Robotic Deburring Tool - ATI Industrial Automation
Contents
1. 30000 25000 20000 15000 Speed 10000 Rotary speed in RPM 5000 0 14 5 29 43 5 58 72 5 87 Drive pressure in psi Figure 5 3 Idle Speed as Function of Applied Drive Pressure Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com 13 Hiac Installation and Operation Manual Document 9610 50 1000 09 6 Operating Instructions These operating instructions are intended to help system integrators program start up and complete a robotic deburring cell containing a Hiac 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 The system integrator 1s responsible for providing user documentation for the complete deburring installation This document is not intended to cover all aspects of such an installation although it contains some information vital for the system user such as maintenance instructions for the Hiac and instructions related to safety 6 1 General Precautions It is important that all personnel involved in operation of the Hiac have a thorough understanding of the operating procedures Failure to follow these or neglecting safety precautions can create hazardous situations which may in the worst case injure personnel or damage the deb2. 21 Hiac Installation and Operation Manual Document 9610 50 1000 09 7 6 Repairs and Spare Parts For repair and spare parts please contact ATI User serviceable parts are shown in Figure 7 2 All other repairs must be performed by ATI ATI recommends stocking the following spare parts in addition to burrs Part No Description 9005 51 1000 Free Flying Piston FFP 3700 51 1009 Cylinder 9005 51 1003 AC 90 Upper Bearing Kit Only original spare parts and burrs from ATI should be used Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com 22 Hiac Installation and Operation Manual Document 9610 50 1000 09 8 Drawings DE DW 0SL6 spealyl 9 10 64L 1 H 0616 Spea14 1 LdN 40 84L 1 H 0816 Nejeledas palspio Jejdepy jeu ondo l 1 i i orejas ppr A i amssead pupa oqo wog 1 i porn oo oaea dd be Hono z wodo i m es H f oneg gt i i ie XZ E i i Y E E pnpa I i ja FUO ogu M woy pajenpe anen menu z vogdo E I oe gt A regoruco Jogos ss AA wog paree anen 18d 92 N ppd vod ueber onewneaud vod jdedqenion deeq z zH l 00001050 86 Ap Ord o g aoueIduoo SW Isneyx3 p 9 Ajddng g wwg gg 0H 6ZLe 1 H 05L6 souel dwod ze 01 sneyx3 LdN p 1 Alddns LdN
3. Hiac Installation and Operation Manual Document 9610 50 1000 09 Axial contact force 5 6 4 5 3 4 2 25 Axial force lbs 1 1 0 29 58 87 116 145 174 203 232 261 29 31 9 34 8 Control pressure psi Figure 5 1 Axial Contact Force measured with rotary burr pointing downwards Due to pressure losses between the pressure regulator and the Free Flying Piston FFP the axial force is lower than theoretical calculations will predict The actual force characteristics will change from installation to installation due to different types of pneumatic components used 400 lt NS 350 300 250 200 Torque Pow er oa o Rotor torque M in Nmm Output power P in W are o o a o 0 5000 10000 15000 20000 25000 30000 Rotor velocity in rpm Figure 5 2 Theoretical Calculations Hiac Output Torque and Power Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com 12 Hiac Installation and Operation Manual Document 9610 50 1000 09 We recommend a working speed of 15 000 to 25 000 RPM for maximum possible output A speed lower than 15 000 RPM is not recommended as it increases the risk of stalling the motor due to the higher torque at lower speeds
4. oooncccincccinncccnnccccnnccnoncnnnnanananan non cn ronca caranccnannn 7 4 2 Unpacking and Handling sesser 7 4 3 Installation 7 4 3 1 Mounting Adapter and Interface Plate ooooccccccnnnnncocccccnnccconanannccnnccnnananrncncnnnno 7 4 3 2 PNOUMAtICS iuris ad 9 44 Transportation and Protection during Transportation ooocnnnccnnnnncccinnnonccnnononananonaracaninnnos 10 45 Storage and Preventive Maintenance during storage oooncccinnncinncccnnncccnncanannanancncanannanos 10 5 Technical Description ee eet E eee eine detest eee 11 5 1 Technical Specification omita li 11 6 Operating INStruCtoms eissis toneis iaren eaaa aae aa led 14 6 1 General PRECAUTIONS iii di ie AA eta 14 6 2 Hac Working EnVIOMONtvistaa il 15 6 3 Tool Center Point TCP POSItiON 0 cceccceceeeeeeeeeeeneeeseeeeseaeeeeaeeseaeeeseeeeseaeeseneeeseaeeseaaes 15 6 4 Operational Considerations ccccccecccececeeeeeeeeeeeeseeeeseaeeseaeeseaeeseaeeeseeeseaeeseieeesseeesaees 15 6 5 Programm o cogsete las Deseo fueck S55 atte oes cotta 17 fs Maintenance IMStructons sce iii ti dd in ck defied 18 7 1 Regular Operational Maintenance oocccncccinoccconcccnnnccnonnncnncnnanon conocia conc n nana c nn n nara cn rnncnine 18 7 2 Mia ilea g A st E tere eer E E rrr ee reeerrrer ere 20 7 3 Replacement Of Burrs comarca aaa iene bite 20 7 4 Replacement of Other Hiac Parts cccccceceeeceeeeeeseeeceeeeseeeeeseaeeeeeneeseeeeseeesseaeessieeeea
