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ATI Technologies VersaFinish 9150-ACT-390-0-0-0 Product Manual

Axially compliant robotic finishing tool
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VersaFinish™
Axially Compliant Robotic Finishing Tool
(Model 9150‑ACT‑390‑0‑0‑0 and 9150‑ACT‑390‑NL)
Product Manual
Document #: 9610-50-1012
Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • 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 VersaFinish 9150-ACT-390-0-0-0

  • Page 1 VersaFinish™ Axially Compliant Robotic Finishing Tool (Model 9150‑ACT‑390‑0‑0‑0 and 9150‑ACT‑390‑NL) Product Manual Document #: 9610-50-1012 Engineered Products for Robotic Productivity Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: +1.919.772.0115 • Fax: +1.919.772.8259 • www.ati‑ia.com • Email: info@ati‑ia.com...

  • Page 2: Foreword

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 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.

  • Page 3: Glossary

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 Glossary Term Definition Axially Compliant Finishing Tool. Adapter Device for attaching the tool to robots or work surfaces. Device for removing contamination from air supply lines. Typically refers to removal of Air Filter particulates. Air Lubricator Device for adding controlled volumes of lubricating oil to the air supplying the air motor.

  • Page 4: Table Of Contents

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 Table of Contents Foreword ............................2 Glossary ............................3 Safety ............................6 1.1 Explanation of Notifications ......................6 General Safety Guidelines ......................6 Safety Precautions ........................7 Product Overview ........................8 2.1 Features and Benefits of the VersaFinish Deburring Tool ............8 VersaFinish Part Numbering Legend ..................9 Technical Description ........................
  • Page 5 Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 Maintenance ..........................22 Routine Operational Maintenance ..................... 22 Media Replacement ........................22 Utilities ............................22 Lubrication ........................... 22 Troubleshooting and Service Procedures ................23 Troubleshooting .......................... 23 Service Procedures ........................24 6.2.1 Media Selection ........................ 24 6.2.2 Flexible Boot Replacement ....................

  • Page 6: Safety

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 1. Safety The safety section describes general safety guidelines to be followed with this product, explanations of the notifications found in this manual, and safety precautions that apply to the product. More specific notifications are imbedded within the sections of the manual where they apply.

  • Page 7: Safety Precautions

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 1.3 Safety Precautions 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.

  • Page 8: Product Overview

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 2. Product Overview ATI's Axially‑Compliant Finishing Tool, also known as VersaFinish, is a robust, low‑speed, high‑torque air tool with an axially floating spindle, suitable for a multitude of robotic and non‑robotic material finishing operations on aluminum, plastic, steel, etc.

  • Page 9: Versafinish Part Numbering Legend

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 Simple Tool Holder • The VersaFinish is supplied with a simple key‑actuated 3/8”chuck for holding common media. The spindle is threaded to allow replacement of the chuck with customer‑supplied or custom‑manufactured media holders. The VershFinish motor has an industry standard 3/8‑24 right‑hand spindle thread.

  • Page 10: Technical Description

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 2.3 Technical Description A technical overview of the product is provided in the following tables and graphs. For additional technical specifications, refer to Section 8—Specifications. 2.3.1 Environmental Limitations 2.3.1.1 Operation Table 2.1—Operation Installation Mounted to machining center by means various, position.

  • Page 11: Compliance Unit Performance

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 2.4 Compliance Unit Performance The friction created by the mass of the customer supplied motor resting on the horizontally mounted stage varies from tool to tool which makes compliance force variable. The compliance force varies linearly with air pressure using the basic formulas shown in the chart below.
  • Page 12 Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 The air motor operating speed will change according to load applied to it developing the power required for the specific task being attempted. The idle speed of the motor will be its maximum as no load is applied. This will drop to a lower operating speed where it will develop the maximum torque.

  • Page 13: Installation

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 3. Installation The compliance housing incorporates a side mounting pattern which can be used directly or through the use of an optional bench mount adapter kit. See Section 9—Drawings. The tool must be rigidly mounted prior to use. Under no circumstances should the unit be used for manual/hand operations.

  • Page 14: Side Mounting Installation

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 3.5 Side Mounting Installation CAUTION: Thread locker applied to fasteners must not be used more than once. Fasteners might become loose and cause equipment damage. Always apply new thread locker when reusing fasteners. CAUTION: The length of the fasteners should not interfere with the compliant motion of the motor spindle.

