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 Radially-Compliant
Robotic Deburring Tools
Flexdeburr™
(Model 9150-RC-151)
Product Manual
US Patent # 7,396,197 B2
UK Patent # GB2,418,631 B
Document #: 9610-50-1014

Manual, Flexdeburr, RC-151 Series
Document #9610-50-1014-07
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 Industrial Automation
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, RC-151 Series
Document #9610-50-1014-07
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
3
Table of Contents
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 ......................................................................................................................8
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 ...........................................................................................9
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.......................................................................................................... 11
3.6 Axial Mounting Installation.........................................................................................................12
3.7 Pneumatics..................................................................................................................................13
4. Operation ................................................................................................................................ 15
4.1 Safety Precautions......................................................................................................................15
4.2.1 Air Quality.........................................................................................................................16
4.2.2 No Lubrication..................................................................................................................16
4.2.3 Bur 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
4.2 Normal Operation........................................................................................................................16
4.3 Flexdeburr Working Environment .............................................................................................17
4.4 Tool Center Point (TCP) Position and Programming...............................................................18
4.5 Cutter Operation and Bur Selection..........................................................................................19
4.5.1 Bur Selection....................................................................................................................20
5. Maintenance............................................................................................................................ 22
5.1 Pneumatics..................................................................................................................................22
5.2 Lubrication...................................................................................................................................22
5.3 Bur Inspection.............................................................................................................................22

Manual, Flexdeburr, RC-151 Series
Document #9610-50-1014-07
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
4
5.4 Spindle Motion Inspection..........................................................................................................22
6. Troubleshooting and Service Procedures ........................................................................... 23
6.1 Troubleshooting Procedures .....................................................................................................23
6.2 Service Procedures.....................................................................................................................24
6.2.1 Bur and Collet Replacement ............................................................................................24
6.2.2 Turbine Motor Replacement.............................................................................................26
6.2.3 Gimbal Bearing Replacement ..........................................................................................31
6.2.4 Ring Cylinder Assembly Replacement.............................................................................32
6.2.5 Rear Housing and Pivot Bearing Replacement................................................................34
6.2.5.1 Rear Housing Replacement..............................................................................34
7. Serviceable Parts ................................................................................................................... 36
7.1 Accessories Tools, and Optional Replacement Parts .............................................................36
8. Specications ......................................................................................................................... 37
9. Drawings ................................................................................................................................. 38
9.1 RC-151 Series Geometry and Mounting....................................................................................38
9.2 RC-151 Series Serviceable Parts...............................................................................................39
10. Terms and Conditions of Sale............................................................................................... 40
10.1 Motor Life and Service Interval Statement...............................................................................41
10.1.1 Turbine Motor Products (Flexdeburr (RC) models)..........................................................41

Manual, Flexdeburr, RC-151 Series
Document #9610-50-1014-07
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
5
Glossary
Term Denition
Adapter Plate Device for attaching the Flexdeburr™ to robots or work surfaces.
Air Filter Device for removing contamination from air supply lines. Typically
refers to removal of particulates.
Bur Cutting tool used to remove 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 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.
-E Euro models.
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 exdeburr tool assembly.
Turbine Motor Turbine motor that drives the spindle.

Manual, Flexdeburr, RC-151 Series
Document #9610-50-1014-07
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
6
1. Safety
The safety section describes general safety guidelines to be followed with this product, explanation 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 notications included here 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,
installation, or setup of 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, good operating practices,
or maintenance tips.
1.2 General Safety Guidelines
Prior to purchase, installation, and operation of the exdeburr product, the customer should rst read and
understand the operating procedures and information described in this manual. Never use the exdeburr 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 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-151 Series
Document #9610-50-1014-07
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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 closely
follow the normal operation procedures outlined in the product manual. Refer to Section 4.2—
Normal Operation. 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, RC-151 Series
Document #9610-50-1014-07
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
8
2. Product Overview
The Radially Compliant (RC) Deburring Tool, also known as exdeburr, is a robust, high-speed and lightweight
turbine motor driven deburring unit for deburring aluminum, plastic, steel, etc. with a robot or CNC machine. The
exdeburr is especially suited for removal of parting lines and ash from parts. However, its exible design allows
it to be used in a wide variety of applications.
The exdeburr’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 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 nish.
The exdeburr also utilizes standard industrial tungsten-carbide bits which allow for adaptation to changing
assembly lines and part requirements.
The RC-151 series provides for two mounting types—side and axial mounting. The side mounting provides two
locating dowel pins and four 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 RC-151 series is equipped with (2) 1/8 NPT ports to supply the motor and compliance air (-E models are
equipped with (2) 1/8 BSPP ports).
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. The RC-151 series is equipped with a 1/8’’ standard collet, (-E models
are equipped with a 3mm collet).
Figure 2.1—RC-151 Series Flexdeburr Tool
Tool Collet System
Side Mounting
Air Block
Compliance Air Connection
Axial
Mounting
Motor Air Connection
2.1 Tool Collet Systems
A collet system secures the bur to the tool. Various collet sizes are available to accomodate a wide variety of
applications.
All exdeburr 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 quick-change or drawbar collet systems.
The standard tool holding system for exdeburr products is an economical, proprietary, single-angle collet
design utilizing multiple 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.

