ATI Technologies Flexdeburr 9150-RC-300 Series 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 Radially‑Compliant
Robotic Deburring Tools
Flexdeburr™
(Model 9150‑RC‑300 and ‑340 Series)
Manual
US Patent # 6,974,286 B2
Document #: 9610‑50‑1019

Manual, Flexdeburr, RC‑300 and RC‑340 Series
Document #9610‑50‑1019‑07
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]
Applications Tel: [phone]
Fax: [phone]
E‑mail: applicationsengineers@ati‑ia.com

Manual, Flexdeburr, RC‑300 and RC‑340 Series
Document #9610‑50‑1019‑07
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........................................................................................................................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...............................................................................................................9
2.2.2 Compliance Unit Performance .........................................................................................10
3. Installation ...............................................................................................................................11
3.1 Transportation and 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 Axial Mounting Installation.........................................................................................................13
3.7 Pneumatics..................................................................................................................................14
4. Operation ................................................................................................................................ 16
4.1 Safety Precautions......................................................................................................................16
4.2 Normal Operation........................................................................................................................17
4.2.1 Air Quality.........................................................................................................................17
4.2.2 No Lubrication..................................................................................................................17
4.2.3 Bur Selection, Design, and Maintenance.........................................................................17
4.2.4 Deburring Tool Approach Path Should be Slow and at an Angle .....................................17
4.2.5 No Axial Loading ..............................................................................................................17
4.2.6 Program the Robot to Incorporate 50% Compliance Travel of the Tool ...........................17
4.3 Flexdeburr Working Environment .............................................................................................18
4.4 Tool Center Point (TCP) Position and Programming...............................................................19
4.5 Cutter Operation and Bur Selection..........................................................................................21
4.5.1 Bur Selection....................................................................................................................21

Manual, Flexdeburr, RC‑300 and RC‑340 Series
Document #9610‑50‑1019‑07
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
4
5. Maintenance............................................................................................................................ 24
5.1 Pneumatics..................................................................................................................................24
5.2 Lubrication...................................................................................................................................24
5.3 Bellows Boot Inspection.............................................................................................................24
5.4 Bur Inspection.............................................................................................................................24
5.5 Spindle Motion Inspection..........................................................................................................24
6. Troubleshooting and Service Procedures........................................................................... 25
6.1 Troubleshooting Procedures .....................................................................................................25
6.2 Service Procedures.....................................................................................................................26
6.2.1 Bur and Collet Replacement ............................................................................................26
6.2.2 Rear Housing and Pivot Bearing Replacement................................................................28
6.2.2.1 Rear Housing Replacement..............................................................................28
6.2.2.2 Pivot Bearing and Keying Dowel Replacement ................................................30
6.2.3 Turbine Motor Replacement.............................................................................................33
6.2.4 Ring Cylinder Assembly Replacement.............................................................................37
6.2.5 Tapered Bellows Boot Replacement ................................................................................40
7. Serviceable Parts ................................................................................................................... 41
7.1 Accessories Tools, and Optional Replacement Parts .............................................................41
8. Specifications......................................................................................................................... 42
9. Drawings ................................................................................................................................. 43
9.1 RC‑300 Series Geometry and Mounting....................................................................................43
9.2 RC‑300 Series Serviceable Parts...............................................................................................44
10. Terms and Conditions of Sale............................................................................................... 46
10.1 Motor Life and Service Interval Statement................................................................................47
10.1.1 Turbine Motor Products (Flexdeburr (RC) models)..........................................................47

Manual, Flexdeburr, RC‑300 and RC‑340 Series
Document #9610‑50‑1019‑07
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 deburring tool to either a robot ange or a stationary
mounting surface.
Air Filter Device for removing contamination from air supply lines. Typically refers to removal
of particulates.
Burr Any unwanted, raised protrusion on the work piece.
Bur Cutting tool used to remove burrs from the work piece. Alternatively referred to as a
rotary le, cutter, or bit.
Climb Milling Cutting method where the direction of cutter rotation and tool motion are the same.
Coalescing Filter Device designed to remove liquid aerosols from the supply air lines.
Collet Gripping device used to hold cutting tools in the spindle.
Compliance The ability of the spindle to passively move in response to protrusions on or
deviations of the work piece.
Conventional Milling Method of cutting where the direction of tool motion is opposite that of tool rotation.
End‑Effector Tool used by the robot to perform a particular function.
Front Housing The main cylindrical body of the unit which includes the mounting features.
RC Radially‑Compliant.
Rear Housing Rear cover to the front housing. The body includes a compliance and spindle air
supply tting.
Regulator Device used to set and control the supplied air pressure to lower acceptable levels.
Solenoid Valve Electrically controlled device for switching air supplies on and off.
Spindle The rotating portion of the deburring tool assembly.
Turbine Air motor that drives the spindle.
‑E Euro models.

Manual, Flexdeburr, RC‑300 and RC‑340 Series
Document #9610‑50‑1019‑07
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).
The safety section describes general safety guidelines to be followed with this product, explanation of the
notifications found in this manual, and safety precautions that apply to the product. More specific notifications are
imbedded within the sections of the 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
Prior to purchase, installation, and operation of the Flexdeburr product, the customer should first read and
understand the operating procedures and information described in this manual. Never use the deburring tool
for any purposes, or in any ways, not explicitly described in this manual. Follow installation instructions and
pneumatic connections as described in this manual.
All pneumatic fittings and tubing must be capable of withstanding the repetitive motions of the application
without failing. The routing of pneumatic lines must minimize the possibility of stress/strain, kinking,
rupture, etc. Failure of critical pneumatic lines to function properly may result in equipment damage.

