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ATI Technologies Flexdeburr User's Product Manual

Ati radially-compliant robotic deburring tools
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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
Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1.919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com

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  • Page 1 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 Engineered Products for Robotic Productivity Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1.919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com...
  • Page 2 Manual, Flexdeburr, RC-151 Series Document #9610-50-1014-07 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.

  • Page 3: Table Of Contents

    4.2.6 Program the Robot to Incorporate 50% Compliance Travel of the Tool ......16 Normal Operation ........................16 Flexdeburr Working Environment ..................... 17 Tool Center Point (TCP) Position and Programming ............... 18 Cutter Operation and Bur Selection ..................19 4.5.1 Bur Selection ........................
  • Page 4 10.1 Motor Life and Service Interval Statement ................41 10.1.1 Turbine Motor Products (Flexdeburr (RC) models) ............41 Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1.919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com...
  • Page 5 Glossary Definition Term 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. Cutting tool used to remove burrs from the work piece. Alternatively referred to as a rotary file, cutter, or bit.

  • Page 6: Safety

    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 flexdeburr 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.

  • Page 7: Safety Precautions

    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.

  • Page 8: Product Overview

    CNC machine. The flexdeburr 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.

  • Page 9: Technical Description

    Manual, Flexdeburr, RC-151 Series Document #9610-50-1014-07 2.2 Technical Description A general description of the flexdeburr 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 Mounted to robot by means of the side mounting pattern or rear adapter flange.

  • Page 10: Compliance Unit Performance

    The actual force characteristics are dependent on mounting orientation and condition of the unit. In applications where the flexdeburr 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.

  • Page 11: Installation

    3.4 Storage and Preventive Maintenance during Storage The flexdeburr tool should be stored in its crate when it is not in use. The flexdeburr tool should also be stored in a dry place.

  • Page 12: Axial Mounting Installation

    Manual, Flexdeburr, RC-151 Series Document #9610-50-1014-07 The side mounting pattern of the flexdeburr tool consists of (2) dowel pin holes and a number of threaded holes. The maximum fastener length specified must not be exceeded lest the fasteners interfere with the compliant motion of the turbine motor spindle.

  • Page 13: Pneumatics

    6.2 bar (90 psi) to the spindle motor. The flexdeburr tool will not operate properly if the supplied air is below 6.2 bar (90 psi).
  • Page 14 Manual, Flexdeburr, RC-151 Series Document #9610-50-1014-07 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.

  • Page 15: Operation

    These operating instructions are intended to help system integrators program, start up, and complete a robotic deburring cell containing a flexdeburr 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.

  • Page 16: Air Quality

    Manual, Flexdeburr, RC-151 Series Document #9610-50-1014-07 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, filtered, and free of oil. A coalescing filter with elements rated for 5 micron or better is required.

  • Page 17: Flexdeburr Working Environment

    Two programming methods include, but are not limited to, the following suggestions: in the first method, a dowel pin of suitable diameter is installed to the flexdeburr 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.

  • Page 18: Cutter Operation And Bur Selection

    The flexdeburr tool will perform best in ‘climb milling,’ when the cutter’s traverse and rotational direction are the same. In the case of the flexdeburr 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.

  • Page 19: Bur Selection

    “long” or “extended” shank. Using extended or long shank burs in the flexdeburr 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.

  • Page 20: Maintenance

    5. Maintenance The flexdeburr 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 to ATI for service.

  • Page 21: Troubleshooting And Service Procedures

    6. Troubleshooting and Service Procedures The flexdeburr 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 should return the unit to ATI for service.

  • Page 22: Service Procedures

    2. If applicable, disconnect the air hose from the compliance and turbine motor supply air fitting. Remove the flexdeburr tool from the robot or work piece. Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1.919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com...
  • Page 23 Collet Collet Nut CAUTION: During operation of the flexdeburr tool, the bur reaches high temperatures. Failure to wear proper personal protection equipment or not allowing the bur to cool, could result in serious injury to the user. Be aware that during operation, the bur becomes very hot, and when removing the bur, take necessary safety precautions to avoid injury.