  • Page 15: Pneumatic Connections

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 3.6 Pneumatic Connections Connect the VersaFinish tool as shown in Figure 3.2. Figure 3.2—Pneumatic Connections WARNING: All pneumatic fittings and tubing must be capable of withstanding the repetitive motions of the application without failing. The routing of pneumatic lines must minimize the possibility of over stressing, pullout, or kinking the lines.
  • Page 16 Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 CAUTION: Pneumatic components used for the motor drive circuit must be capable of meeting the air consumption requirements (See Section 8—Specifications). Poor performance will result if the correct components are not used. Lubricators must be located as close to the unit as possible with performance rapidly deteriorating when the distance exceeds 15 feet (5 meters).

  • Page 17: Operation

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 4. Operation These operating instructions are intended to help system integrators program, start up, and complete a robotic cell containing a finishing tool. The system integrator should be familiar with the task of finishing in general, and should have extensive knowledge relating to robots and automation incorporating robots.

  • Page 18: Normal Operation

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 4.2 Normal Operation The following sections describes the normal operating conditions for VersaFinish deburring tools. 4.2.1 Air Quality The air supply should be clean, dry, filtered, and lubricated. A coalescing filter that has elements rated for 5 micron or better is required.

  • Page 19: Deburring Tool Approach Path Should Be Slow And At An Angle

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 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.

  • Page 20: Sensor Connections

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 Sensor Connections The VersaFinish tool can be equipped with up to (3) sensors to monitor spindle position and speed. These include the Forward, Retract, and Tachometer sensors. Each sensor is a PNP (sourcing) type proximity switch using (3) wire electrical hook‑up.

  • Page 21: Tool Position And Programming

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 4.4 Tool Position and Programming The VersaFinish dimensions are provided in Section 9—Drawings. The VersaFinish provides axial compliance and performs best when spindle is displaced through approximately one‑half of its allowable travel (approximately 8 mm). The tool spindle must never be running while programming a machining center.

  • Page 22: Maintenance

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 5. Maintenance The air motor is supported by (2) guide rods attached to the front plate of the finishing tool. To prevent binding of the compliance, one of these guide rods is rigidly attached to the front plate. The second guide rod and the compliance piston rods are free to float in the front plate.

  • Page 23: Troubleshooting And Service Procedures

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 6. Troubleshooting and Service Procedures The following section provides troubleshooting information to help diagnose conditions with the product and service procedures to help resolve these conditions. 6.1 Troubleshooting The following table is presented to assist in solving finishing problems. Table 6.1—Troubleshooting Symptom Cause...

  • Page 24: Service Procedures

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 6.2 Service Procedures The following service procedures provide instructions for component replacement, when the user chooses to service the unit in the field. For all service, the user should disconnect the air supply before the solenoid valves and vent trapped air pressure from the lines.

  • Page 25: Air Motor Muffler Replacement

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 6.2.3 Air Motor Muffler Replacement The motor includes a muffler that vents air to the atmosphere. If the muffler becomes clogged the air motor will not function efficiently, and the muffler will need to be replaced. The following steps must be performed: Parts required: Refer to Section 9—Drawings...

  • Page 26: Air Motor Replacement

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 6.2.4 Air Motor Replacement The motor includes a gearbox (gearhead) to lower the spindle speed. Maintenance of either the motor or the gearbox requires the motor be removed from the tool. VersaFinish units with defective motors should be returned to ATI during the warranty period. For customer replacement the motor after the warranty period, the following steps must be performed: Parts required: Refer to Section 9—Drawings...
  • Page 27 Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 6. Insert the chuck key into the chuck. While holding the 15 mm wrench securely, unscrew the chuck counterclockwise using the chuck key as a lever. 7. If a tachometer target disk is installed, remove the tachometer target disk. 8.
  • Page 28 Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 17. When the motor bottoms out against the seal plate, tighten the (4) M4 socket flat head screws on the seal plate to 14 in‑lb (1.58 Nm). Refer to Figure 6.5. 18. Apply a thin film of grease to the shoulder of the 15 mm nut that goes behind the chuck and thread the nut onto the spindle until it bottoms out using fingers.

