ATI Technologies Flexdeburr User's Product Manual

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: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]

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.

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:

A TI Industrial Automation
1031 Goodworth Drive
Apex, NC 27539 USA
www.ati-ia.com

Tel: [phone]
Fax: [phone]

E-mail: [e-mail]

Technical support and questions:

Application Engineering

Tel: [phone], Option 2, Option 2
Fax: [phone]

E-mail: [e-mail]

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

Table of Contents

Foreword .......................................................................................................................................... 2

Glossary ........................................................................................................................................... 5

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 ......................................................................................................................9

2.2 Technical Description ...................................................................................................................9

2.2.1 Environmental Limitations ..................................................................................................9

2.2.1.1 Operation ............................................................................................................9

2.2.1.2 Storage .............................................................................................................10

2.2.2 Compliance Unit Performance ......................................................................................... 11

3. Installation .............................................................................................................................. 12

3.1 Transportation and Protection during Transportation ............................................................. 12

3.2 Inspection of Condition When Delivered ..................................................................................12

3.3 Unpacking and Handling ............................................................................................................12

3.4 Storage and Preventive Maintenance during Storage .............................................................12

3.5 Side Mounting Installation ..........................................................................................................13

3.6 Axial Mounting Installation .........................................................................................................14

3.7 Pneumatics ..................................................................................................................................15

4. Operation ................................................................................................................................ 17

4.1 Safety Precautions ......................................................................................................................17

4.2.1 Air Quality .........................................................................................................................18

4.2.2 No Lubrication ..................................................................................................................18

4.2.3 Bur Selection, Design, and Maintenance .........................................................................18

4.2.4 Deburring Tool Approach Path Should be Slow and at an Angle .....................................18

4.2.5 No Axial Loading ..............................................................................................................18

4.2.6 Perpendicular Loading .....................................................................................................18

4.2 Normal Operations ......................................................................................................................18

4.3 Flexdeburr Working Environment .............................................................................................19

4.2.7 Program the Robot to Incorporate 50% Compliance Travel of the Tool ...........................19

4.4 Tool Center Point (TCP) Position and Programming ...............................................................20

4.5 Cutter Operation and Bur Selection ..........................................................................................22

4.5.1 Bur Selection ....................................................................................................................22

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

5. Maintenance ............................................................................................................................ 25

5.1 Pneumatics ..................................................................................................................................25

5.2 Lubrication ...................................................................................................................................25

5.3 Boot Inspection ...........................................................................................................................25

5.4 Bur Inspection .............................................................................................................................25

6. Troubleshooting and Service Procedures ...........................................................................26

6.1 Troubleshooting ..........................................................................................................................26

6.2 Service Procedures .....................................................................................................................27

6.2.1 Bur and Collet Replacement ............................................................................................27

6.2.2 Turbine Motor Replacement .............................................................................................29

6.2.3 Ring Cylinder Assembly Replacement .............................................................................31

7. Serviceable Parts ................................................................................................................... 33

7.1 Accessories Tools, and Optional Replacement Parts .............................................................33

8. Specications ......................................................................................................................... 34

9. Drawings ................................................................................................................................. 35

9.1 RS-340 Geometry and Mounting ................................................................................................35

9.2 RS-340 Serviceable Parts Drawing ............................................................................................36

10. Terms and Conditions of Sale ............................................................................................... 37

10.1 Motor Life and Service Interval Statement ................................................................................38

10.1.1 Turbine Motor Products (Flexdeburr (RS) models) ..........................................................38

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

Glossary

Term Denition

Adapter Plate

Air Filter
Air Turbine Air motor that drives the spindle.
Bur
Burr Any unwanted, raised protrusion on the work piece.
Climb Milling
Chattering Machine vibrations. The cutting tool bounces as it contacts the work surface.

Coalescing Filter Device designed to remove the liquid aerosols from the supply air lines.
Collet Gripping device used to hold cutting tools in the spindle.

Compliance

Conventional Milling
End-Effector Tool used by the robot to perform a particular function

Flexdeburr Product family name for ATI’s line of radially compliant deburring tools.
Main Housing The main cylindrical body of the unit which includes the mounting features.
Positive Stop The tool has contacted a physical limitation and can no longer move.
Qty Quantity.

Regulator

Rear Housing
RS Single-axis radially-compliant.

Solenoid Valve Electrically controlled device for switching air supplies on and off.
Spindle The rotating portion of the deburring tool assembly.
Turbine Air motor that drives the spindle.

Device for attaching the deburring tool to either a robot ange or a stationary

mounting surface.
Device for removing contamination from the air supply lines. Typically refers to

removal of the particulates.

Cutting tool used to remove the burrs from the work piece. Alternatively

referred to as a rotary le, cutter, or bit.

Cutting method where the direction of the cutter rotation and tool motion are
the same.

