ATI Technologies 9150-CRT User manual

Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
ATI Compliant
Reciprocating Tool
(Model 9150‑CRT)
Product Manual
Document #: 9610-50-1028

Manual, Compliant Reciprocating Tool, CRT Series
Document #9610-50-1028-04
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• 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 the product, otherwise damage to the product or unsafe conditions may occur.
Information contained in this document is the property of ATI IndustrialAutomation, 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 IndustrialAutomation 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 IndustrialAutomation. 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, Compliant Reciprocating Tool, CRT Series
Document #9610-50-1028-04
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• 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............................................................................................................6
1.3 Safety Precautions........................................................................................................................6
2. Product Overview..................................................................................................................... 7
2.1 File Holder Systems......................................................................................................................8
2.1.1 Reciprocating Tool Part Number Structure.........................................................................8
2.2 Technical Description ...................................................................................................................8
2.2.1 Environmental Limitations..................................................................................................8
2.2.1.1 Operation............................................................................................................8
2.2.1.2 Storage...............................................................................................................9
2.2.2 Compliance Unit Performance ...........................................................................................9
3. Installation .............................................................................................................................. 10
3.1 Protection During Transportation..............................................................................................10
3.2 Inspection of Condition When Delivered..................................................................................10
3.3 Unpacking and Handling............................................................................................................10
3.4 Storage and Preventive Maintenance During Storage.............................................................10
3.5 Axial Mounting Installation......................................................................................................... 11
3.6 Side Mounting Installation..........................................................................................................12
3.7 Pneumatics..................................................................................................................................13
4. Operation ................................................................................................................................ 14
4.1 Safety Precautions......................................................................................................................14
4.2 Normal Operation........................................................................................................................15
4.2.1 Air Quality.........................................................................................................................15
4.2.2 Lubrication........................................................................................................................15
4.2.3 Media Selection, Design, and Maintenance.....................................................................15
4.2.4 Reciprocating Tool Approach Path Should Be Slow and at an Angle...............................15
4.2.5 Program the Robot to Incorporate 50% Compliance Travel of the Tool ...........................15
4.3 Reciprocating Tool Working Environment................................................................................16
4.4 File Operation and File Selection...............................................................................................16
4.5 Locking and Unlocking Single Axis Compliance.....................................................................17

Manual, Compliant Reciprocating Tool, CRT Series
Document #9610-50-1028-04
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
4
5. Maintenance............................................................................................................................ 18
5.1 Pneumatics..................................................................................................................................18
5.2 Lubrication...................................................................................................................................18
5.3 File Inspection.............................................................................................................................18
5.4 Spindle Boot Inspection.............................................................................................................18
6. Troubleshooting and Service Procedures........................................................................... 19
6.1 Troubleshooting..........................................................................................................................19
6.2 Service Procedures.....................................................................................................................20
6.2.1 File Replacement .............................................................................................................20
6.2.2 Ring Cylinder Assembly Replacement.............................................................................22
6.2.3 Boot Replacement............................................................................................................24
7. Serviceable Parts ................................................................................................................... 25
7.1 Accessories.................................................................................................................................25
8. Specifications......................................................................................................................... 26
9. Drawings ................................................................................................................................. 27
9.1 CRT-12-5 Drawing........................................................................................................................27
9.2 Pneumatic Diagram.....................................................................................................................29
9.3 Interface Plate..............................................................................................................................30
10. Terms and Conditions of Sale............................................................................................... 31

Manual, Compliant Reciprocating Tool, CRT Series
Document #9610-50-1028-04
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
5
Glossary
Term Denition
Adapter Plate Device for attaching the CRT (Compliant Reciprocating Tool) to either a robot ange or
a stationary mounting surface.
Aerosols A suspension of ne solid or liquid particles in gas.
Air Filter Device for removing contamination from air supply lines. ATI suggests air lters for the
removal of up to 30 microns particulates.
Boot A exible protective cover.
Burr Any unwanted, raised protrusion on the workpiece.
Coalescing Filter Device designed to remove liquid aerosols from the supply air lines.
Compliance The ability of the spindle to passively move in response to deviations of the workpiece.
CRT Compliant Reciprocating Tool
Deburr To remove the burrs from a machined piece of machined work.
End‑Effector Tool used by the robot to perform a particular function.
File a hardened steel tool with cutting ridges for smoothing surfaces.
Flash Extra material left from molding process.
Holder Gripping device used to hold cutting tools in the spindle.
Parting Lines The line along which sections of a foundry mold, die, or pattern separate.
Regulator Device used to set and control the supplied air pressure to acceptable levels.
Solenoid Valve Electrically controlled device for switching air supplies on and off.