5. Email info ati ia com 14 Hiac Installation and Operation Manual Document 9610 50 1000 09 6 2 6 3 6 4 In order to increase the life of the Hiac motor and bearings always use proper lubrication Please consult Section 7 2 Lubrication Hiac Working Environment As described in previous sections the Hiac 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 The barrier could consist partly or fully of Plexiglas to facilitate observation of the deburring operations During system or Hiac maintenance make sure the Hiac and robot are stopped before entering the robot cell When installing and testing never be present in the cell when the Hiac is running Be aware of rotating parts Use eye protection while working around the Hiac Be aware of high sound levels Always use hearing protection while working in the neighborhood of the deburring cell Tool Center Point TCP Position Figure 6 1 shows the TCP position and Hiac dimensions When setting the TCP position in the robot controller use the mid position of the 0 31 inch axial stroke of the FFP Also remember to take into account the depth of the Speedeburr adapter please consult Section 4 3 1 Mounting Adapter and
6. Interface Plate In case an additional interface plate is used in order to fit the adapter to the robot this depth must be considered as well TCP Without Speedeburr adapter Dx 2 95 in Dy 0 in Dz 2 75 in With Speedeburr adapter Dx 4 33 in Dy 0 in Dz 2 75 in Operational Considerations To obtain best results it is important for the FFP to be running with low friction in the cylinder Please consult Section 7 1 Regular and Operational Maintenance The Hiac should not be operated for extensive periods of time with the cutting tip pointing up This orientation will increase the amount of debris entering the cylinder and cause premature wear of the cylinder and piston possibly preventing the piston from floating altogether If the Hiac must be mounted in this orientation then a continuous or regular burst of high velocity air should be used to blow debris away from the piston and cylinder to insure low friction between the FFP and the cylinder For instructions on how to replace the burr please consult Section 7 3 Replacement of Burrs Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com 15 Hiac Installation and Operation Manual Document 9610 50 1000 09 CAUTION The Hiac should not be operated for extensive periods of time with the cutting tip pointing up This orientation will increase the amount of debris entering the
7. equal axial force a conventional manual pressure regulator can be used If the burrs to be removed are varying 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 axial force by using an analog pressure regulator controlled from the robot controller An analog output port in the robot controller will be needed Table 4 1 Pneumatic Connections It is recommended that 3 8 plastic tube be used for the motor air supply inlet and 5 32 tube for the axial force air supply inlet Note that a 10 32 connection is used for the axial force air supply inlet and a 1 8 NPT connection for the motor air supply inlet Use two silencers directly mounted on the two 1 4 NPT exhaust outlets Information on the sound intensity is given in Section 5 1 Technical Specifications If more noise suppression in desired install silencers on the exhaust line further away from the Speedeburr Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com 9 Hiac Installation and Operation Manual Document 9610 50 1000 09 adapter An oil recovery unit may be installed on the exhaust line to avoid the mist lubrication droplets from entering the atmosphere around the robot installation Additionally to reduce the sound in neighboring working areas a barrier consult Section 6 2 Hiac Working Envi
8. g wwgg 841 1 H 0916 S9ZIS HOd Y SUOISUSUIJ d Jejdepy euondo e Lobb a G amm SY ajdepy jeuondo yum palddns smal9g dead s ZH OPIS 124 Wo1 posoquayunoD 0 96 SM9 99 deg pe H 191908 9N S10 0 10 MYL 9D Xv sneyX3 JOO Aiddng JOJOJA Lee 081 9W UORISOANINA f j j 7 yonpolg ceba7 10 SHOd y y L L IVOS e Y 1 Jing uo 9904 jJue su0D INSS Jd 8 Xy souel dwoD r g S sneyx3 Joyo e ung apiquea usjsBun UOJSId BulA 4 9914 Ueduog pelasibay 1006 OSI Woo e ne mmM 6SZ9 Z22 616 1 Xe MOILYWOLNY Z0 L0L 0OS 0EZ6 8 Ejd Jardepy m Jingapaads 06 9Y wove ye oju ewa GLLO ZZZ 616 1 181 YSN 6 SZZ ON redy ema yiompoos Leg TPISLSNAANI Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com 23 Hiac Installation and Operation Manual Document 9610 50 1000 09 9 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 Speedeburr products purchased hereunder will be free from defects in material and workmanship under normal use for a period o
