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]
10
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)