Manual, Flexdeburr, RC-151 Series
Document #9610-50-1014-07
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
9
2.2 Technical Description
A general description of the exdeburr product is provided in Section 2—Product Overview. The technical
overview of the product is provided below.
2.2.1 Environmental Limitations
2.2.1.1 Operation
Installation
position
Mounted to robot by means of the side mounting
pattern or rear adapter ange. Refer to Section 3.4—
Storage and Preventive Maintenance during Storage
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 9.2—RC-151 Series Geometry and Mounting.
Mounted to machining center by various means,
customer-supplied tool holders/adapters.
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.
• Air supplied to the spindle at 6.2 bar (90 psi).
• The radial compliance (centering) air must be
supplied from a regulated source between 1.4-4.2
bar (20-60 psi).
2.2.1.2 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.

Manual, Flexdeburr, RC-151 Series
Document #9610-50-1014-07
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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2.2.2 Compliance Unit Performance
The charts below illustrate the variation of compliance force with applied air pressure.
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 exdeburr 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 will attempt 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-151 Series Compliance Force Curves (Measured at the Spindle Tip)

Manual, Flexdeburr, RC-151 Series
Document #9610-50-1014-07
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
11
3. Installation
The RC-151 series exdeburr tools are 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 exdeburr tool is packaged in a crate designed to secure and protect it during transportation. Always use
the crate when transporting the exdeburr tool in order to minimize the risk of damage.
3.2 Inspection of Condition When Delivered
Upon receipt, the following should be checked:
• Delivery in accordance with freight documents.
• Damage to packaging.
If there is damage to any of the packaging, or if any of the goods have been exposed to abnormal handling,
unpack the parts that may have been damaged for closer inspection. If necessary, notify ATI for assistance in
evaluation of the product condition.
3.3 Unpacking and Handling
The exdeburr tool should always be placed inside the accompanying box (crate) during transportation,
storage 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 exdeburr tool should be stored in its crate when it is not in use. The exdeburr tool should also be
stored in a dry place.
For long-term storage, the exdeburr tool should be thoroughly cleaned of any burrs or debris. It should not
be disassembled. Place the exdeburr tool inside a sealed plastic bag inside the crate.
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
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 features. Liquid thread
lockers should not be used for the mounting hardware as this may damage or remove
thread inserts during disassembly.

Manual, Flexdeburr, RC-151 Series
Document #9610-50-1014-07
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
12
The side mounting pattern of the exdeburr tool consists of (2) dowel pin holes and a number of threaded
holes. The maximum fastener length specied must not be exceeded lest the fasteners interfere with the
compliant motion of the turbine motor spindle. The exdeburr tool’s side mounting feature requires a bench
mount adapter plate, available from ATI (9005-50-1054). Refer to Section 9.2—RC-151 Series Geometry
and Mounting for more information.
Figure 3.1—Bench (Side) Installation
Side Mounting
on Front Housing
Assembly
(6) M4 Socket Head
Cap Screw
(2) Lock Washer
Benchtop Adapter
Plate Assembly (4) 4 mm Dowel
(9005-50-1054)
3.6 Axial Mounting Installation
A blank robot adapter plate is also available to allow axial mounting off the rear of the exdeburr tool
housing. This plate may be modied by the system integrator or by the owner/user of the exdeburr tool.
ATI can provide custom interface plates and adapters upon request. An optional bench mount adapter plate
allows the exdeburr tool to be permanently attached to a bench or other work surface. If the exdeburr tool
is permanently mounted to a work surface, the robot carries the part to be deburred to the exdeburr tool.
The axial mounting requires a clamping collar kit which includes the blank rear adapter plate. The kit is
available from ATI (9005-50-1005). Refer to Section 9.2—RC-151 Series Geometry and Mounting for more
information.
Figure 3.2—Axial Installation (Model shown for reference)
(2) M5 Socket
Head Cap Screw
Clamping Collar
Blank Rear
Adapter Plate
Axial Mounting Flange on
Flexdeburr Tool Rear Housing

