ATI Technologies 9150-RCV-490 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 Multi‑Axis, Radially‑Compliant
Robotic Deburring Tool
(Model 9150‑RCV‑490)
Product Manual
Document #: 9610‑50‑1032

Manual, Robotic Deburring Tool, RCV‑490 Series
Document #9610‑50‑1032‑06
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 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, Robotic Deburring Tool, RCV‑490 Series
Document #9610‑50‑1032‑06
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
3
Table of Contents
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 Tool Collet Systems ...................................................................................................................... 8
2.2 Deburring Tool Part Number Structure ....................................................................................... 8
2.3 Technical Description ................................................................................................................... 8
2.3.1 Environmental Limitations .................................................................................................. 8
2.3.1.1 Operation ............................................................................................................ 8
2.3.1.2 Storage ............................................................................................................... 9
2.3.2 Compliance Unit Performance ........................................................................................... 9
2.3.3 Air Motor Performance ..................................................................................................... 10
3. Installation ...............................................................................................................................11
3.1 Protection During Transportation.............................................................................................. 11
3.2 Inspection of Condition When Delivered .................................................................................. 11
3.3 Unpacking and Handling ............................................................................................................ 11
3.4 Storage and Preventive Maintenance During Storage............................................................. 11
3.5 Side Mounting Installation.......................................................................................................... 12
3.6 Pneumatics .................................................................................................................................. 13
4. Operation ................................................................................................................................ 15
4.1 Safety Precautions ...................................................................................................................... 15
4.2 Normal Operation ........................................................................................................................ 15
4.2.1 Air Quality......................................................................................................................... 15
4.2.2 Lubrication........................................................................................................................ 16
4.2.3 Media Selection, Design, and Maintenance ..................................................................... 16
4.2.4 Deburring Tool Approach Path Should Be Slow and at an Angle ..................................... 16
4.2.5 No Axial Loading .............................................................................................................. 16
4.2.6 Program the Robot to Incorporate 50% Compliance Travel of the Tool ........................... 16
4.3 Deburring Tool Working Environment....................................................................................... 17
4.4 Tool Center Point (TCP) Position and Programming ............................................................... 17
4.5 Bur Operation and Bur Selection............................................................................................... 19
4.5.1 Bur Selection .................................................................................................................... 19
4.6 Locking and Unlocking Single Axis Compliance ..................................................................... 22
5. Maintenance............................................................................................................................ 23
5.1 Pneumatics .................................................................................................................................. 23

Manual, Robotic Deburring Tool, RCV‑490 Series
Document #9610‑50‑1032‑06
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
4
5.2 Lubrication................................................................................................................................... 23
5.3 Bur Inspection ............................................................................................................................. 23
5.4 Spindle Boot Inspection ............................................................................................................. 23
6. Troubleshooting and Service Procedures ........................................................................... 24
6.1 Troubleshooting .......................................................................................................................... 24
6.2 Service Procedures..................................................................................................................... 25
6.2.1 Bur Replacement.............................................................................................................. 25
6.2.2 Air Motor Removal and Installation .................................................................................. 27
6.2.3 Ring Cylinder Assembly Replacement ............................................................................. 29
6.2.4 Muffler Replacement ........................................................................................................ 31
6.2.5 Boot Replacement............................................................................................................ 33
7. Serviceable Parts ................................................................................................................... 34
7.1 Accessories ................................................................................................................................. 34
8. Specifications ......................................................................................................................... 35
9. Drawings ................................................................................................................................. 36
9.1 RCV‑490 Drawing......................................................................................................................... 36
9.2 RCV Pneumatic Diagram ............................................................................................................ 38
10.2 Axial Air Supply Interface Plate ................................................................................................. 39
10. Terms and Conditions of Sale ............................................................................................... 40
10.1 Motor Life and Service Interval Statement................................................................................ 41
10.1.1 Vane Motor Products ........................................................................................................ 41

Manual, Robotic Deburring Tool, RCV‑490 Series
Document #9610‑50‑1032‑06
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 RCV‑490 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. Air lters used in ATI
applications are for the removal particulates (up to 5 microns).
Burr Any unwanted, raised protrusion on the workpiece.
Bur Cutting tool used to remove burs from the workpiece. Alternatively referred to
as a rotary le, bur, or bit.
Climb Milling Cutting method where the direction of bur 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 deviations
of the workpiece.
Conventional Milling Method of cutting where the direction of tool motion is opposite of tool rotation.
Deburr To remove the burrs from a machined piece of machined work.
End‑Effector Tool used by the robot to perform a particular function.
RCV
The ATI series of products that has radial compliance vane motor and can limit
articulation to a single axis for increased rigidity that is parallel to the direction
of bur motion.
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.
Spindle The rotating portion of the RCV‑490 assembly.
Vane‑Type A positive displacement air motor design utilizing partitions (vanes) to separate
expansion regions inside a housing.