Manual, Compliant Reciprocating Tool, CRT Series
Document #9610-50-1028-04
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• 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.
1.2 General Safety Guidelines
The customer should first read and understand the operating procedures and information described in this
manual. Never use the CRT for any purpose 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
CAUTION: Do not use files rated for less than the speed of the CRT. Using these
may cause injury or damage equipment. Always use files rated for at least the
speed of the CRT.
CAUTION: Do not use serviceable parts other than original ATI serviceable parts. Use
of serviceable parts not supplied by ATI can damage equipment and void the warranty.
Always use original ATI serviceable parts.
CAUTION: Do not perform maintenance or repair on the reciprocating tool 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 reciprocating tool product.

Manual, Compliant Reciprocating Tool, CRT Series
Document #9610-50-1028-04
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
7
2. Product Overview
ATI's Compliant Reciprocating Tool (CRT) is a robust, high‑speed, and lightweight reciprocating material removal
unit for materials such as: aluminum, plastic, and steel with a robot. The CRT is especially well‑suited for removal
of parting lines and flash from parts; however, its flexible design allows it to be used in a variety of applications.
The reciprocating tool’s pneumatically controlled, articulated design allows the file to follow the part profile and
compensate for surface irregularities while maintaining a constant, configurable force. This allows high feed rates
with uniform quality in any orientation. The CRT has a single axis lockout feature to limit articulation which
provides increased rigidity that is parallel to the direction of file motion. The rigid parallel support is capable
of producing greater control of surface finish and reduces tool chatter. Maintaining the proper orientation of the
cutting tool and the part profile requires more skill and effort in robot programming.
Compliance is supported by air pressure applied to the motor of the unit and is used to perform consistent
reciprocating on irregular part patterns.
The CRT provides a side mounting with (2) dowel pin locations and threaded holes. Custom adapter plates for side
mounting are available from ATI (refer to Section 9—Drawings for more information).
The CRT is equipped with a 3/8" (10 mm) push‑to‑connect fitting to supply the motor air and a 5/32" (4 mm)
push‑to‑connect fitting to supply the compliance air.
A 5 mm file holder system secures the file. Many file tools are available to accommodate a wide variety
of applications.
The CRT can be locked to single axis compliance using the single axis lockout (refer to Section 4.5—Locking and
Unlocking Single Axis Compliance for more information).
The selection of a file is dependent upon the workpiece material, geometry, and the depth of cut. Please see
Section 4.4—File Operation and File Selection for a short list of files and suitable applications.
Figure 2.1—CRT Reciprocating Tool
Compliance Air
Connection
Pneumatic Drive Connection
Side Mounting
Single Axis Lockout
File Holder
Axial Mounting Flange

Manual, Compliant Reciprocating Tool, CRT Series
Document #9610-50-1028-04
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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2.1 File Holder Systems
The file holding system for CRT series of products is an industry standard 5 mm file holder design. The
5 mm file holder system is used worldwide on machine tools which allows users to procure different holder
sizes from local industrial supply firms.
The holder retaining set screws are loosened to open the holder, allowing files to be removed and inserted.
Once the tool is set to the desired depth, a hex key is used to tighten the holder set screws securing the file.
2.1.1 Reciprocating Tool Part Number Structure
For the following part number: 9150‑CRT‑XX‑X
• “CRT” designates a multi‑axis a tool of radial compliance and reciprocating tool
• “XX” designates the strokes per minute in thousands
• “X” designates the length of stroke in millimeters
2.2 Technical Description
A technical overview of the product is provided in the following section: For additional technical
specifications, refer to Section 8—Specifications.
2.2.1 Environmental Limitations
2.2.1.1 Operation
Table 2.1—Operation
Installation Position
Mounted to robot with the side mounting pattern.
Mounted to a table or stand by means of the bench
adapter. The robot is carrying the work piece to the
CRT.
Temperature Range 5°C – 35°C
41°F – 95°F
Utilities
The tool requires the following:
• Clean, dry, ltered air. The motor can be
operated with 1‑2 drops per minute of air tool oil
to the motor air supply.
• A coalescing lter and lter elements rated 30
micron or better.
• Air supply to the spindle must be supplied at 6.2
bar (90 psi) to develop the full rated power.
• The radial compliance (centering) air must
be supplied at 1.0–4.1 bar (15–60 psi) from a
regulated source.

