ATI Technologies Flexdeburr 9150‑RC‑300 Series Manual
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ATI Technologies Flexdeburr 9150‑RC‑300 Series Manual

Radially‑compliant robotic deburring tools
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ATI Radially‑Compliant
Robotic Deburring Tools
Flexdeburr™
(Model 9150‑RC‑300 and ‑340 Series)
Manual
US Patent # 6,974,286 B2
Document #: 9610‑50‑1019
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

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Summary of Contents for ATI Technologies Flexdeburr 9150‑RC‑300 Series

  • Page 1 ATI Radially‑Compliant Robotic Deburring Tools Flexdeburr™ (Model 9150‑RC‑300 and ‑340 Series) Manual US Patent # 6,974,286 B2 Document #: 9610‑50‑1019 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...

  • Page 2: Foreword

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 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. 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: Table Of Contents

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 Table of Contents Foreword ............................2 Glossary ............................5 Safety ............................6 Explanation of Notifications ......................6 General Safety Guidelines ......................6 Safety Precautions ........................7 Product Overview ........................8 Tool Collet Systems ........................9 Technical Description ........................
  • Page 4 Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 Maintenance ..........................24 Pneumatics ..........................24 Lubrication ........................... 24 Bellows Boot Inspection ......................24 Bur Inspection ..........................24 Spindle Motion Inspection ......................24 Troubleshooting and Service Procedures ................25 Troubleshooting Procedures ..................... 25 Service Procedures ........................

  • Page 5: Glossary

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 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 air supply lines. Typically refers to removal Air Filter of particulates.

  • Page 6: Safety

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 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. Product specific notifications are imbedded within the sections of this manual (where they apply).

  • Page 7: Safety Precautions

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 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.

  • Page 8: Product Overview

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 2. Product Overview The Radially Compliant (RC) deburring tool, also known as Flexdeburr, is a robust, high‑speed and lightweight turbine driven deburring unit for deburring aluminum, plastic, steel, etc. with a robot or CNC machine. The RC deburring tool is especially suited for removal of parting lines and flash from parts.

  • Page 9: Tool Collet Systems

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 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.

  • Page 10: Compliance Unit Performance

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 2.2.2 Compliance Unit Performance The graphs in Figure 2.2 illustrate the variation of compliance force with applied air pressure in the vertical orientation with the collet pointed toward the ground. Measurements may vary from one product to another and should only be treated as nominal.

  • Page 11: Installation

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 3. Installation The RC‑300 and RC‑340 series Deburring 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 RC deburring tool is packaged in a crate designed to secure and protect it during transportation.

  • Page 12: Side Mounting Installation

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 3.5 Side Mounting Installation The side‑mounting pattern of the RC deburring tool consists of (2) dowel pin holes and a number of threaded holes as can be seen in the following figure. The maximum fastener length specified must not be exceeded so that the fasteners do not interfere with the compliant motion of the turbine motor spindle.

  • Page 13: Axial Mounting Installation

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 3.6 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.

  • Page 14: Pneumatics

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 3.7 Pneumatics Connect the RC deburring tool as shown in the following figure. Figure 3.3—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 15 Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 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 16: Operation

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 4. Operation These operating instructions are intended to help system integrators program, start up, and complete a robotic deburring cell containing a deburring 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 17: Normal Operation

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 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 18: Flexdeburr Working Environment

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 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.

  • Page 19: Tool Center Point (Tcp) Position And Programming

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 4.4 Tool Center Point (TCP) Position and Programming Figure 4.1 shows the RC 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 20 Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 Figure 4.2—Flexdeburr Pointed Teaching Tool Inside corners represent a complex situation for compliant deburring tools. In general, the bur 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.

  • Page 21: Cutter Operation And Bur Selection

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 4.5 Cutter Operation and Bur Selection The RC deburring tool will perform best in “climb milling”. This refers to a bur whose directions of traverse and bur rotation are the same. In the case of the RC deburring tools, the bur rotation is clockwise when viewed from above.
  • Page 22 Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 Table 4.1—Bur Selection Features/Benefits: Materials/Application 9150‑RC‑B‑24061 ‑ Standard Cut, 3/8” Burr Diameter, 3/4” Bur Length, 1/4” Shank For steels of high tensile strength Without chip breaker, for • • die steels, cast steel, built up scratch‑free surfaces.
  • Page 23 Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 Table 4.1—Bur Selection Features/Benefits: Materials/Application 3710‑50‑1492 ‑ Bur for Composites, 1/4” Burr Diameter, 3/4” Burr Length, 1/4” Shank For trimming and contour milling Special cut geometry allows • • of all glass and carbon fiber high feed rates due to low reinforced plastics.

  • Page 24: Maintenance

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 5. Maintenance The RC deburring 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. Section 6—Troubleshooting and Service Procedures is provided to assist the user when they choose to service the unit in the field.

  • Page 25: Troubleshooting And Service Procedures

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 6. Troubleshooting and Service Procedures 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.

  • Page 26: Service Procedures

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 Table 6.1—Troubleshooting Symptom Cause Resolution Incorrect feed rate Reduce feed rate. Too heavy a cut Decrease width of cut; make multiple passes. Choose bur designed for work material.Refer to Section 4.5.1—Bur Improper Bur selection Secondary burrs are Selection.
  • Page 27 Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 3. If the bur is to be replaced with an identical type, measure and record the tool length extending beyond the collet lock nut. Alternatively, the optional ATI 9150‑RC‑T‑4230 bur setting tool accessory can be used to duplicate tool exposure length.

