edge of the part, and then manually or automatically adding offsets to the robot path points to achieve the
nal correct bur path (see Figure 4.2). The programming method used will depend on the robot’s capabilities
and programmer preferences.
Figure 4.1— Flexdeburr Dowel Teaching Tool