ATI Technologies Flexdeburr User'S Product Manual Download Page 1

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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: [email protected]

ATI Single-Axis, Radially-Compliant

Robotic Deburring Tools

Flexdeburr™

(Model 9150-RS-340)

Product Manual

Document #: 9610-50-1016

Summary of Contents for Flexdeburr

Page 1: ...nacle 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 ATI Single Axis Radially Compliant Robotic Deburring Tools Flexdeburr Model 9150 RS 340 Product Manual Document 9610 50 1016 ...

Page 2: ... 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 fitness 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 consequentia...

Page 3: ... 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 A...

Page 4: ...ce 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 Specifications 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 Sal...

Page 5: ...aerosols from the supply air lines Collet Gripping device used to hold cutting tools in the spindle Compliance The ability of the spindle to passively move in the response to protrusions on the or deviations of the work piece Conventional Milling Method of cutting where the direction of the tool motion is opposite that of the tool rotation End Effector Tool used by the robot to perform a particula...

Page 6: ... consequences of not avoiding the hazard and the method for avoiding the situation CAUTION Notification of information or instructions that if not followed could result in moderate injury or will cause damage to equipment The notification provides information about the nature of the hazardous situation the consequences of not avoiding the hazard and the method for avoiding the situation NOTICE Not...

Page 7: ...ed 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...

Page 8: ...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 finish 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 ...

Page 9: ...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 specifications refer to Section 8 Specifications 2 2 1 Environmental Limitations 2 2 1 1 Operation Table 2 1 Operation Installation position Mount...

Page 10: ...9 772 8259 www ati ia com Email info ati ia com 10 2 2 1 2 Storage Table 2 2 Storage Temperature range 0 C 45 C 32 F 113 F Conditions 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 ...

Page 11: ...ted 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 Th...

Page 12: ...n 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 stor...

Page 13: ...d on all mounting fasteners Liquid thread lockers should not be used for the mounting fasteners as this may damage or remove thread inserts during disassembly The side mounting pattern of the RS deburring tool consists of 2 dowel pin holes and 4 of threaded holes as shown in the following figure An optional bench mount adapter plate allows the deburring tool to be permanently attached to a bench o...

Page 14: ...nting 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 Figure 3 2 Axial Installation 2 M5 Socket Head Cap Screws Clampi...

Page 15: ...ltered and free of oil A coalescing filter with elements rated for 5 micron or better is required A high flow air pressure control regulator is required to supply the spindle motor at 6 2 bar 90 psi A second precision self relieving regulator will supply air for the compliance or centering force The compliance force is applied radially and is adjusted until the desired cut is made The robot s trav...

Page 16: ...nnection Type Pressure Motor Inlet 9150 RS 340 3 8 quick connect tube Alternates Use 5 16 8 mm tubing adapter or Remove the supplied fitting to use 1 4 NPT port in the motor body 6 2 bar 90 psi Compliance Radial Force Inlet 9150 RS 340 ER E 5 32 4 mm quick connect tube Alternate Remove the supplied fitting to use 1 8 NPT port 1 0 4 1 bar 15 60 psi Maximum Exhaust Vented to atmosphere through the h...

Page 17: ...airment Always use hearing protection while working in proximity of the deburring tool WARNING Never operate the Flexdeburr product without wearing eye protection Flying debris can cause injury Always use eye protection while working in the proximity of the deburring tool CAUTION Do not use burs rated for less than the speed of the RS deburring tool being used Using lower rated burs may cause inju...

Page 18: ...maximum rated speed of the brush is less than the operating speed of the deburring tool Operating the brush above its maximum rated speed can be unsafe due to unbalanced loading Additionally even balanced brushes can result in an excessive load on the motor and reduced motor life Do not use a tool that requires axial loading on the RS tool 4 2 4 Deburring Tool Approach Path Should be Slow and at a...

Page 19: ...ans 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 The barrier could consist partly or fully of Plexiglas to facilitate observation of the deburring operations During system or deburring tool maintenance make sure the RS deburring tool and robot are stopped ...

