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ATI Technologies Flexdeburr User's Product Manual

Single-axis, radially-compliant robotic deburring tools
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ATI Single-Axis, Radially-Compliant
Robotic Deburring Tools
Flexdeburr™
(Model 9150-RS-340)
Product Manual
Document #: 9610-50-1016
Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1.919.772.0115 • Fax: +1.919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com

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Summary of Contents for ATI Technologies Flexdeburr

  • Page 1 ATI Single-Axis, Radially-Compliant Robotic Deburring Tools Flexdeburr™ (Model 9150-RS-340) Product Manual Document #: 9610-50-1016 Engineered Products for Robotic Productivity Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1.919.772.0115 • Fax: +1.919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com...

  • Page 2: Foreword

    Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 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

    No Axial Loading ......................18 4.2.6 Perpendicular Loading ..................... 18 Normal Operations ........................18 Flexdeburr Working Environment ..................... 19 4.2.7 Program the Robot to Incorporate 50% Compliance Travel of the Tool ......19 Tool Center Point (TCP) Position and Programming ............... 20 Cutter Operation and Bur Selection ..................
  • Page 4 10.1 Motor Life and Service Interval Statement ................38 10.1.1 Turbine Motor Products (Flexdeburr (RS) models) ............38 Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1.919.772.0115 • Fax: +1.919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com...

  • Page 5: Glossary

    Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 Glossary Definition Term Device for attaching the deburring tool to either a robot flange or a stationary Adapter Plate mounting surface. Device for removing contamination from the air supply lines. Typically refers to Air Filter removal of the particulates.

  • 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 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.

  • Page 7: Safety Precautions

    ATI can damage equipment and void the warranty. Always use original ATI spare parts. CAUTION: Do not perform maintenance or repair on the Flexdeburr product unless the tool is safely supported or placed in the tool stand and air has been turned off. Injury or equipment damage can occur with tool not placed in a tool stand and air remaining on.

  • Page 8: Product Overview

    Document #9610-50-1016-08 2. Product Overview The single-axis radially-compliant (RS) Deburring tool, also known as Flexdeburr, is robust, high-speed and lightweight air turbine-driven deburring units for deburring aluminum, plastic, steel, etc. with a robot or CNC machine. The RS deburring tool is especially suited for removal of parting lines and flash from the parts. However, its flexible design allows it to be used in a wide variety of applications.

  • Page 9: Tool Collet Systems

    Document #9610-50-1016-08 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 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.

  • Page 10: Storage

    Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 2.2.1.2 Storage Table 2.2—Storage Temperature 0° C–45° C range 32° F–113° F The tool should be stored in its crate and in a dry place. Conditions When not in use, keep the unit in its crate If possible.

  • Page 11: Compliance Unit Performance

    Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 2.2.2 Compliance Unit Performance The variation of the compliance force with applied air pressure are illustrated in the following graph. Measurements may vary from one product to another, and should only be treated as nominal.

  • Page 12: Installation

    Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 3. Installation The RS-340 Deburring Tool is 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 RS deburring tool arrives in packaging to secure and protect it during transportation. Always use this packaging when transporting the deburring tool in order to minimize the risk of damage.

  • Page 13: Side Mounting Installation

    Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 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 Section 9—Drawings for the maximum fastener length. Do not use fasteners that exceed the maximum length; otherwise, damage will occur.

  • Page 14: Axial Mounting Installation

    A blank robot adapter plate is also available to allow axial mounting off the rear of the deburring tool housing. This plate may be modified by the system integrator or by the owner/user of the Flexdeburr. ATI can provide custom interface plates and adapters upon request. If the RS deburring tool is permanently mounted to a work surface, the robot carries the part to be deburred to the deburring tool.

  • Page 15: Pneumatics

    Connect the RS deburring tool as shown in the following figure. CAUTION: Do not use lubricated air with the Flexdeburr. Oil in the air stream will result in premature failure of the turbine motor and is not covered under warranty. It is recommended that the customer use a coalescing filter and filter elements that are rated 5 micron or better.
  • Page 16 Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 A second, precision, self-relieving regulator (ATI Part # 9150-P16-B-G, or equivalent) is used to supply the compliance (centering) mechanism. This pressure corresponds to the side force on the bur. Because very little air flow is required for the compliance mechanism, a significantly smaller valve can be used. (Consult the valve and regulator supplier’s literature when selecting these components).

  • Page 17: Operation

    4.1 Safety Precautions DANGER: NEVER use the Flexdeburr for purposes other than robotic deburring. If used in any other way, serious injury or damage to equipment may occur. WARNING: All personnel, who are involved in operation of the RS deburring tool, should have a thorough understanding of the operating procedures.

  • Page 18: Air Quality

    Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 4.2 Normal Operations The following sections describes the normal operating conditions for RS 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 19: Flexdeburr Working Environment

    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.