  • Page 24: Turbine Motor Replacement

    There are no user serviceable parts in the turbine motor. Flexdeburr units with defective motors should be returned to ATI during the warranty period. Motors are sold as complete, modular assemblies to simplify and expedite user installation.
  • Page 25 Manual, Flexdeburr, RC-151 Series Document #9610-50-1014-07 6. Ease the garter spring off the front boot. 7. Remove the (6) M3 button head screws from the boot ring using a 2 mm Allen wrench. Remove the boot ring securing the boot to the front of the unit.
  • Page 26 Manual, Flexdeburr, RC-151 Series Document #9610-50-1014-07 Figure 6.3— Turbine Motor Assembly Removal Air Supply Ring Gimbal Ring Turbine Motor Pivot Pin Front Housing M3 Set Screw 17. Loosen the (3) M3 set screws from the air supply ring using a 1.5 mm Allen wrench.
  • Page 27 Manual, Flexdeburr, RC-151 Series Document #9610-50-1014-07 23. Reassembly: Coat the wave spring with light grease and place it on the shoulder inside the gimbal ring prior to sliding the motor assembly in place. The grease will hold the spring in position during this step.
  • Page 28 Manual, Flexdeburr, RC-151 Series Document #9610-50-1014-07 28. Locate and align the axial scribe marks on the gimbal ring and air supply ring. 29. Slide the air supply ring down the motor body. The air tubes from step will enter the seals on the inner face of the air supply ring.
  • Page 29 Manual, Flexdeburr, RC-151 Series Document #9610-50-1014-07 37. Lubricate the counterbore of the air supply block and insert the O-ring seal within the counterbore. 38. Install the air supply block to the flat of the housing. 39. Apply Loctite 7649 Primer and Loctite 222 to the threads of the (2) M4 socket head cap screws that secure the air supply block to the housing.

  • Page 30: Gimbal Bearing Replacement

    2. Disconnect any air hoses from the turbine motor supply air fitting. 3. Remove the flexdeburr tool from the robot or work location. 4. Clean the debris from the flexdeburr tool using compressed air and a clean rag to wipe any grease from the outer surfaces.

  • Page 31: Ring Cylinder Assembly Replacement

    2. Disconnect the air hose from the compliance and spindle supply air fitting. 3. Remove the flexdeburr tool from the robot or work location. 4. Remove the turbine motor assembly. Refer to Section 6.2.2—Turbine Motor Replacement steps through 16.
  • Page 32 Manual, Flexdeburr, RC-151 Series Document #9610-50-1014-07 7. Invert the unit and press the ring cylinder assembly outwards to the rear, removing the cylinder from the housing. Use a non-metallic drift (plastic or wooden rod) to prevent damage. (It may be necessary to use a small arbor press and support plate to remove the ring cylinder if the unit has been in service for a prolonged time).

  • Page 33: Serviceable Parts

    7. Serviceable Parts For repair and spare parts please contact ATI. Refer to Section 9.2—RC-151 Series Geometry and Mounting exploded drawings showing all the user replaceable components of the Flexdeburr. Available accessories, tools, and optional replacement parts are listed below.

  • Page 34: Specifications

    Manual, Flexdeburr, RC-151 Series Document #9610-50-1014-07 8. Specifications Table 8.1—RC-151 Series Specifications Parameter Rating Motor Type Turbine Motor Part Number 3490-0001026-01 Motor Series 201JSL Idle Speed (RPM) 65,000 Power 150 W (0.20 hp) @ 65,000 RPM Weight (without Adapter) 2.4 lbs (1.1 kg) +/-5 mm max., +/-2.5 mm recommended...

  • Page 35: Drawings

    Manual, Flexdeburr, RC-151 Series Document #9610-50-1014-07 9. Drawings 9.1 RC-151 Series Serviceable Parts Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1.919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com...

  • Page 36: Rc-151 Series Geometry And Mounting

    Manual, Flexdeburr, RC-151 Series Document #9610-50-1014-07 9.2 RC-151 Series Geometry and Mounting Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1.919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com...

  • Page 37: Terms And Conditions Of Sale

    Manual, Flexdeburr, RC-151 Series Document #9610-50-1014-07 10. Terms and Conditions of Sale The following Terms and Conditions are a supplement to and include a portion of ATI’s Standard Terms and Conditions, which are on file at ATI and available upon request.

  • Page 38: Motor Life And Service Interval Statement

    Other failure modes that are outlined in the manual and relate to improper machining practices and deburring media selection. 10.1.1 Turbine Motor Products (Flexdeburr (RC) models) Turbine motors are not serviceable at this time. The expected life of a turbine motor in normal...

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