Page 20: ...d a dowel pin of suitable diameter is inserted in place of a bur simulating the cutter shank diameter when teaching the robot path For 6 mm collets this will mean a 6 mm diameter pin of suitable length The dowel pin should extend sufficiently from the collet to reach the surface on the bur where cutting is desired refer to the following figure The diameter of the bur should not exceed that of the ...

Page 21: ...closer to the tip Note When working near the tip of a tapered bur the surface cutting speed is reduced When deburring inside radii a similar situation may arise Do not attempt to deburr an inside radius less than 1 5 times the diameter of the desired bur Rmin 1 5 x Cutter diameter Depending on the depth of cut failing to follow these guidelines may result in excessive cutter contact resulting in e...

Page 22: ...ection 4 5 1 Bur Selection for a short list of burs and suitable applications A specific family of burs is available for working with die cast alloys aluminum and plastics These burs have fewer teeth and increased relief to minimize chip loading Plastics represent the most difficult deburring challenge due to the phenomenon of chip re welding In this process if the bur is dull or the feeds and spe...

Page 23: ...chamfering For deburring Without chip breaker for scratch free surfaces 9150 RC B 24063 Diamond Cut 3 8 Bur Diameter 3 4 Bur Length 1 4 Shank For hardened and tough materials super alloys and stainless steel alloyed cast steel and fiber reinforced plastics Edge and surface working Built up welds of high tensile strength in mold and die making Higher cutting capacity than standard cuts Smoother fin...

Page 24: ...Length 1 4 Shank For trimming and contour milling of all glass and carbon fiber reinforced plastics Special cut geometry allows high feed rates due to low cutting forces 9150 RC B 24862 Alt Diamond Cut 1 4 Bur Diameter 3 4 Bur Length 1 4 Shank Universal use for ferrous and non ferrous metals plastics Rough finishing of castings Surface working Weld removal Brazed welds Smoother operation improved ...

Page 25: ...e The life of the filter elements is dependent on the quality of compressed air at the customer s facility and therefore cannot be estimated 5 2 Lubrication Lubrication systems are not to be used Refer to Section 4 2 2 No Lubrication The Flexdeburr turbine motor must be supplied with clean dry filtered air Oil in the air stream will cause the turbine motor to fail prematurely Failure of the motor ...

Page 26: ...er to Section 6 2 2 Turbine Motor Replacement Poor finish on the work piece Feed rate is too fast Reduce the feed rate The bur is worn Inspect the bur If worn replace Refer to Section 6 2 1 Bur and Collet Replacement Motor bearings are worn Inspect spindle shaft If the shaft feels loose or has play replace the turbine motor Refer to Section 6 2 2 Turbine Motor Replacement Bur is chattering during ...

Page 27: ...be locked out to prevent accidental operation of the spindle 6 2 1 Bur and Collet Replacement In normal operation the bur will become worn If improper feeds and speeds are used the bur may become loaded with material In both instances replace the bur During initial production the bur and the work piece should be examined often in order to determine at what interval the bur should be replaced Repla...

Page 28: ...h Collet Collet Nut 5 To remove a worn bur pull the bur out of the loosened collet 6 If the collet is being replaced completely remove the nut and extract the old collet Insert the new collet and refit the nut leaving it loose 7 If an identical new bur is replacing a worn one insert the new bur and measure and adjust the length of the its exposed portion according to the measurement taken in the s...

Page 29: ...main housing by rotating the fitting counter clockwise 6 Remove the internal retaining ring and supply boot ATI recommends replacing the internal retaining ring and supply boot at the air supply when the motor is replaced 7 Ease the garter spring off the front spindle boot 8 Using a 2 5 mm Allen wrench remove the 6 M3 socket button head cap screws holding the boot retainer ring and boot to the fro...