  • Page 29: Sensor Replacement

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 6.2.5 Sensor Replacement The VersaFinish may be outfitted with up to (3) proximity sensors. These sensors may be monitored by the customer to determine the following information. 1. Option –F: The Forward Sensor. It is ON when the spindle is fully forward. Refer to Section 6.2.5.1—Forward Sensor (Option ‑F).
  • Page 30 Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 3. Remove the rear housing and observe the nickel plated cylindrical sensor mounted in the plastic block. Figure 6.9—Replacing the Sensor Sensor Cable Sensor M3 Socket Head Cap Screw Plastic Block 4. Replacing or adjusting the sensor: •...
  • Page 31 Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 Figure 6.11—Installing the Rear Housing Front Housing Rear Housing M8 Stainless Steel Button Head Screw (3) M5 Socket Head Cap Screw 11. Using a 5 mm hex key, remove the M8 stainless button head screw from the rear housing and reach through the opening with the 5 mm hex key to turn the target screw (M6 socket head cap screw).

  • Page 32: Retract Sensor (Option -R)

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 6.2.5.2 Retract Sensor (Option -R) The retract sensor is mounted to the rear housing inside the tool. When the spindle is within 1.5 mm of being fully retracted the sensor will turn on. This may be utilized to indicate when excessive brush force is being applied (i.e., the brush has been pushed back so far and so hard that the end of compliance travel has been reached).
  • Page 33 Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 8. Using a 2 mm hex key, tighten the M3 socket flat head cap screw to 60 in‑oz. 9. Install the rear housing to the front housing. Ensure the (2) o‑ring seals are in place before securing. Apply Loctite 222 to the (3) M5 socket cap screws that secure the rear housing.

  • Page 34: Tachometer Sensor (Option -T)

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 6.2.5.3 Tachometer Sensor (Option -T) The tachometer sensor is an optional speed sensing system that allows the user to monitor the rotating speed of the spindle. A target disk is sandwiched between the spindle chuck and the nut securing it (2) equally spaced holes in this disk serve as targets for the sensor.
  • Page 35 Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 5. If a tachometer target disk is installed, remove the tachometer target disk. 6. Remove the 15 mm nut previously held by the open end wrench. Figure 6.15—Flexible Boot Main Housing Plate (2) Garter Spring Boot 7.
  • Page 36 Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 Figure 6.17—Tachometer Sensor Jam Nut Sensor Cable Jam Nut Tachometer Sensor Washer Motor Mount 10. Using a 13 mm wrench, remove the jam nut and washer that secure the tachometer sensor to the motor mount. 11.
  • Page 37 Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 20. Adjust the tachometer sensor: Ensure the sensor jam nut is loose. Using fingers, advance the tachometer sensor until there is a gap of 1 mm between the sensor and the back of the target disk. Rotate the spindle through one complete revolution by turning the chuck.

  • Page 38: Serviceable Parts

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 7. Serviceable Parts For repair and spare parts, please contact ATI. Refer to Section 9—Drawings for exploded drawings that show all the user replaceable components of the VersaFinish. Available accessories, tools, and optional replacement parts are listed in the following section.

  • Page 39: Specifications

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 8. Specifications Table 8.1—Specifications for the ACT‑390 Series Parameter Rating Motor Air motor, vane type Idle Speed 5,600 RPM Working Speed (max. power) 2,600 RPM Power 390 W (0.52 hp) at 2,600 RPM Torque (max. power) 1.4 Nm (1 lb‑ft) (starting/stall) 2.7 Nm (2 lb‑ft) Weight total (w/o adapter)

  • Page 40: Drawings

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 9. Drawings Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: +1.919.772.0115 • Fax: +1.919.772.8259 • • Email: www.ati‑ia.com info@ati‑ia.com...
  • Page 41 Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: +1.919.772.0115 • Fax: +1.919.772.8259 • • Email: www.ati‑ia.com info@ati‑ia.com...
  • Page 42 Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: +1.919.772.0115 • Fax: +1.919.772.8259 • • Email: www.ati‑ia.com info@ati‑ia.com...

  • Page 43: Terms And Conditions Of Sale

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 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. ATI warrants the compliant tool product will be free from defects in design, materials and workmanship for a period of one (1) year from the date of shipment and only when used in compliance with manufacturer’s specified normal operating conditions.

  • Page 44: Motor Life And Service Interval Statement

    Manual, VersaFinish, ACT‑390 Series Document #9610‑50‑1012‑18 10.1 Motor Life and Service Interval Statement The air motors that are used in ATI deburring/finishing tools are subject to wear and have a finite life. Motors that fail, during the warranty period, will be repaired or replaced by ATI as long as there is no evidence of abuse or neglect and that the normal operating practices outlined in this manual have been observed.

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Versafinish 9150-act-390-nl

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