Manual, Flexdeburr, RC-151 Series
Document #9610-50-1014-07
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
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3.7 Pneumatics
Connect the exdeburr tool as shown:
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 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 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.
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 exdeburr
tool. ATI recommends that the user install a high-ow pneumatic pressure regulator (ATI Part Number 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 6.2 bar (90 psi) to the spindle motor. The exdeburr tool will
not operate properly if the supplied air is below 6.2 bar (90 psi).
A second, precision, self-relieving regulator (ATI Part Number 9150-P16-B-G or equivalent) and valve
are used to supply the compliance (centering) mechanism. This pressure corresponds to the side force on
the rotary bur. Very little airow is required for the compliance mechanism. This allows for a signicantly
smaller valve to be used. The regulator is available fromATI upon request. Consult the valve and regulator
supplier’s literature when selecting these components).

Manual, Flexdeburr, RC-151 Series
Document #9610-50-1014-07
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
14
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-RC-151 Series) 1/8 NPT Port for customer connection
(1/8 BSPP motor air for -E models) 6.2 bar [90 psi]
Compliance (Radial) Force
Inlet
(9150-RC-151 Series)
1/8 NPT Port for customer connection
(1/8 BSPP compliance air for -E models)
1.4–4.2 bar
(Maximum)
[20–60 psi]
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 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 1.4-4.2 bar (20–60 psi) range. When testing for the proper contact
force, start with a very low pressure and increase slowly until the desired cut is achieved.

Manual, Flexdeburr, RC-151 Series
Document #9610-50-1014-07
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
15
4. Operation
These operating instructions are intended to help system integrators program, start up, and complete a robotic
deburring cell containing a exdeburr tool. The system integrator should be familiar with the task of deburring, in
general, and should have extensive knowledge relating to robots and automation incorporating robots.
4.1 Safety Precautions
WARNING: Never operate the exdeburr tool 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 exdeburr tool.
WARNING: Never operate the exdeburr tool without wearing eye protection. Flying
debris can cause injury. Always use eye protection while working in the neighborhood
of the exdeburr tool.
CAUTION: Do not use burs rated for less than the speed of the exdeburr tool being
used as it may cause injury or damage equipment. Always use burs rated for at least
the speed of the exdeburr 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 exdeburr tool while it is started or in operation.
Flying debris and rotating parts can cause injury. If it is necessary to approach the
exdeburr tool while in motion, stand behind appropriate Plexiglas windows. Provide a
barrier to prohibit people from approaching the exdeburr tool while in operation.
CAUTION: Never use or start the exdeburr tool without rst reading and
understanding the operating procedures described in this manual. Never use the
exdeburr tool for any purposes, or in any ways, not explicitly described in this
document. Using the exdeburr tool without fully understanding the installation and
operating procedures may cause injury to personnel or damage to equipment. Mount
the exdeburr tool and connect the pneumatic control equipment as described in this
manual. Operate the exdeburr tool as described in the manual.

Manual, Flexdeburr, RC-151 Series
Document #9610-50-1014-07
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
16
4.2 Normal Operation
The following sections describe the normal operating conditions for RC 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 not 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.
RC tools have higher operating speeds and the media must be rated to at least the RC idle speed.
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 results in axial loading on the RC 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 cutting bit. 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 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 impacts on the positive stop create slop in the compliance and reduce recentering
repeatability.