Manual, Compliant Reciprocating Tool, CRT Series
Document #9610-50-1028-04
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
9
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 3.4—Storage and
Preventive Maintenance During Storage of this
manual.
2.2.2 Compliance Unit Performance
The following graph illustrates the variation of compliance force with applied air pressure in the
vertical orientation with the holder pointed downward (toward the ground). Measurements may
vary from one product to another and should only be regarded as nominal.
The actual force characteristics are dependent on the mounting orientation and condition of the
unit. In applications where the CRT 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 workpiece, type of file tool, and the amount of material that is removed.
Figure 2.2—CRT Compliance Force Curves (Measured at the Spindle Tip)
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
10.00
11.00
12.00
010 20 30 40 50 60
Radial Compliance Force (lbs)
Supply Pressure (psi)
Supply Pressure vs Radial Compliance Force

Manual, Compliant Reciprocating Tool, CRT Series
Document #9610-50-1028-04
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
10
3. Installation
The CRT is delivered fully assembled. Optional equipment, such as: mounting adapter plates and files will be
sold separately.
3.1 Protection During Transportation
The CRT is packaged in a crate that secures and protects the tool during transportation. Always use the crate
when storing and transporting the CRT in order to minimize the risk of damage.
3.2 Inspection of Condition When Delivered
The following should be checked upon receipt of the CRT:
• Delivery 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 improper handling,
unpack those parts that may have been damaged for a closer inspection. Notify ATI for assistance in the
evaluation of the product condition, if necessary.
3.3 Unpacking and Handling
The CRT should always be placed inside the accompanying crate while storing and handling.
Pneumatic lines 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 CRT should always be stored in its crate, when not in use. The CRT should be stored in a dry place. For
long‑term storage, the CRT should be thoroughly cleaned of any burrs or debris. Do not disassemble the
CRT. Place the CRT within a sealed plastic bag inside the crate.

Manual, Compliant Reciprocating Tool, CRT Series
Document #9610-50-1028-04
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
11
3.5 Axial Mounting Installation
A blank robot adapter plate is also available to allow axial mounting of the rear of the deburring tool
housing. This plate may be modified by the system integrator or by the owner/user. 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 3.1—Axial Installation
Interface
Plate
(2) M5 Socket Head Cap Screw
Clamping Collar
Axial Mounting Flange on Rear Housing Assembly

Manual, Compliant Reciprocating Tool, CRT Series
Document #9610-50-1028-04
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3.6 Side Mounting Installation
CAUTION: The length of the fasteners should not interfere with the compliant motion of
the air 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 CRT consists of (2) dowel pin holes and (4) threaded holes (refer to
Figure 3.2 and Section 9—Drawings). An optional bench mount adapter plate allows the CRT to attach to a
bench or other work surface. The bench mount adapter may also be used with intermediate plates to attach
the CRT to a robot flange or to an ATI Tool Changer. If the CRT is permanently mounted to a work surface,
the robot carries the part to the reciprocating tool to be deburred.
Figure 3.2—Side Mounting Installation
(4) M6 Socket Head Cap Screw
Bench Mount
Adapter (Optional)
(4) M6 Socket Head
Cap Screw
Side Mounting

