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ATI Radially-Compliant Robotic Deburring Tools
Flexdeburr™
(Models 9150-RC-300, -340 & -660)
Installation and Operation Manual
US Patent # 6,974,286 B2
9150-RC-340
Document #: 9610-50-1007-11
September 2009
Engineered Products for Robotic Productivity
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Pinnacle Park
1031 Goodworth Drive
Apex, NC 27539
Tel: 919.772.0115
Fax: 919.772.8259
www.ati-ia.com
Email: [email protected]
Table of Contents
Related Manuals for ATI Technologies Flexdeburr 9150-RC-300
Summary of Contents for ATI Technologies Flexdeburr 9150-RC-300
- Page 1 ATI Radially-Compliant Robotic Deburring Tools Flexdeburr™ (Models 9150-RC-300, -340 & -660) Installation and Operation Manual US Patent # 6,974,286 B2 9150-RC-340 Document #: 9610-50-1007-11 September 2009 Engineered Products for Robotic Productivity • • • • • • Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259...
- Page 2 Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 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 this product, otherwise damage to this product or unsafe conditions may occur.
- Page 3 Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 Glossary of Terms The Flexdeburr™ product family is ATI's line of Radially-Compliant (RC) deburring tools. Articulated motion of the high-speed, air turbine-driven spindle allows for the rapid removal of parting lines and burrs while following irregular part profiles.
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Page 4: Table Of Contents
Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 Table of Contents General Data ..........................5 Environmental Limitations ......................5 Cutting Tool Holding Systems (Collets) ................. 5 Deburring Tool Part Numbers ....................6 Handling, Installation, Storage and Transportation..............7 Inspection of Condition When Delivered................7 Unpacking and Handling ...................... -
Page 5: General Data
Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 1. General Data 1.1 Environmental Limitations Operation: Installation position: Mounted to robot by means of the side mounting pattern or rear adapter flange. The flange is specific to each type of robot. This optional flange is normally supplied by ATI in a blank form suitable for customer modification. -
Page 6: Deburring Tool Part Numbers
Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 collet system represents a greater initial expense and its wrenches and collet nut are more delicate. The two collet systems are not interchangeable. An ER-11 collet cannot be used in a standard Flexdeburr and the standard Flexdeburr collet cannot be used with an air motor designed for the ER-11 collet system. -
Page 7: Handling, Installation, Storage And Transportation
Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 2. Handling, Installation, Storage and Transportation 2.1 Inspection of Condition When Delivered Upon receipt, the following should be checked: - Delivery in accordance with freight documents - Damage to packaging 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. - Page 8 Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 Figure 2.1—RC-300 Series Geometry and Mounting • • • • • • Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: [email protected]...
- Page 9 Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 Figure 2.2—RC-300-ER Series Geometry and Mounting • • • • • • Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: [email protected]...
- Page 10 Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 Figure 2.3—RC-660 Geometry and Mounting • • • • • • Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: [email protected]...
- Page 11 Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 Figure 2.4—RC-660-ER Geometry and Mounting • • • • • • Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: [email protected]...
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Page 12: Pneumatics
Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 2.3.2 Pneumatics Connect the RC deburring tool as shown in Figure 2.3. Figure 2.3—Pneumatic Connections The air supply should be dry, filtered, 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- 6.5 bar [90-95 psi]. - Page 13 Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 (Consult the valve and regulator supplier’s literature when selecting these components.) If the complete workpiece 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 workpiece, and this variation is repeatable for all workpieces of the same type, it may be necessary to adjust the force using an analog pressure regulator controlled from the robot.
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Page 14: Transportation And Protection During Transportation
Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 2.4 Transportation and Protection during Transportation The RC deburring tool is packaged in a crate designed to secure and protect it during transportation. Always use the crate when transporting the deburring tool in order to minimize the risk of damage. -
Page 15: Technical Description
Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 3. Technical Description 3.1 Product Description Attached at the end of this document you will find the RC deburring tool product description. 3.2 Technical Specifications Main specifications for the RC deburring tools: Parameter Rating Motor Air Turbine... - Page 16 Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 All noise emission measurements were taken under no load idle conditions without a cutting tool. Because the working environment is unknown, it is impossible to predict the noise that will occur during a deburring operation. Each RC deburring tool receives a thorough test procedure before it is shipped.
- Page 17 Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 RC-660 Series Radial Contact Force Centering Air Pressure (Bar) RC-660 Series Radial Contact Force Centering Air Pressure (PSI) Figure 3.2—RC-660 Series Radial Compliance Force Curves (Measured at the Spindle Tip) The actual force characteristics will vary slightly from installation to installation due to mounting orientation and condition of the unit.