Manual, Flexdeburr, RC‑300 and RC‑340 Series
Document #9610‑50‑1019‑07
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
7
1.3 Safety Precautions
WARNING: Never operate the Flexdeburr product without wearing hearing protection.
High sound levels can occur during cutting. Failure to wear hearing protection can
cause hearing impairment. Always use hearing protection while working in the
neighborhood of the deburring tool.
WARNING: Never operate the Flexdeburr product without wearing eye protection.
Flying debris can cause injury. Always use eye protection while working in the
neighborhood of the deburring tool.
CAUTION: Do not use burs rated for less than the speed of the RC deburring tool
being used. Using these too may cause injury or damage equipment. Always use burs
rated for at least the speed of the RC deburring tool being used.
CAUTION: Do not use spare parts other than original ATI spare parts. Use of spare
parts not supplied by ATI can damage equipment and void the warranty. Always use
original ATI spare parts.
CAUTION: Never be present near the deburring tool while it is started or in operation.
Flying debris and rotating parts can cause injury. If it is necessary to approach the
deburring tool while in motion, stand behind appropriate Plexiglas windows. Provide a
barrier to prohibit people from approaching the deburring tool while in operation must
secure the installation.
CAUTION: Do not perform maintenance or repair on the Flexdeburr product unless the
tool is safely supported or docked in the tool stand and air has been turned off. Injury
or equipment damage can occur with tool not docked and air on. Dock 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 filtered to remove particulates and moisture. Exposing the turbine motors to oil in
the air supply results in premature failure.

Manual, Flexdeburr, RC‑300 and RC‑340 Series
Document #9610‑50‑1019‑07
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
8
2. Product Overview
The Radially Compliant (RC) deburring tool, also known as Flexdeburr, is a robust, high‑speed and lightweight
turbine driven deburring unit for deburring aluminum, plastic, steel, etc. with a robot or CNC machine. The RC
deburring tool is especially suited for removal of parting lines and flash from parts. However, its flexible design
allows it to be used in a wide variety of applications.
The RC deburring tool’s pneumatically controlled, articulated design allows the cutting bit to follow the part
profile and compensate for surface irregularities while maintaining a constant, settable force. This allows high feed
rates with uniform quality in any orientation. The tool also requires no oil, allowing clean exhaust air to be vented
directly into the work environment.
Compliance is supported by air pressure applied to the shaft of the unit and is used to perform consistent deburring
on irregular part patterns. The motor’s internal governor maintains high spindle speeds for optimum surface
finish. The RC deburring tool also utilizes standard industrial tungsten‑carbide bits which allows for adaptation to
changing assembly lines and part requirements.
The RC‑300 and RC‑340 series 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 flange that
requires an adapter plate. Custom adapter plates for both side and axial mounting are available from ATI. Refer to
Section 9—Drawings for more information.
The RC‑300 and RC‑340 series is equipped with a 3/8" Push‑to Connect fitting to supply the motor air (for ‑E
models ATI supplies an adapter from 3/8” to 8 mm) and a 5/32" (4 mm) Push‑to Connect fitting to supply the
compliance air.
A tool collet system secures the cutting bur. Many collet sizes and a various selection of tools are available to
accommodate a wide variety of applications.
Figure 2.1—RC‑300 Series Deburring Tool
Tool Collet System
Side Mounting
Spindle Air
Supply Fitting
Compliance Air
Fitting
Axial
Mounting
Tapered Bellows
Boot

Manual, Flexdeburr, RC‑300 and RC‑340 Series
Document #9610‑50‑1019‑07
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
9
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 or bur 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 air motor design does not allow the installation of quick‑change or drawbar collet systems.
The standard tool holding system for Flexdeburr products is an economical, proprietary, single‑angle collet
design utilizing multiple gripping fingers. 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
The technical overview of the product is provided in the following tables and graphs. 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 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—RC‑300 Series
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).
2.2.1.2 Storage
Table 2.2—Storage
Temperature
range 5°C–35°C 41°F–95°F
Conditions
The tool should be stored in its crate and in a
dry place.
When not in use, keep the unit in its crate if possible.
Consult Section 3.4—Storage and Preventive
Maintenance during Storage of this manual.

Manual, Flexdeburr, RC‑300 and RC‑340 Series
Document #9610‑50‑1019‑07
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati‑ia.com
10
2.2.2 Compliance Unit Performance
The graphs in Figure 2.2 illustrate the variation of compliance force with applied air pressure in the
vertical orientation with the collet pointed toward the ground. Measurements may vary from one
product to another and should only be treated as nominal.
The actual force characteristics are dependent on mounting orientation and condition of the unit. In
applications, where the deburring tool is mounted horizontally, additional compliance air pressure
is required to overcome the weight of the motor. Compliance pressure is also dependent upon the
material of the work piece, type of bur tool, and the amount of material that is removed.
The turbine motor attempts to maintain its full rated speed even under loaded conditions. However,
when extremely heavy cuts are taken, the motor may eventually stall. Therefore, multiple, light
passes are preferred over slow, heavy cuts.
Figure 2.2—RC‑300 and RC‑340 Series Compliance Force Curves (Measured at the Spindle Tip)
0
1
2
3
4
5
6
7
8
9
10
10 20 30 40 50 60 70
RadialForce (lbs)
Compliance Air Pressure (PSI)
0
10
20
30
40
50
1.0 2.0 3.0 4.0 5.0
RadialForce (N)
Compliance Air Pressure (Bar)