9. rate and speed In most applications it is best to adjust the regulator to a maximum pressure 73 90 psi with the adjustment screw in the full out position approximately flush with the surface DANGER The Hiac must never run without proper lubrication Damage to the unit will occur Please consult Section 7 2 Lubrication Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com 17 Hiac Installation and Operation Manual Document 9610 50 1000 09 7 Maintenance Instructions 7 1 Regular Operational Maintenance To obtain best results it is important for the piston to be running with low friction in the cylinder This should be checked at regular intervals Some debris will always enter the cylinder and regular cleaning is recommended The Hiac should not be operated for extensive periods of time with the cutting tip pointing up This orientation will increase the amount of debris entering the cylinder and cause premature wear of the cylinder and piston possibly preventing the piston from floating altogether If the Hiac must be operated in this orientation then a continuous or regular burst of high velocity air should be used to blow debris away from the piston and cylinder to insure low friction between the FFP and the cylinder Additionally the outside of the Hiac should be kept clean to ensure proper cooling Recommended Inspection and Cleaning Proc
10. Flying Piston FFP 5 1 3700 51 1009 Cylinder 6 1 Call ATI for Information Hiac Rotary File Burr 7 1 3700 51 1000 Hiac Motor Housing 8 1 3700 51 1001 90 Degree Bracket 9 1 3700 51 1015 Adjustment Screw 10 1 9150 HIAC 4796 O ring Set Figure 7 1 User Serviceable Parts Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com 19 Hiac Installation and Operation Manual Document 9610 50 1000 09 7 2 Lubrication Before start up be sure a lubricator is installed as described in the pneumatic diagram in the drawing in Section 8 Drawings Make sure the air lubrication system is filled with oil Use oil similar to machine oil 10 spindle oil 60 Shell Exxon ATF DEXRON II automatic transmission oil or similar Oilfog air lubrication systems are not recommended as a means for providing lubricated air for this product Only microfog systems should be used The system should be adjusted to 10 15 drops per minute Only part of the oil drop actually enters the air stream Fill the lubricator with the proper type of oil at regular intervals CAUTION When the system is first installed use a higher than recommended oil setting 2 times until the unit is receiving consistently oiled air If possible run oil through the entire pneumatic tube between the oiler and the unit prior to operation It is recommended that the exhaust containing lubrication be filter
11. INDUSTRIAL AUTOMATION ISO 9001 Registered Axial Compliant Robotic Deburring Tool Installation and Operation Manual 9150 AC 90 Document 9610 50 1000 09 June 2012 Engineered Products for Robotic Productivity Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com Hiac Installation and Operation Manual Document 9610 50 1000 09 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 Information contained in this document is the property of ATI Industrial Automation Inc ATT 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 reflect and incorporate changes made to the product The information contained herein is confidential 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 fitness of this device for a particular application ATI Industrial Automation shall not be liable for any errors cont
12. aes 21 do COV OMA secs isidro ii 21 7 6 Repairs and Spare Parts ccccscececeeseseeceeeeeeeaeeeeeeeeseaeeseaeeeseaeeseeeeeseaeeseaeeeseaeeeneeeeseaeess 22 A A eet aaadulevenentincts 23 Terms and Conditions ccccccccocccnnncconcoooonnnnnnncnnnnoonononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnnnnnnnnnnnnninnnnnnnnns 24 Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com 3 Hiac Installation and Operation Manual Document 9610 50 1000 09 1 Safety Precautions Please consult Section 6 2 Hiac Working Environment in this User Manual e Never use or start the unit without first reading and understanding this Installation and Operation Manual Make sure that the unit is mounted into the installation position as described in Section 3 1 Environmental Limitations of this document Never use the unit for other purposes than those explicitly described in this document Never use the unit in any other way than that described Make sure that the pneumatic control equipment is mounted as described in Section 4 3 2 Pneumatics of this document Only original spare parts and files burrs delivered from ATI must be used see Section 7 6 Repairs and Spare Parts Never be near the unit while it is started or running If it is necessary to approach the unit while in motion stand behind appropriate Plexiglass windows Beware of rotating p
13. ained 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 OCopyright by ATI Industrial Automation All rights reserved How to Reach Us Sales Service and Information about ATI products ATI Industrial Automation 1031 Goodworth Drive Apex NC 27539 USA www ati ia com Tel 919 772 0115 Fax 919 772 8259 E mail info ati ia com Technical support and questions Application Engineering Tel 919 772 0115 Option 2 option 2 Fax 919 772 8259 E mail mech_support ati ia com Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com 2 Hiac Installation and Operation Manual Document 9610 50 1000 09 Table of Contents Ti Safety Precautions aiii da ada dla iia 4 TOOL INTO nel e MAE acicate llendo dni eden licita 5 General Data cuida ltd litio 6 3 1 Environmental Limitations ia tii a ii 6 3 2 Extent of Warranties and Warranty CONQItiONS ooococonnccnnnnicnnnccnnncncnrncnancnnononnnnnnn nana canannanas 6 4 Handling Installation Storage and Transportation oooocnnccinnnininnncnnccnnnccnnnrnnronrcnnnrnnnnnr cana cana nccnnn 7 4 1 Inspection of Condition when Delivered