Manual, Compliant Reciprocating Tool, CRT Series
Document #9610-50-1028-04
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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3.7 Pneumatics
Connect the CRT as shown in Section 9.2—Pneumatic Diagram.
CAUTION: Pneumatic components used for the 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 CRT.
To utilize full power from the pneumatic drive, ATI recommends that the user install a high‑flow pneumatic
pressure regulator (ATI Part #9150‑FRL‑4, or equivalent) and a high‑flow valve to properly supply a stable
air supply of 6.2 bar (90 psi) to the drive. See Section 8—Specifications for the maximum flow requirements.
Lubrication is required for the motor. The air supply should be dry and filtered, using a coalescing filter with
elements rated for 30 micron or better.
A second self‑relieving regulator (ATI Part # 9150‑P16‑B‑G, or equivalent) and valve supply the compliance
(centering) mechanism. The compliance air pressure corresponds radially applied force on the file.Adjust
the compliance air pressure and robot traverse speed to achieve the desired finish. The compliance air supply
must be dry. Because very little airflow is required, a significantly smaller valve can be used (consult the
valve and regulator manufacturer’s literature when selecting these components).
If the work piece can be filed with equal force, a conventional manual pressure regulator can be used for
the compliance air supply. If the burrs 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 that is controlled from the robot. An analog output port in the robot or logic controller
will be needed.
All solenoid valves are actuated from the robot or program logic controller by means of a
digital output signal.
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 the equipment.
Table 3.1—Pneumatic Connections
Connection Function Connection Type Pressure Requirement
Pneumatic Drive Inlet 3/8" (10 mm) push‑to‑connect 6.2 bar
(90 psi)
Compliance (Radial) Force Inlet 5/32” (4 mm) quick‑connect tube
1.0–4.1 bar
(15–60 psi)
(Maximum)
Exhaust Vented to atmosphere Not Applicable
The sound level around reciprocating equipment cannot be predicted by ATI because the sound pressure
from reciprocating operations is process and part dependent. To reduce the sound from the cutting operation
in neighboring work 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 range of 1‑4.1 bar (15‑60 psi). When
testing for the proper contact force, start with about 1 bar (15 psi) and increase slowly until the desired
cut is achieved.

Manual, Compliant Reciprocating Tool, CRT Series
Document #9610-50-1028-04
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
14
4. Operation
These operating instructions are intended to help system integrators program, start up, and set up a robotic
reciprocating cell containing a reciprocating tool. The system integrator should be familiar with the task of
reciprocating and have extensive knowledge about automation applications that incorporate robots.
4.1 Safety Precautions
DANGER: Never use the CRT for purposes other than robotic deburring. If used in any
other way, serious injury or damage to equipment may occur.
DANGER: Never use the CRT as a hand‑held machine. If used in this way, serious
injury or damage to equipment will occur.
WARNING: All personnel involved in the operation of the reciprocating 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 reciprocating installation and the CRT.
WARNING: Never operate the CRT product without wearing hearing protection.
High sound levels can occur during cutting. Failure to wear hearing protect
can cause hearing impairment. Always use hearing protection while working in
proximity of the CRT.
WARNING: Never operate the CRT product without wearing eye protection.
Flying debris can cause injury. Always use eye protection while working in the
neighborhood of the CRT.
CAUTION: Do not use files that are rated for less than the speed of the CRT. Using
lower speed files, may cause injury or damage equipment. Always use files rated for at
least the speed of the CRT that is being used.
CAUTION: Never be present near the CRT while it is started or in operation. Flying
debris and rotating parts can cause injury. If it is necessary to approach the CRT while
in motion, stand behind appropriate Plexiglas or Lexan windows. Provide a barrier to
prohibit people from approaching the CRT while in operation.
CAUTION: Never use or start the CRT without first reading and understanding the
operating procedures described in this manual. Never use the CRT for any purposes,
or in any ways, not explicitly described in this document. Using the deburing tool
without fully understanding the installation and operating procedures may cause
injury to personnel or damage to equipment. Mount the CRT and connect the
pneumatic control equipment as described in this manual. Operate the CRT as
described in the manual.

Manual, Compliant Reciprocating Tool, CRT Series
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4.2 Normal Operation
The following sections describe the normal operating conditions for the CRT.
4.2.1 Air Quality
The air supply should be clean, dry, filtered, and lubricated.A coalescing filter that has elements
rated for 30 micron or better is required. The air must be supplied at 6.2 bar (90 psi).
Air quality can affect tool performance substantially. Particulates can block airflow or impede
reciprocating motion. If reciprocating tools do not receive the proper air pressure, the tool stalls.
Any water in the system damages the housing and pneumatic drives.
4.2.2 Lubrication
Lubricate the air supply with 1‑2 drops of commercial air tool oil per minute (SAE
10W recommended).
The CRT should be run with lubrication in the air supply to maximize motor life.
4.2.3 Media Selection, Design, and Maintenance
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 tool that results in premature tool failure.
In many robotic reciprocating applications, including steel and aluminum, no cooling or lubrication
of the rotary file is necessary. For some materials and applications, the addition of coolants or
compressed air may aid the cutting process. If it is determined that liquid coolants are required, a
non‑oil cutting fluid should be used to prevent premature wear of the tool.
4.2.4 Reciprocating Tool Approach Path Should Be Slow and at an Angle
The CRT should approach the workpiece slowly and at an angle.
When beginning a reciprocating 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.
Gouging and premature wear of the tool can occur if the tool perpendicularly approaches the
workpiece too quickly.Additionally, collisions could result and create a hazardous situation for
both personnel and equipment.
4.2.5 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 impact on the positive stop creates "slop" in the compliance and reduces recentering.