  • Page 20: Tool Center Point (Tcp) Position And Programming

    4.4 Tool Center Point (TCP) Position and Programming The following figure shows the RS deburring tool dimensions. The Flexdeburr provides radial compliance and performs best when the cuts taken are not excessively deep. The deburring tool spindle must never be running while programming the robot.
  • Page 21 Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 Figure 4.2— Flexdeburr Pointed Teaching Tool Inside corners represent a complex situation for compliant deburring tools. In general, the bur must not contact simultaneously both perpendicular surfaces of an inside corner. The resulting force imbalance in two planes will cause severe tool chatter.

  • Page 22: Cutter Operation And 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 warranty.

  • Page 23: Manual, Flexdeburr, Rs

    Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 ATI can provide guidance in the bur selection, however, only experimentation will yield the results desired. The following table is presented to assist in the burr selection. Table 4.1—Bur Selection Features/Benefits: Materials/Application 9150-RC-B-24033 - Diamond Cut, 1/4” Bur Diameter, 5/8” Bur Length, 1/4” Shank For hardened and tough materials, •...
  • Page 24 Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 Table 4.1—Bur Selection Features/Benefits: Materials/Application 9150-RC-B-26408 - Cut FVK, 1/4” Bur Diameter, 5/8” Bur Length, 1/4” Shank For trimming and contour milling of • Special cut geometry allows high • all glass and carbon fiber reinforced...

  • Page 25: Maintenance

    The air lines to the deburring tools should routinely be checked for their general condition and replaced as required. The air to the Flexdeburr must be filtered, dry, and non-lubricated. The air filters should be checked and replaced as required to maintain optimum performance. The life of the filter elements is dependent on the quality of compressed air at the customer’s facility and therefore cannot be estimated.

  • Page 26: Troubleshooting And Service Procedures

    Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 6. Troubleshooting and Service Procedures Deburring process development is an iterative, learning task. The following table is presented to assist in the solving deburring problems. 6.1 Troubleshooting Deburring process development is an iterative, learning task. The following table is presented to assist in solving deburring problems.

  • Page 27: Service Procedures

    Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 Table 6.1—Troubleshooting Symptom Cause Resolution Too heavy a cut Decrease width of the cut. Make multiple passes. Chip packing of the Use a bur with less flutes. Refer to Not enough chip Section 4.5—Cutter Operation...
  • Page 28 Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 Figure 6.1— Bur and Collet Replacement 9/16" [14.5 mm] Open Wrench Spindle Shaft Collet Nut Bur Tool Measure and record the length of the tool 7/16" [11 mm] extending beyond Open Wrench the collet nut...

  • Page 29: Turbine Motor Replacement

    The motor may also require replacement after an extended operating life or following a severe collision. 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 speed user installation.
  • Page 30 Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 Figure 6.2— Turbine Motor Replacement Coat the wave spring (6) M3 Socket Head with Magnalube and Cap Screws position as shown Compliance Air Fitting in the front of the housing. Rear Housing Spindle Motor Air...

  • Page 31: Ring Cylinder Assembly Replacement

    Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 6.2.3 Ring Cylinder Assembly Replacement The compliant motion of the turbine motor spindle can occur because of an array of the pistons (ring cylinder) that are installed inside the rear housing. After extended operation, this component may need replacing to ensure free motion of the pistons.
  • Page 32 Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 8. Apply a thin film of the Magnalube to the housing bore where the ring cylinder seats prior to installation. 9. Apply Magnalube to the (2) new o-rings, if the old unit is being reinstalled. (Do not reuse the old o-rings.)

  • Page 33: Serviceable Parts

    For repair and spare parts please contact ATI. Refer to Section 9.2—RS-340 Serviceable Parts Drawing exploded drawings showing all the user replaceable components of the Flexdeburr. Available accessories, tools, and optional replacement parts are listed inSection 7.1—Accessories Tools, and Optional Replacement Parts.

  • Page 34: Specifications

    Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 8. Specifications Table 8.1—RS-340 Specifications Parameter Rating Motor Turbine Motor Idle Speed (RPM) 40,000 Torque (Max.) 0.08 N-m (0.7 lb-in) Power 340 W (0.46 hp) @ 40,000 RPM Weight (without Adapters) 1.2 kg (2.6 lbs) Compensation (Radial) +/- 5.5 mm max., +/- 3 mm recommended...

  • Page 35: Drawings

    Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 9. Drawings 9.1 RS-340 Geometry and Mounting Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1.919.772.0115 • Fax: +1.919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com...

  • Page 36: Rs-340 Serviceable Parts Drawing

    Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 9.2 RS-340 Serviceable Parts Drawing Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1.919.772.0115 • Fax: +1.919.772.8259 • www.ati-ia.com • Email: info@ati-ia.com...

  • Page 37: Terms And Conditions Of Sale

    Manual, Flexdeburr, RS-340 Document #9610-50-1016-08 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 (RS) models) Turbine motors are not serviceable at this time. The expected life of a turbine motor in normal operation is entirely application dependent based on a multitude of factors.

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