14. arts Use eye protection e g safety glasses The installation must be protected by a barrier to prohibit people from approaching the unit while in operation Beware of high sound levels Always use hearing protection while working in the neighborhood of the unit ATT is not liable for damages if the above instructions and instructions found elsewhere in this manual are not followed Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com 4 Hiac Installation and Operation Manual Document 9610 50 1000 09 2 Tool Information The following information is included in the Hiac shipping and storage crate INDUSTRIAL AUTOMATION ISO 9001 Registered Speedebur r Deburring Tool Engineered Products for Manufacturing Productivity Pinnacle Park 1031 Goodworth Drive Apex NC 27502 USA Tel 1 919 772 0115 E mail info ati ia com Fax 1 919 772 8259 www ati ia com Model Serial no Weight Output power Min Max file burr diameter Air vane motor Max drive pressure WARNINGS e Never use or start the tool without first reading and understanding the Installation and Operation Manual Make sure that the tool is mounted as described in Section 3 1 Environmental Limitations of this Installation and Operation Manual Never use the tool for other purposes than those explicitly described in the Installation and Operation Manual Make sur
15. cylinder and cause premature wear of the cylinder and piston possibly preventing the piston from floating altogether Under normal conditions no cooling or lubrication of the rotary burr is necessary The Hiac is used in most robot deburring installations with aluminum and steel workpieces without any coolants E 3 583 2 953 Max Min 3 858 13 54 O N 1 260 Figure 6 1 Hiac and Tool Center Point TCP Dimensions Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com Email info ati ia com 16 Hiac Installation and Operation Manual Document 9610 50 1000 09 6 5 Programming The Hiac must never be running while programming the robot There are various techniques that may be used to program the robot path In any case the burr should be nominally at the mid point of its stroke while deburring the part It will move up and down with part and path variation One programming method is to teach the path using the point of the burr as a guide following the edge of the part then manually or automatically adding offsets to the path points to achieve the final correct burr path Another method is to program the actual points making sure that at each point the burr
16. d Transportation 4 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 If necessary notify ATI for assistance in evaluation of the product condition 4 2 Unpacking and Handling The Hiac tool during transportation storing and handling should always be placed inside the accompanying box crate 4 3 Installation 4 3 1 Mounting Adapter and Interface Plate Figure 4 1 is a drawing of the Speedeburr pneumatic adapter ATI Part 9150 H T 3178 This adapter or equivalent should be used for mounting the Hiac to the robot or to other equipment The adapter facilitates the connection of the pneumatics to the Hiac The Hiac can be mounted on the robot or on a stand in which case the robot carries the part to be deburred to the Hiac Refer to the drawing in Section 8 Drawings The Hiac is mounted to the Speedeburr adapter by means of 8 M4 screws Be sure the O rings Figure 7 1 Item No 10 are positioned correctly into the grooves on the Hiac bracket before mounting the Hiac to the pneumatic adapter Removable thread locker should be used for all mounting bolts The Speedeburr adapter is mounted to the wrist of the robot usually by means of a robot spec
17. e e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com 20 Hiac Installation and Operation Manual Document 9610 50 1000 09 FFP holder Rotary Carbide File 4195 Free Flying Piston CA 8 File holder 4196 Q Figure 7 2 Burr Replacement 7 4 Replacement of Other Hiac Parts In addition to burrs Hiac parts such as the blades in the air vane motor and bearings should be replaced at regular intervals nominally every 2 years as part of a general overhaul see Section 7 5 Overhaul Experience has shown that during installation programming and sometimes during operation the Hiac and the workpiece collide or the radial forces acting are too high This sometimes results in damage to the cylinder and or the FFP In this case these parts may also need to be replaced Refer to Sections 7 1 Regular Operational Maintenance and Figure 7 2 Only original spare parts supplied by ATI should be used 7 5 Overhaul As described in previous sections of this User Manual the motor unit and Free Flying piston should be inspected and overhauled at regular intervals In addition to the above the Hiac should be thoroughly cleaned inspected and tested This overhaul must be performed by ATI in order to maintain the technical specifications and tool life of the Hiac Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com