Manual, Compliant Reciprocating Tool, CRT Series
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4.3 Reciprocating Tool Working Environment
As described in previous sections, the CRT should only be used in conjunction with a robot in a secured
work cell/chamber.
The work cell must be secured by 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
reciprocating operations.
During system or reciprocating tool maintenance, make sure the CRT and robot are stopped before entering
the robot cell. When installing and testing, never be present in the cell when the CRT is running.
Be aware of rotating parts. Use eye‑protection while working around the CRT.
Be aware of high sound levels. While the CRT air motor is not loud, the cutting action associated with
reciprocating frequently is loud. Always use hearing protection while working in the proximity of the
material removal cell.
The CRT should not be used to remove 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.
4.4 File Operation and File Selection
A family of files is available for working with die cast alloys, aluminum, and plastics; these files have fewer
teeth and increased relief to minimize chip loading.
Plastics represent a difficult deburring challenge due to the phenomenon of chip re‑welding. In this process,
if the file is dull or the settings are not correct for the material, chips will melt and weld to the file or work
piece. This can quickly load a file and produce unacceptable results.
ATI can provide guidance in bur selection; however, only experimentation will yield desired result. The
following table includes files recommended for particular applications.
Table 4.1—File Selection
Materials/Application Features/Benets
3710-50-1459, File, Rectangular
• For steels, plastics, soft metals, wood • General purpose work, accessing deep
cavities
3710-50-1460, File, Round
• For steels, plastics, soft metals, wood • Complex geometries, opening holes or
slots, accessing deep cavities
3710-50-1461, File, Half Round
• For steels, plastics, soft metals, wood • For use on at, concave or convex
surfaces. Great for cylindrical surfaces
3710-50-1462, File, Triangular
• For steels, plastics, soft metals, wood • For acute internal angles or to clear out
square corners

Manual, Compliant Reciprocating Tool, CRT Series
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4.5 Locking and Unlocking Single Axis Compliance
The CRT can be locked to be compliant in a single axis.
Tools required: Flat headed screwdriver
1. Turn the single axis lockout screw as shown in Figure 4.1 for desired compliance.
• Locked = Single axis compliance
• Unlocked = 360° of compliance
Figure 4.1—Single Axis Compliance
Single Axis
Lockout Screw
(Unlocked Position)
Single Axis
Lockout Screw
(Locked Position)

Manual, Compliant Reciprocating Tool, CRT Series
Document #9610-50-1028-04
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
18
5. Maintenance
The CRT is designed to provide reliable service for long periods of operation. While simple in design, there are
parts in the assembly that are not serviceable by the user. The user is encouraged to return the unit toATI for
service. Section 6—Troubleshooting and Service Procedures is provided to assist the user when they choose to
service the unit in the field.
For all service, it is recommended that the air supply (before the solenoid valves) be disconnected. Purge any
trapped air pressure in the lines. It is suggested that the air supply be “locked out” to prevent accidental operation
of the spindle. During maintenance operations, refer to Section 6—Troubleshooting and Service Procedures
for maintenance instructions. Service and repair parts are identified in Section 7—Serviceable Parts and
Section 9—Drawings.
The CRT is of modular construction. The subassemblies shown in Section 9—Drawings may be purchased and
installed quickly to return a unit to operation.
5.1 Pneumatics
The air lines to the reciprocating tools should be checked routinely for their general condition and replaced
as "required". The air to the CRT must be filtered and lubricated. The air filters should be checked and
replaced as required to maintain optimum performance. The life of the filter elements is dependent on the
quality of compressed air at the customer’s facility and therefore cannot be estimated.
5.2 Lubrication
The CRT air motor must be supplied with clean, filtered, and lubricated air. See Section 3.7—Pneumatics for
details on air supply and quality.
CAUTION: It is recommended that the customer use a coalescing filter and filter
elements rated 30 micron or better.
5.3 File Inspection
The file will wear depending on cut depth, feed rate, and the material that is being filed. Inspect the file
regularly for wear and refer to Section 6—Troubleshooting and Service Procedures for symptoms of a worn
file. If necessary, replace the file (refer to Section 6.2.1—File Replacement).
5.4 Spindle Boot Inspection
The spindle boot prevents debris from entering the housing and protects internal components. Inspect the
boot regularly for damage (refer to Section 6.2.3—Boot Replacement).