The ability of the spindle to passively move in the response to protrusions on
the or deviations of the work piece.

Method of cutting where the direction of the tool motion is opposite that of the
tool rotation.

Device used to set and control the supplied air pressure to lower acceptable
levels.

Rear cover to the main housing. The body includes a connection port for
compliance and motor air.

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

1. Safety

The safety section describes general safety guidelines to be followed with this product, explanations 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 following notications 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,

installing, or setting up 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, best operating practices,

and maintenance tips.

1.2 General Safety Guidelines

Prior to purchase, installation, and operation of the Flexdeburr product, the customer should rst 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.

All pneumatic ttings and tubing must be capable of withstanding the repetitive motions of the application
without failing. The routing of the pneumatic lines must minimize the possibility of stress/strain, kinking,

rupture, etc. Failure of the critical pneumatic lines to function properly may result in the equipment damage.

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]

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

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: 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. Place 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 follow

closely the normal operation procedures outlined in the product manual. 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.

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Manual, Flexdeburr, RS-340
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 ash from the parts. However,
its exible design allows it to be used in a wide variety of applications.

The RS deburring tool’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 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 motors internal governor maintains high spindle speeds for optimum surface

nish. The RS deburring tool also utilizes standard industrial tungsten-carbide bits which allows for adaptation to

changing assembly lines and part requirements.

The RS-340 provides for (2) mounting types, a side mounting and an axial mounting. The side mounting provides
(2) locating dowel pins and (4) 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 RS-340 is equipped with a 1/2" (12 mm on the Euro models) push-to connect tting to supply the motor air and
a 5/32" (4 mm) Push-to Connect tting to supply the compliance air.

A tool collet system secures the bur tool. Many collet sizes and a various selection of tools are available to

accommodate a wide variety of applications.

Figure 2.1—RS-340 Deburring Tool

Tool Collet System

Side Mounting

Axial
Mounting

Compliance Air
Connection

Motor Air

Connection

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Manual, Flexdeburr, RS-340
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.
The turbine motor design does not allow the installation of the quick-change or drawbar collet systems.

The standard tool holding system for Flexdeburr products is an economical, proprietary, single-angle collet
design utilizing (3) 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.

2.2 Technical Description

A technical overview of the product is provided in the following tables and graphs. For additional technical
specications, refer to Section8—Specications.

2.2.1 Environmental Limitations

2.2.1.1 Operation

Installation
position

Temperature
range

Table 2.1—Operation

Mounted to robot by means of the side mounting

pattern or rear adapter ange. Refer to Section 3.5—

Side Mounting Installation 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 9.1—RS-340 Geometry

and Mounting.

Mounted to a table or stand by means of the bench
adapter (the robot is carrying the work piece).

5° C–35° C
41° F–95° F

The tool requires the following:

• Clean, dry, ltered, non‑lubricated air.

• A coalescing lter and lter elements rated

5 micron or better.

Utilities

• The motor spindle must be supplied air at

6.2 bar (90 psi).

• The radial compliance (centering) air must be

supplied from a regulated source between

1.0–4.1 bar (15–60 psi).

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]

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

2.2.1.2 Storage

Temperature
range

Conditions

Table 2.2—Storage

0° C–45° C
32° F–113° F

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 3.7—Storage and Preventive

Maintenance during Storage of this manual.

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [e-mail]

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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.

The actual force characteristics are dependent on mounting orientation and the condition of the

unit. In applications, where the deburring 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 attempts 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—RS-340 Compliance Force Curves (Measured at the Spindle Collet)

1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00 3.25 3.50 3.75 4.00

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Compliance Air Pressure (bar)

40

8

7

6

5

4

3

2

15 20 25 30 35 40 45 50 55 60

Compliance Air Pressure (psi)

36

31

27

Axial Force (N)Axial Force (lbs)

22

18

13

9

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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.

3.2 Inspection of Condition When Delivered

Upon receipt, the following should be checked:

• Delivery is in accordance with freight documents.

• Packaging is in good condition.

If there is damage to any of the packaging, or if any of the goods have been exposed to abnormal handling,

unpack those parts that may have been damaged for a closer inspection. If necessary, notify ATI for
assistance in evaluation of the product condition.

3.3 Unpacking and Handling

The deburring tool should always be placed inside the accompanying packaging during transportation,
storing and handling.

Pneumatic lines and electrical cables are attached, bundled, and must be strain-relieved in a manner that
allows for freedom of movement during operation.

3.4 Storage and Preventive Maintenance during Storage

The deburring tool should be stored in its packaging when it is not in use. The deburring tool should also be
stored in a dry place.

For long-term storage, the deburring tool should be thoroughly cleaned of any burrs or debris. It should not
be disassembled. Place the deburring tool inside a sealed, plastic bag inside its packaging.

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