Manual, Robotic Deburring Tool, RCV‑490 Series
Document #9610‑50‑1032‑06
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 RCV‑490 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 burs rated for less than the speed of the RCV‑490. Using these
too may cause injury or damage equipment. Always use burs rated for at least the
speed of the RCV‑490.
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 deburring 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 deburring tool product.

Manual, Robotic Deburring Tool, RCV‑490 Series
Document #9610‑50‑1032‑06
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
7
2. Product Overview
ATI Multi‑Axis, Radially‑Compliant Robotic Deburring Tool (RCV‑490) is a robust, high‑speed, and lightweight
vane‑type air motor deburring unit for deburring materials, such as: aluminum, plastic, and steel with a robot. The
RCV‑490 is especially 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 deburring tool’s pneumatically controlled, articulated design allows the cutting bit 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 RCV‑490 has a single axis lockout feature to limit articulation to
a single axis to provide increased rigidity that is parallel to the direction of bur motion. The rigid parallel support is
capable of producing greater control of surface finish and reduced tool chatter. To maintain 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 shaft of the unit and is used to perform consistent deburring
on irregular part patterns. The RCV‑490 utilizes standard industrial tungsten‑carbide bits that allow for adaptation
to changing assembly lines and part requirements.
The RCV‑490 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 RCV‑490 is equipped with at 1/4" NPT push‑to‑connect fitting to supply the motor air and 5/32"
push‑to‑connect fittings to supply the compliance air.
A tool collet system secures the bur. Many collet sizes and bur tools are available to accommodate a wide variety
of applications.
The RCV‑490 can be locked to single axis compliance using the single axis lockout (refer to Section 4.6—Locking
and Unlocking Single Axis Compliance for more information)
Figure 2.1—RCV‑490 Deburring Tool
Compliance Air
Connection
Motor Air Connection
Side Mounting
Single Axis Lockout
Collet

Manual, Robotic Deburring Tool, RCV‑490 Series
Document #9610‑50‑1032‑06
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
8
2.1 Tool Collet Systems
The standard tool holding system for RCV‑490 series of products is an economical, industry standard
ER‑11 collet design. This design is suitable for most applications where industry standard shank diameter
cutting tools are used and run out tolerances of up to 0.001” (0.025 mm) are acceptable. The ER‑11 collet
system is used worldwide on machine tools which allows users to procure different collet sizes from local
industrial supply firms.
All deburring tool products utilize removable collets to grip customer supplied cutting tools. Different collet
diameters may be substituted to retain the various bur 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, wrenches are used to tighten the collet nut causing the collet securing the cutting tool. The air motor
design does not allow the installation of quick‑change or drawbar collet systems.
2.2 Deburring Tool Part Number Structure
For the following part number, 9150‑RCV‑XXX
• “RCV” designates a multi‑axis a tool of radial compliance and vane motor
• “XXX” designates the motor power in Watts
2.3 Technical Description
A technical overview of the product is provided in the following section: For additional technical
specifications (refer toSection 8—Specifications)
2.3.1 Environmental Limitations
2.3.1.1 Operation
Table 2.1—Operation
Installation Position
Mounted to robot by means of 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 RCV‑490.
Temperature Range 5 °C – 35 °C
41 °F – 95 °F
Utilities
The tool requires the following:
• Clean, dry, ltered air. The vane‑type air motor
can be operated with the recommended amount
of air tool oil to the motor air supply.
• A coalescing lter and lter elements that are
rated 5 micron or better.
• Air supply to the spindle must be 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, Robotic Deburring Tool, RCV‑490 Series
Document #9610‑50‑1032‑06
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
9
2.3.1.2 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.
2.3.2 Compliance Unit Performance
The following graph illustrates the variation of compliance force with applied air pressure in the
vertical orientation with the collet 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 RCV‑490 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 bur tool, and the amount of material that is removed.
Figure 2.2—RCV‑490 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, Robotic Deburring Tool, RCV‑490 Series
Document #9610‑50‑1032‑06
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
10
2.3.3 Air Motor Performance
The following graphs illustrate the motor torque and power performance. The air motor operating
speed changes according to the applied load, until the motor develops the power that is required
to perform the specific task. The idle speed of the motor is at maximum when no load is applied.
Without an applied load, the motor decreases to a slower operating speed at which the motor
develops maximum torque. If the torque that is required to perform a specific task exceeds the
maximum available operating speed, the motor will stall. Therefore, multiple light passes are
preferred over slow, heavy cuts.
Figure 2.3—RCV‑490 Motor Power Curves (SAE)
Figure 2.4—RCV‑490 Motor Power Curves (Metric)