18. e that the pneumatic control equipment is mounted as described in the Installation and Operation Manual in Section 4 3 2 Pneumatics Only original spare parts and files burrs delivered from the tool manufacturer must be used see Section 7 6 Repairs and Spare Parts Never stand near the tool while it is started and running If it is necessary to approach the tool while in motion stand behind appropriate Plexiglass windows Be aware of rotating parts A barrier to prohibit people from approaching the tool while in operation must secure the installation Be aware of high sound levels Always use earplugs while working near the tool If the above instructions and instructions found in the Installation and Operation Manual are not followed no claims may be raised against the manufacturer or the supplier of the tool The crate must be used whenever transporting or storing the tool Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com 5 Hiac Installation and Operation Manual Document 9610 50 1000 09 3 General Data 3 1 Environmental Limitations General Area classification Gas group ignition group Operation Installation position Temperature range Storage Temperature range Conditions None None Mounted to robot by means of the Speedeburr adapter and flange The flange is specific to each type of robot This flange i
19. ed through an oil recovery system before exhausting it to the atmosphere Long time exposure to air containing oil could be dangerous for personnel CAUTION Lack of lubrication will cause untimely wear on the motor and failure within a relatively short period If the lubrication is not working properly the motor will run slower than normal and may vary in speed Install the lubrication equipment near the robot base maximum 16 feet from the Hiac for best results 7 3 Replacement of Burrs Figure 7 2 shows the burr changing tools the Free Flying Piston FFP and burr rotary file The FFP and Cylinder should be inspected whenever a burr is replaced The Piston should rotate freely by hand in the Cylinder with no binding If binding is detected the FFP and or Cylinder should be replaced as described in Section 7 1 Regular Operational Maintenance To change the burr unscrew it with the burr changing tools and replace it with a new one Re assemble the parts as described in Section 7 1 Regular Operational Maintenance After the burr is changed and the unit re assembled check that the Free Flying Piston FFP is rotating with the burr If the FFP is not rotating static friction may be inspected for any visible scratches If a burr with an imbalance is used the FFP may also stop rotating All burrs are checked for imbalance before they are shipped Only original ATI burrs should be used Pinnacle Park e 1031 Goodworth Driv
20. edure Refer to Figure 7 1 e Remove the Lock Ring Item No 3 from the Hiac Motor Housing Item No 7 using the hook spanner wrench not shown e Gently pull the Cylinder Item No 5 and Free Flying Piston FFP Item No 4 assembly from the Hiac Motor Housing e Thoroughly clean the Male Spline the interior of the Motor Housing and the Lock Ring with a mild solvent e Spin the burr by holding the Free Flying Piston and assure it spins freely If it does not spin freely replace the Free Flying Piston e Separate the FFP from the Cylinder and clean thoroughly e Inspect the FFP and Cylinder for scratches Deep scratches may require replacement of the part s e Check the Burr Item No 6 condition and replace as necessary e Lightly lubricate the outside diameter of the Free Flying Piston and the inside diameter of the Cylinder with the same oil used for operational air lubrication e Assemble the Free Flying Piston in the Cylinder and assure the Piston moves freely without excessive play The fit between the Free Flying Piston and the Cylinder provides the seal for the axial down force air pressure therefore the fit must be consistent and without excessive play If the play is excessive replace the Cylinder e Install the Cylinder and the Free Flying Piston assembly on the Motor Housing and replace the Lock Ring Do not over tighten the Lock Ring e Assure the axial down force and the drive are working properly Pinnacle Pa
21. f one 1 year from the date of shipment This warranty does not cover components subject to wear and tear under normal usage or those requiring periodic replacement ATI will have no liability under this warranty unless a ATI is given written notice of the claimed defect and a description thereof within thirty 30 days after Purchaser discovers the defect and in any event not later than the last day of the warranty period and b the defective item is received by ATI not later ten 10 days after the last day of the warranty period ATI s entire liability and Purchaser s sole remedy under this warranty is limited to repair or replacement at ATI s election of the defective part or item or at ATI s election refund of the price paid for the item The foregoing warranty does not apply to any defect or failure resulting from improper installation operation maintenance or repair by anyone other than ATI ATI will in no event be liable for incidental consequential or special damages of any kind even if ATI has been advised of the possibility of such damages ATI s aggregate liability will in no event exceed the amount paid by purchaser for the item which is the subject of claim or dispute ATI will have no liability of any kind for failure of any equipment or other items not supplied by ATI No action against ATI regardless of form arising out of or in any way connected with products or services supplied hereunder may be brought more than