  • Page 28: Rear Housing And Pivot Bearing Replacement

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 9. Use the 7/16” (11 mm) open‑end wrench to hold the spindle just behind the collet nut. 10. Use the 9/16” (14.5 mm) collet wrench to turn the collet locknut clockwise (when viewed from the bur tip) to tighten the collet.
  • Page 29 Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 Figure 6.2—Rear Housing Assembly Replacement Spindle Air Supply Fitting Front Compliance Air Housing Fitting O-ring Dowel Pin Pivot Post Rear Housing M8 Socket Flat (6) M3 Socket Head Head Cap Screw Cap Screw 11.

  • Page 30: Pivot Bearing And Keying Dowel Replacement

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 6.2.2.2 Pivot Bearing and Keying Dowel Replacement Refer to Figure 6.3 through Figure 6.6. Parts required: Refer to Section 7—Serviceable Parts. Tools required: 2.5 mm and 3 mm hex key, torque wrench, small diameter magnet Supplies required: Magnalube, Loctite 7649 primer, Loctite 222, clean lint free rag 1.
  • Page 31 Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 Figure 6.3—Remove the Pivot Bearing and Keying Dowel M4 Radial Set Screw Pivot Bearing Keying Dowel M4 Axial Set Screw Spherical Pivot Bearing Pivot Bearing Clamping Washer Press Tool M5 Pivot Bearing Preload Set Screw Rear Housing (Loosen Screw)
  • Page 32 Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 Figure 6.5—Pivot Bearing Set Screw Installation Rear Housing Edge of Outer Race M4 Axial Set Screw M4 Radial Set Screw Rotate pivot ball until the bottom surface of the keyway is flush with the edge of the outer race.

  • Page 33: Turbine Motor Replacement

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 Figure 6.6—Pivot Bearing Adjustment Compliance Air Fitting Spindle Air Supply Fitting Move the turbine motor spindle like a joy stick. M5 Pivot Bearing Preload Screw 24. Replace hose connection to the spindle supply air fitting. 25.
  • Page 34 Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 7. Lift the retaining ring and rubber boot out of the housing. ATI recommends replacing the retaining ring and rubber disk when the turbine motor is replaced. 8. Remove the spindle air supply fitting from the side of the main housing by using a crescent wrench and rotating the fitting counter‑clockwise.
  • Page 35 Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 Figure 6.8—Remove the Turbine Motor Assembly Turbine Motor Assembly Front Housing Lubricate contact sleeve Pivot Post 13. Apply a thin coating of Magnalube or equivalent to the outer surface of the new turbine motor contact sleeve.
  • Page 36 Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 Figure 6.10—Installation of Turbine Motor Assembly, Spindle Air Supply Fitting, and Rear Cover Spindle Air Supply Fitting Small Flat Blade Screwdriver Retaining Ring Rubber Boot Disk Spindle Air Supply Fitting Centerd in Front Housing Front Housing Compliance Air Fitting...

  • Page 37: Ring Cylinder Assembly Replacement

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 6.2.4 Ring Cylinder Assembly Replacement The compliant motion of the turbine motor spindle is accomplished using a circular array of pistons (ring cylinder) at the front of the housing. After extended operation, this component may need replacing to ensure free motion of the pistons.
  • Page 38 Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 Figure 6.12—Remove Ring Cylinder with a Non‑Metallic Drift (plastic or wooden rod) Non-Metallic Rod O-ring Front Housing Alignment Dowel Pin (2) O-rings Ring Cylinder 8. Using a clean lint free rag, remove any debris and lubrication from the alignment dowel pin, O‑ring, and front housing (including the bore inside the housing).
  • Page 39 Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 17. Apply Locite 222 to the (7) M3 button head cap screws. 18. Using a 2 mm hex key, install the (7) M3 button head cap screws into the boot ring, flat disk boot, and ring cylinder.

  • Page 40: Tapered Bellows Boot Replacement

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 6.2.5 Tapered Bellows Boot Replacement The tapered bellows boot prevents debris from entering the housing and protects internal components. Replace the tapered bellows boot if damaged. Parts required: Refer to Section 7—Serviceable Parts.

  • Page 41: Serviceable Parts

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 7. Serviceable Parts For repair and spare parts please contact ATI. Refer to Section 9.2—RC‑300 Series Serviceable Parts for exploded drawings showing all the user replaceable components of the Flexdeburr. Available accessories, tools, and optional replacement parts are listed in Section 7.1—Accessories Tools, and Optional Replacement Parts.

  • Page 42: Specifications

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 8. Specifications The following table lists specifications. For an additional Technical Description of the product, refer to Section 2.2—Technical Description. Table 8.1—RC‑300 and RC340 Series Specifications Rating Parameter RC‑300 Series RC‑340 Series Motor Type Turbine Motor part number...

  • Page 43: Drawings

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 9. Drawings 9.1 RC‑300 Series 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...

  • Page 44: Rc-300 Series Serviceable Parts

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 9.2 RC‑300 Series Serviceable Parts Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1.919.772.0115 • Fax: +1.919.772.8259 • www.ati‑ia.com...
  • Page 45 Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1.919.772.0115 • Fax: +1.919.772.8259 • www.ati‑ia.com...

  • Page 46: Terms And Conditions Of Sale

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 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. 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 the manufacturer’s specified normal operating conditions.

  • Page 47: Motor Life And Service Interval Statement

    Manual, Flexdeburr, RC‑300 and RC‑340 Series Document #9610‑50‑1019‑07 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.

This manual is also suitable for:

Flexdeburr 9150‑rc‑340 series

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