- Page 18 Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 RC-300/340 Series Performance Curve (RC-300 Stops at 30,000 RPM) (Watts & Torque at 6.2 Bar) 0.14 Torque 0.12 0.10 0.08 0.06 0.04 Watts 0.02 0.00 10,000 20,000 30,000 40,000 RC-300/340 Series Performance Curve (RC-300 Stops at 30,000 RPM) (Horsepower &...
- Page 19 Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 RC-660 Series Performance Curve (Watts & Torque at 6.2 Bar) 0.40 Watts 0.30 0.20 Torque 0.10 0.00 10,000 20,000 30,000 40,000 RC-660 Series Performance Curve (Horsepower & Torque at 90 PSI) 1.00 4.00 Horsepower 0.80 3.00...
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Page 20: Operation
Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 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 21: Operational Considerations
Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 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. Always use hearing protection while working in the neighborhood of the deburring cell. -
Page 22: Cutter Operation And Burr Selection
Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 Figure 4.2—Flexdeburr Pointed Teaching Tool Inside corners represent a complex situation for compliant deburring tools. In general, the cutter 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 23: Safety Precautions
Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 Plastics represent the most difficult deburring challenge due to the phenomenon of chip re- welding. In this process, if the cutter is dull or the feeds and speeds are not correct for the material the removed, chip will melt and weld to the cutter or the workpiece. -
Page 24: Maintenance Instructions
Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 5. Maintenance Instructions 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. -
Page 25: Pivot Bearing Replacement
Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 • Install the spindle air supply fitting in the air motor using non-hardening thread sealant. • Insure that the spindle air supply fitting is centered in the housing (side boot) opening before tightening the fastener in the pivot post. 5.3 Pivot Bearing Replacement The pivot bearing allows articulation of the motor assembly. -
Page 26: Ring Cylinder Assembly
Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 • Always use a new keying dowel pin. Insert the keying dowel pin with its crowned (radiused) end first so it rests in the slot machined in the pivot bearing’s ball. • Apply low strength thread locker such as Loctite-222 to the socket head screws used to secure the clamping washer and refit both the washer and screws to the rear housing. -
Page 27: Pneumatics
Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 small o-ring and dowel pin for reuse. Always replace the large o-rings on the outside of the ring cylinder assembly when it is reinstalled. 5. Replacing the ring cylinder assembly is the reversal of these steps with the following points. •... -
Page 28: Recommended Spare Parts
Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 6. Recommended Spare Parts For repair and spare parts please contact ATI. Figure 6.1 and 6.2 are exploded drawings showing all the user replaceable components of the Flexdeburr. Suggested user-replaceable, optional, and spare parts are listed in the tables below. - Page 29 Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 Figure 6.1—RC-300 Series Serviceable Parts • • • • • • Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: [email protected]...
- Page 30 Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 Figure 6.2—RC-300-ER Series Serviceable Parts • • • • • • Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: [email protected]...
- Page 31 Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 Figure 6.3—RC-660 Series Serviceable Parts • • • • • • Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: [email protected]...
- Page 32 Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 Figure 6.3—RC-660-ER Series Serviceable Parts • • • • • • Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: [email protected]...
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Page 33: Troubleshooting And Burr Selection
Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 7. Troubleshooting and Burr Selection 7.1 Troubleshooting Matrix Deburring process development is an iterative, learning task. The following table is presented to assist in solving deburring problems. Problem Cause Solution Hard work material Use better grade burr material add coating Wear (TiAlN) -
Page 34: Burr Selection Table
Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 7.2 Burr Selection Table Standard length commercial burrs are used with Flexdeburr products. The length of these tools is typically around 2 inches for 1/4” shank diameter burrs [50mm for 6mm diameter]. Longer shank burrs are available from industrial suppliers and will appear in their catalogs with descriptions such as “long”... - Page 35 Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 9150-RC-B-24063 Diamond Cut, 3/8" Burr Diameter, 3/4" Burr Length, 1/4" Shank • Materials/Application: For hardened and tough materials, super alloys, and stainless steel, alloyed cast steel and fiber reinforced plastics • Edge and surface working •...
- Page 36 Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 9150-RC-B-26408 Cut FVK, 1/4" Burr Diameter, 5/8" Burr Length, 1/4" Shank • Materials/Application: For trimming and contour milling of all glass and carbon fiber reinforced plastics • Features/Benefits: Special cut geometry allows high feed rates due to low cutting forces 9150-RC-B-24862 Alt Diamond Cut, 1/4"...
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Page 37: Terms And Conditions
Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 8. Terms and Conditions 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 to Purchaser that robotic deburring products purchased hereunder will be free from defects in material and workmanship under normal use for a period of one (1) year from the date of shipment. -
Page 38: Attachments
Flexdeburr Installation and Operation Manual Document: 9610-50-1007-11 9. Attachments • • • • • • Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: [email protected]...