Manual, Compliant Reciprocating Tool, CRT Series
Document #9610-50-1028-04
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
19
6. Troubleshooting and Service Procedures
CAUTION: Thread locker applied to fasteners must not be used more than once. Fasteners
might become loose and cause equipment damage. Always apply new thread locker when
reusing fasteners.
The CRT is designed to provide reliable service for long periods of operation. While simple in design, there are
parts in the assembly that are not serviceable by the user. The user is encouraged to return the unit toATI for
service. Section 6.1—Troubleshooting is provided to assist the user when they choose to service the unit in the field.
For all service, it is recommended that the air supply be disconnected. Purge any trapped air pressure in the lines.
It is suggested that the air supply be "locked out" to prevent accidental operation during troubleshooting. During
maintenance operations, refer to Section 6.2—Service Procedures for instructions. Service and repair parts are
identified in Section 7—Serviceable Parts and Section 9—Drawings.
6.1 Troubleshooting
Reciprocating process development is an iterative, learning task. The following table is presented to assist in
solving problems.
Table 6.1—Troubleshooting
Symptom Cause Resolution
File wear Hard work material Use better grade burr material add coating (TiAlN) Too heavy a cut Decrease depth of cut, make multiple passes
Feed rate is too slow Increase feed rate
File breakage Too heavy a cut Decrease depth of cut, make multiple passes
Impacting the part Decrease feed rate at contact, enter part at an angle
Unequal compliance
Regulator is defective Replace regulator
Worn ring cylinder Replace ring cylinder. Refer to Section 6.2.2—Ring Cylinder
Assembly Replacement.
Poor nish on work
piece
Feed rate is too fast Reduce feed rate.
File is worn Inspect le if worn, replace. Refer to Section 6.2.1—File
Replacement.
File is chattering
during cut
Feed rate is too fast Reduce feed rate
Lack of rigidity Increase radial compliance pressure
Too heavy a cut Decrease depth of cut, make multiple passes
Improper le selection Choose le designed for work material
File is worn Inspect le. If worn, replace. Refer to Section 6.2.1—File
Replacement.
Secondary burrs
are created on work
piece after cut
Incorrect feed rate Reduce feed rate
Too heavy a cut Decrease depth of cut, make multiple passes
Improper le selection Choose le designed for work material
File is worn Inspect le. If worn, replace. Refer to Section 6.2.1—File
Replacement.
Chip packing of le Too heavy a cut Decrease depth of cut, make multiple passes
Not enough chip clearance Use a le with fewer rasps
File stalls Not enough or no drive air Verify drive air regulator is operating at 90 psi (6.2 bar), and
check for leaks
File is not secure in holder Properly tighten le in holder
Too much side load Decrease depth of cut, make multiple passes

Manual, Compliant Reciprocating Tool, CRT Series
Document #9610-50-1028-04
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
20
6.2 Service Procedures
Component replacement and adjustment procedures are provided in the following section:
CAUTION: During operation of the reciprocating tool, the file reaches high
temperatures. Failure to wear proper personal protection equipment or not allowing
the file to cool could result in serious injury to the user. Be aware that during operation,
the file becomes very hot, and removing the bur, take necessary safety precautions
to avoid injury.
6.2.1 File Replacement
The file becomes worn during normal operation. If improper feeds and speeds are used, the file
may become “loaded” with material. In both instances, replace the file. During initial production,
the file and the workpiece should be examined often in order to determine when the file
should be replaced.
Refer to the following steps for replacing the file (Figure 6.1 on the following page):
Tools required: 2.5 mm hex key
1. Lock‑out and remove the reciprocating drive air supply for safety. De‑energize all energized
circuits such as: air and power.
2. Use a 2.5 mm hex key to loosen the (2) M5 set screws in the body of the file holder.
3. To remove a worn file, pull the file out of the holder by hand.
4. Replace the file.
5. Use a 2.5 mm hex key to tighten the (2) M5 set screws in the body of the file holder securing
the file in place.
6. Safely resume normal operation.