22. he Hiac should also be stored in a dry place For short term storage limited to a few weeks no preventive maintenance is needed except for cleaning For long term storage the Hiac should be thoroughly cleaned of any burrs or debris It should not be disassembled After cleaning the Hiac should be filled with oil of the same type used as lubrication during operation The oil should be poured into the Hiac through the adapter or through the Hiac bracket Place the Hiac inside a sealed plastic bag and place the Hiac inside the crate This is necessary in order to keep the blades in the air vane motor from drying out and for preventing the risk of corrosion Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com 10 Hiac Installation and Operation Manual Document 9610 50 1000 09 5 Technical Description 5 1 Technical Specifications Main specifications for the Hiac Motor Air motor vane type Speed Idle 30 000 RPM while deburring 18 000 25 000 RPM Torque 0 295 ft lbs at lower speeds Power 250 W at 20 000 RPM Weight total 1 124 lbs Weight FFP with burr 0 11 Ibs Compensation burr float Max 4 mm axial and lateral 2 mm recommended Axial force 0 23 5 6 lbs supply pressure of 0 43 psi Burr surface speed 24 6 34 4 ft sec measured at 8mm dia halfway between center tip and outer rim Air consumption Approx 14 1 CFM at 75 ps
23. i line pressure Sound pressure level 75 dB A Sound pressure value 87 dB C Rotary burrs 1 90 coned shape straight fluting 2 90 coned shape spiraled fluting 3 C2 C5 Carbide Other rotary burr file qualities on request Special tools Burr changing tool All noise emission measurements were taken at a distance of 3 feet from the Hiac and at a height of 5 feet from the floor The Hiac was mounted on a laboratory test bench No barriers or noise reduction facilities were used except for exhaust return to an oil recovery unit located beneath the test bench A drive pressure of 75 psi was applied full Hiac drive pressure No axial force pressure was applied The Hiac was running at full idle speed Because the working environment is not known this method was considered the best method for measurements The equivalent continuous A weighted sound pressure level was measured as 75 dB A The peak C weighted instantaneous sound pressure value was measured as 87 dB C Each Hiac goes through a thorough test procedure before it is shipped Below are theoretical and measured forces relative to applied axial air pressure Please note that theoretical calculations are not necessarily identical to actual data Measurements may vary from one product to another and should only be treated as nominal Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com 11
24. ific interface plate In some cases the Speedeburr adapter will mount directly to the robot without an interface plate The interface plate is manufactured either by the robot supplier the Hiac supplier the system integrator or by the owner user of the Hiac The Hiac with the Speedeburr adapter may be mounted to a table or stand using an interface plate or directly using the Speedeburr pneumatic adapter Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com 7 Hiac Installation and Operation Manual Document 9610 50 1000 09 _ 8 M4 0 7 0 59 deep Ea B C 1 732 0 238 0 75 deep equally spaced 0 250 S i XK NX 0 157 0 24 deep E a q of B C i of Hiac body 0 394 t 2 0 157 1 22 deep Interface Facing HIAC Axial force air supply 10 32 2 Exhaust 1 4 NPT F Motor Air supply 1 8 NPT ee Pneumatic Connections 2 Optional ports 0 2367 0 236 deep iad 0 2362 A b 1 9695 6mm H7 i C nole 1 9685 B C 1 575 i 0 079 deep 50mm H7 4 0 242 thru a C bored opposite E of Hiac body side B C 1 575 equally spaced E o po for M6 screws i a H 0 250 Dimensions in inches 26 Interface Facing Robot Figure 4 1 Speedeburr Hiac Adapter Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Emai