Manual, Flexdeburr, RC-151 Series
Document #9610-50-1014-07
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
17
4.3 Flexdeburr Working Environment
As described in previous sections, the RC 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 RC 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.
4.4 Tool Center Point (TCP) Position and Programming
Figure 4.1 shows the exdeburr tool dimensions. The exdeburr tool provides radial compliance and
performs best when the cuts taken are not excessively deep. The exdeburr tool spindle must never be
running while programming the robot. During teaching, the compliance air must be on and supplied above a
minimum of 1.4 bar (20 psi).
Two programming methods include, but are not limited to, the following suggestions: in the rst method,
a dowel pin of suitable diameter is installed to the exdeburr in place of a cutting tool. The dowel will
simulate the cutter shank diameter when teaching the robot path—i.e., for 1/8’’ collets, a 1/8’’ diameter
dowel pin of suitable length will be inserted in the tool’s collet. With this method, the diameter of the cutter
installed after teaching should not exceed that of the dowel pin by more than the compliance of the RC
deburring tool. The dowel pin should extend a sufcient distance from the collet to reach the surface on the
burr where cutting is desired (see Figure 4.1).
Another programming method is to teach the path using the center line of the bur as a guide, following the
edge of the part, then manually or automatically add offsets to the robot path points to achieve the coreect
nal burr 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

Manual, Flexdeburr, RC-151 Series
Document #9610-50-1014-07
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
18
Figure 4.2— Flexdeburr Pointed Teaching Tool
Inside corners present a complex situation for compliant exdeburr tools. The cutter must not be allowed to
simultaneously contact both perpendicular surfaces of an inside corner. The resulting force imbalance in two
planes will cause severe tool chatter. The customer is advised to create a tool path that will prevent the cutter
from simultaneously contacting two perpendicular surfaces. For example, a tapered cutter may reach further
into an inside corner if the tool is oriented at an incline and the corner is contacted by the extreme tip of the
tool (Note: When working near the tip of a tapered cutter, the surface cutting speed is reduced).
When deburring inside radii, a similar situation may arise. No attempt should be made to deburr an inside
radius less than 1.5 times the diameter of the cutter in use (Rmin = 1.5 x Cutter diameter). Failing to follow
these guidelines may cause excessive cutter contact, resulting in excessive tool chatter.
The speed at which the robot is programmed should always correspond with the speed at which the
exdeburr tool is utilized.When the robot path speed is increased, note that the robot may deviate from the
programmed path. When running the robot program the rst time, turn the radial compliance air supply
down to approximately 1.4 bar (20 psi) and observe the exdeburr tool’s path when the robot program is
run, to verify the bur is deected but also contacts the work surface at operational robot path speed. Once
this is conrmed, the compliance force of the bur can be adjusted (as described in Section 3.7—Pneumatics )
in order to achieve a correct depth of cut.
4.5 Cutter Operation and Bur Selection
The exdeburr tool will perform best in ‘climb milling,’ when the cutter’s traverse and rotational direction
are the same. In the case of the exdeburr tools, the cutter rotation is clockwise when viewed from above.
Climb milling would therefore involve clockwise motion around the part being deburred. In climb milling,
the heaviest cut is made as the tool enters the work piece and the chip becomes narrower as the cut is
completed. In ‘conventional milling’, the cutter travels in a direction opposite of cutter rotation. This may
aid in cutter stability for some operations; however, the cutting edge of the tool is subjected to higher friction
and cutting forces. Tool wear is accelerated in this mode and surface nish quality will generally be reduced.
In conventional milling extra care must be taken around corners. This poses a potential hazard where the
cutting force can deect the bur causing it to break as the robot continues along its path.
The selection of a cutting tool is highly dependent upon the part’s material and geometry as well as the
depth of cut. It is not practical to present all the possibilities in this document. Please see Section 4.5.1—Bur
Selection for a short list of burs and suitable applications. Addtionally, a specic family of burs is available
for working with die cast alloys, aluminum, and plastics. These cutters have fewer teeth and increased relief
to minimize chip loading.
Plastics present the most difcult exdeburr challenge due to the phenomenon of chip re-welding. This
occurs if the cutter is dull or the feeds and speeds are not correct for the material removed, causing the chip
to melt and weld to the cutter or the work piece. Chip re-welding can quickly load a cutter and produce
unacceptable results. Generally, the traverse or feed rate of the exdeburr tool will be higher for plastics to
minimize this behavior. This results in larger cuts, which more effectively remove heat from the cutter-tool
interface.