Page 30: ...the boot over the turbine motor spindle and align to the front housing assembly 23 Apply Loctite primer 7649 and Loctite 222 to the 6 M3 socket button head cap screws 24 Install the boot retaining ring over disk boot and secure with 6 M3 socket button head cap screws Tighten to contact and an additional 1 2 turn 25 Assemble the garter spring over the boot it will seat in the groove in the turbine ...

Page 31: ...rench torque wrench Supplies required Magnalube Loctite 222 1 Remove and or lock out the spindle motor air supply for safety De energize all energized circuits such as air and power 2 Disconnect the air hose from the compliance and spindle supply air fitting 3 Remove the deburring tool from the robot or work location 4 Remove the 6 M4 socket head cap screws that secure the rear housing to the fron...

Page 32: ...pin hole on the rear housing prior to pressing the ring cylinder into the bore Insert the new ring cylinder assembly into the rear housing 12 If the 2 M3 socket head cap screws do not have pre applied adhesive apply Loctite 222 to the threads 13 Using a 2 5 Allen wrench secure the ring cylinder assembly to the rear housing using the 2 M3 socket head cap screws Tighten to 12 in lbs 1 4 Nm 14 Assemb...

Page 33: ...9150 RC B XXXXX Refer to Table 4 1 for bur part numbers and descriptions 2 OPT 9150 RC C 12442 Ø 3 mm Collet 9150 RC C 12443 Ø 1 8 Collet OPT 9150 RC C 12444 Ø 3 16 Collet OPT 9150 RC C 12445 Ø 6 mm Collet Standard on the Metric Models OPT 9150 RC C 12446 Ø 1 4 Collet Standard on the Inch Models 3 OPT 9150 RC T 12479 9 16 14 5 mm Collet Wrench 4 OPT 9150 RC T 12475 7 16 11 mm Collet Wrench 5 1 370...

Page 34: ...try and Motor Speed Spindle Air Pressure 6 2 bar 90 psi All Models Air Consumption Idle 2 8 l s 6 CFM Air Consumption Stall 10 2 l s 21 5 CFM Air Connection Spindle 3 8 Tube Air Connection Compliance 5 32 Tube Sound Pressure Level1 Less than 78 dB A without Cutter Collet Size Standard2 1 4 6 mm on the Euro Models Rotary Burs 3 Commercial Units Rated 40 000 RPM or Higher Special Tools Open End Wren...

Page 35: ... 32 4mm Push to Connect Fitting Notes Motor Spindle air to be regulated to 6 2 Bar 90 PSI 1 Air supply to be dry NOT lubricated and filtered 5 Micron or 2 better The use of a coalescing filter is recommended Air consumption 2 83 l s 6 CFM at idle 10 2 l s 21 5 CFM 3 at stall DO NOT restrict air flow or pressure to alter motor speed 4 The installed air supply fittings may be removed to utilize 5 cu...

Page 36: ...3405 2210001 01 1 8NPT Swivel Elbow 5 32 4mm PL Tubing 3 1 3410 0001151 01 O RING 1 16 x 1 16 4 7 3500 1158008 21 M3 X 8 BHCS SS 5 1 3540 0102008 11 Dia 2mm x 8mm Dowel Pin 6 2 3610 0235001 21 GARTER SPRING RC 150 7 1 3610 0340001 21 GARTER SPRING RC 340 8 1 3610 0494000 20 GARTER SPRING SR 081 Boot 9 1 3690 1200001 11 RET INT 2 76 UR 268 10 5 3690 7500003 11 RET INT 1 5005 100 11 4 3700 50 3005 D...

Page 37: ...g out of or in any way connected with products or services supplied hereunder may be brought more than one 1 year after the cause of action occurred No representation or agreement varying or extending the warranty and limitation of remedy provisions contained herein is authorized by ATI and may not be relied upon as having been authorized by ATI unless in writing and signed by an executive officer...

Page 38: ...tact ATI for part numbers and pricing Premature bearing failure can occur from exposing the deburring tool to coolants and water or impacts from collisions 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...

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