25. is at its nominal mid point when in contact with the part and that there are no radial forces The method used will depend on the robot s capabilities and programmer preferences If you are deburring sharp inner corners it may be required to use the area of the burr closer to its tip Note that in this case some of the compensation ability of the Hiac as well as the cutting surface speed is reduced When running the robot program the first time observe the path with the axial supply turned off When increasing the path speed it is important to notice that path deviation may increase with speed Verify that at operational robot path speed the Hiac burr remains near the mid point of its axial travel CAUTION The brass Cylinder Figure 7 1 Item No 5 that encloses the Free Flying Piston must be protected from collisions If struck it may be damaged and need replacement The axial force of the burr should be adjusted as described in Section 4 3 2 Pneumatics in order to achieve a correct sized and even chamfer To change the drive speed adjust the main supply pressure the greater the pressure the greater the speed and vice versa It is also possible to adjust the speed by using a small flat blade screwdriver to turn the adjustment screw on the side of the 90 degree bracket see Figures 7 1 and the drawing in Section 8 Drawings This adjustment varies the flow rate clockwise to decrease counter clockwise to increase the flow
26. l info ati ia com 8 Hiac Installation and Operation Manual Document 9610 50 1000 09 4 3 2 Pneumatics Connect the Hiac as shown in the drawing in Section 8 Drawings Pneumatic Diagram Two connection methods are shown Option 1 uses one solenoid valve to control both motor drive air supply and axial force air supply Option 2 uses two solenoid valves to independently control the two air supplies CAUTION Pneumatic components used for the motor drive circuit must be able to meet the air consumption requirements see Section 5 1 Technical Specifications Poor performance will result if the correct components are not used Function Thread Type Pressure Motor inlet 1 8 NPT 45 75 psi maximum 90 psi Axial contact force inlet 10 32 M5 0 45 psi maximum 45 psi Control functions 10 32 M5 Optional Exhaust 1 4 NPT Not Applicable Conventional pneumatic components not supplied with the Hiac tool are used to control the air supply to the Hiac ATI recommends that the user install a pneumatic pressure regulator in order to achieve a stable air supply and to reduce the air supply to the maximum of 90 psi The solenoid operated valve s are actuated from the robot controller by means of a digital output signal The external pressure regulator is used to control the air supply to the axial force compliance mechanism thus enabling control of the axial force on the rotary burr If the complete workpiece can be deburred with
27. one 1 year after the cause of action accrued 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 of ATI Unless otherwise agreed in writing by ATI all designs drawings data inventions software and other technology made or developed by ATI in the course of providing products and services hereunder and all rights therein under any patent copyright or other law protecting intellectual property shall be and remain ATI s property The sale of products or services hereunder does not convey any express or implied license under any patent copyright or other intellectual property right owned or controlled by ATI whether relating to the products sold or any other matter except for the license expressly granted below In the course of supplying products and services hereunder ATI may provide or disclose to Purchaser confidential and proprietary information of ATI relating to the design operation or other aspects of ATI s products As between ATI and Purchaser ownership of such information including without limitation any computer software provided to Purchaser by ATI shall remain in ATI and such information is licensed to Purchaser only for Purchaser s use in operating the products supplied by ATI hereunder in Purchaser s internal business o
28. perations Without ATI s prior written permission Purchaser will not use such information for any other purpose or provide or otherwise make such information available to any third party Purchaser agrees to take all reasonable precautions to prevent any unauthorized use or disclosure of such information Purchaser will not be liable hereunder with respect to disclosure or use of information which a is in the public domain when received from ATI b is thereafter published or otherwise enters the public domain through no fault of Purchaser c is in Purchaser s possession prior to receipt from ATI d is lawfully obtained by Purchaser from a third party entitled to disclose it or f is required to be disclosed by judicial order or other governmental authority provided that with respect to such required disclosures Purchaser gives ATI prior notice thereof and uses all legally available means to maintain the confidentiality of such information Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com 24