Manual, Flexdeburr, RC-151 Series
Document #9610-50-1014-07
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
19
4.5.1 Bur Selection
Standard length commercial burs are used with Flexdeburr products. The length of these tools is
typically around 2” for 1/4” shank diameter burs (50 mm for 6 mm diameter). Avoid the longer
shank burs available from industrial suppliers that appear in catalogs desrcibed as, “long” or
“extended” shank. Using extended or long shank burs in the exdeburr will place higher loads and
vibrations on the motor bearings resulting in reduced motor life. Bearing failure caused by the use
of extended shank burs is not covered under the warranty.
CAUTION: DO NOT use long or extended shank burs with the Flexdeburr.
Long shank tools can lead to premature failure of the turbine motor and is not
covered under warranty.
ATI can provide guidance in bur selection; however, only experimentation will yield the results
desired. The following table is presented to assist in burr selection.
The table is not comprehensive but includes many common bur types and burs recommended for
particular applications.
Table 4.1—Bur Selection
Materials/Application Features/Benets:
9150-RC-B-17203 - Double Cut, 1/8” Bur Diameter, 9/16” Burr Length, 1/8” Shank
• For hardened and tough materials,
super alloys, stainless steel, alloyed
cast steel and ber reinforced
plastics.
• Edge and surface working.
• Built up Welds of high-tensile strength
in mold and die making.
• Higher cutting capacity than
standard cuts.
• Smoother nish for surface
treatments.
9150-RC-B-17903 - Double Cut, Flame, 1/8” Burr Diameter, 1/4” Bur Length, 1/8”
Shank
• Universal Use.
• For ferrous and Non-ferrous metal,
plastics.
• Rough nishing of castings
• Surface working.
• Weld removal.
• Brazed welds.
• Smoother operation.
• Improved tool control.
• High cutting action.
• Non-clogging.
• Smaller chips, reduced slivers.
• Even, smooth surfaces.
9150-RC-B-18053 - Double Cut, 1/8” Burr Diameter, 9/16” Bur Length, 1/8” Shank
• For hardened and tough materials,
super alloys, and stainless steel,
alloyed cast steel and ber reinforced
plastics.
• Edge and surface working.
• Higher cutting capacity than
standard cuts
• Smoother nish for surface
treatments.
9150-RC-B-73003 - Cut, 1/8” Burr Diameter, 1/2” Bur Length, 1/8” Shank
• For trimming and contour milling of
all glass and carbon ber reinforced
plastics
• Special cut geometry allows high
feed rates due to low cutting
forces.

Manual, Flexdeburr, RC-151 Series
Document #9610-50-1014-07
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
20
5. Maintenance
The exdeburr tool is designed to provide reliable service for long periods of operation. While simple in design,
there are few user serviceable parts in the assembly. 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 eld.
For all service, it is recommended that the air supply (before the solenoid valves) be disconnected. Drain 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 identied in Section 6—Troubleshooting and Service
Procedures and Section 7—Serviceable Parts.
5.1 Pneumatics
The air lines to the exdeburr tools should be routinely checked for their general condition and replaced as
required. The air to the exdeburr must be ltered, dry, and non-lubricated. The air lters should be checked
and replaced as required to maintain optimum performance. The life of the lter elements is dependent on
the quality of compressed air at the customer’s facility and therefore cannot be estimated.
5.2 Lubrication
Lubrication systems are not to be used. The exdeburr turbine motor must be supplied with clean, dry,
ltered air. Oil in the air stream will cause the turbine motor to fail prematurely. Failure of the motor due to
oil in the air stream is not covered under the warranty. See Section 3.7—Pneumatics for details on air supply
and quality.
CAUTION: DO NOT use lubricated air with the exdeburr. Oil in the air stream will
result in the 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 rated 5
micron or better.
5.3 Bur Inspection
The bur will wear depending on cut depth, feed rate, and material being deburred. Inspect the bur regularly
for wear and refer to Section 6—Troubleshooting and Service Procedures for symptoms of a worn bur.
5.4 Spindle Motion Inspection
The pivot bearing allows articulation of the motor assembly. The pivot bearings in the gimbal ring and the
pivot pins in the housing are subject to wear; both components should be replaced when excessive spindle
motion is observed. Refer to Section 6.2.4—Ring Cylinder Assembly Replacement