29. rk e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com 18 Hiac Installation and Operation Manual Document 9610 50 1000 09 CAUTION The Hiac should not be operated for extensive periods of time with the cutting tip pointing up This orientation will increase the amount of debris entering the cylinder and cause premature wear of the cylinder and piston possibly preventing the piston from floating altogether The burr must be replaced at regular intervals During initial production the burr and the workpiece should be examined often in order to determine at what interval the burr should be replaced as described in Section 7 3 Replacement of Burrs At regular intervals normally once every two years or more often depending on the application an overhaul of the Hiac should be performed in order to fully comply with the technical specifications Parts inside the Hiac such as the blades in the air vane motor and bearings should be replaced as part of the overhaul Please consult Section 7 5 Overhaul At regular intervals the pneumatics used to control the Hiac should also be checked especially the air filter and lubricator Remember to fill the lubricator with oil Item No Qty Part No Description 1 1 3500 1062012 11 Spine Lock Screw 2 1 3700 51 1002 Male Spline 3 1 3700 51 1012 Lock Ring 4 1 9005 51 1000 Free
30. ronment surrounding the installation may be installed Plexiglas or Lexan is preferred The axial force air supply pressure regulator should have a 0 45 psi range When testing for the proper contact force start with a very low pressure and increase slowly until the desired chamfer is achieved typically 3 psi for aluminum and more for steel workpieces Before start up make sure the air lubrication system is filled with oil See Section 7 2 Lubrication for proper lubricants and lubricating systems CAUTION Lack of lubrication will cause destruction of the motor within a relatively short time If the lubrication is not working properly you can hear the motor running slower than normal and the speed may be varying Install the lubrication equipment near the robot base maximum 16 feet away from the Hiac for proper operation See Section 7 2 Lubrication for more about lubrication 4 4 Transportation and Protection during Transportation The Hiac is packaged in a wooden crate designed to secure and protect it during transportation Always use the crate when transporting the Hiac in order to minimize the risk of damage When taking the Hiac out of the crate and carrying or performing maintenance try to always grab and hold it around the motor housing please refer to the drawing in Section S Drawings 4 5 Storage and Preventive Maintenance during storage The Hiac should be stored in the wooden crate when it is not in use T
31. s normally not supplied by ATL Mounted to a table or stand by means of the Speedeburr adapter the robot is carrying the workpiece 5 C 35 C 41 F 95 F 0 C 45 C 32 F 113 F The tool should be stored in its crate and in a dry place The tool should be kept dry and full of pneumatic oil when stored Keep unit in crate if possible Consult Section 4 5 Storage and Preventative Maintenance during Storage of this manual 3 2 Extent of Warranties and Warranty Conditions ATI Industrial Automation warrants the Hiac deburring tool for manufacturing errors for one 1 year from the delivery date delivery date is defined to be the date the Hiac is shipped from ATI s facility The warranty is not valid if the Hiac is used for other purposes than deburring The warranty is not valid if handling installation storage transportation operation or maintenance of the Hiac does not comply with the instructions given in this Manual The warranty is not valid if the warnings given are not obeyed If the instructions in this Manual and other instructions given in writing that accompany the Hiac are not followed no claims can be raised against the manufacturer or the supplier of the Hiac Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com 6 Hiac Installation and Operation Manual Document 9610 50 1000 09 4 Handling Installation Storage an
32. urring installation and the Hiac The Hiac must only be used for robotic deburring applications The Hiac is a deburring tool only O DANGER Never use the Hiac for purposes other than robotic deburring Grinding countersinking or other metal forming processes should not be performed by the Hiac It may be dangerous to operate the Hiac for these purposes If a failure occurs due to forces caused by improper use hazardous situations for both personnel and equipment could be created The Hiac is intended to perform deburring only The Hiac should not be used to deburr materials that are prone to fracture A fracturing workpiece may result in pieces of material damaging surrounding working environment and personnel Material removed correctly should be in the form of chips Reduce the robot velocity when the workpiece and the Hiac are making initial contact Making the contact movement between the Hiac and the workpiece too fast may in some situations result in a collision Collisions may create hazardous situations for both personnel and equipment When performing maintenance always remember to tighten nuts and bolts thoroughly and use a removable thread lock adhesive When replacing burrs always attach the burr correctly Please consult Section 7 3 Replacement of Burrs O DANGER Never use the Hiac as a hand held machine Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e
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