VersaFinish™ Axially Compliant Robotic Finishing Tool (Model 9150-ACT-390) Installation and Operation Manual 9150-ACT-390 Document # 9610-50-1012-14 December 2012 Engineered Products for Robotic Productivity Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: info@ati-ia.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 ! 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.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 Glossary of Terms Term Definition Adapter Device for attaching the tool to robots or work surfaces. Air Filter Device for removing contamination from air supply lines. Typically refers to removal of particulates. Air Lubricator Device for adding controlled volumes of lubricating oil to the air supplying the air motor. Vane Motor Air motor that drives the tool spindle. Bur Any unwanted, raised protrusion on the workpiece.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 Table of Contents 1. General Data ................................................................................................................ 5 1.1 2. Handling, Installation, Storage and Transportation .................................................. 6 2.1 2.2 2.3 2.4 2.5 3. 5.6 5.7 Routine Operational Maintenance ................................................................................ 16 Media Replacement ......
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 1. General Data 1.1 Environmental Limitations Operation Installation position Mounted to machining center by means various, customer-supplied tool holders/adapters. Temperature range 5°C–35°C 41F–95F Storage Temperature range 0°C–45°C 32F–113F Conditions The tool should be stored in its crate and in a dry place. Consult Section 2.5 of this manual. Utilities The tool requires clean, dry, filtered, lubricated air.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 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.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 2.3.2 Pneumatics and Lubrication Connect the tool as shown in Figure 2.3 Figure 2.3—Pneumatic Connections The air supply should be dry, filtered, and lubricated as described in Section 5.6. 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.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 Function Connection Type Pressure 1/4-NPT Port 6.2 bar (90 psi) Compliance (Axial) Force 1/8-NPT Port .34–4.1 bar (Maximum) (5–60 psi) Exhaust 1/4-NPT Port (High-flow Muffler Supplied) Not Applicable Motor Inlet Table 2.1—Pneumatic Connections The tool must be plumbed using flexible tubing.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 3. Technical Description 3.1 Product Description Attached at the end of this document you will find the VersaFinish product description. 3.2 Technical Specifications Main specifications for the axially compliant tool: Motor Air motor, vane type Idle Speed 5,600 RPM Working Speed (max. power) 2,600 RPM Power 390 W (0.52 hp) at 2,600 RPM Torque (max. power) 1.4 Nm (1 lb-ft) (starting/stall) 2.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 ACT-390 Horizontal Compliance Force 30 140 25 120 Compliance Forec (N) Compliance Forec (lbf) ACT-390 Horizontal Compliance Force 20 15 10 5 100 80 60 40 20 0 0 0 20 40 60 80 0 100 1 2 3 4 5 6 7 Air Pressure (bar) Air Pressure (psi) Figure 3.1—ACT-390 Horizontal Compliance Force Curves The force characteristics shown graphically above are for horizontal, rigidly-mounted installations.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 ACT-390 Motor Power (hp) ACT-390 Motor Power (kW) 0.6 0.4 0.5 Power (kW) Power (hp) 0.3 0.4 0.3 0.2 0.2 0.1 0.1 0.0 0.0 0 2000 4000 6000 0 RPM 2000 4000 6000 RPM Figure 3.3—ACT-390 Motor Power Curves Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: info@ati-ia.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 4. Operation These operating instructions are intended to help system integrators program, start up, and complete an installation containing an axially compliant tool. The system integrator should be familiar with the task in general and should have extensive knowledge of programming and automation. Important Note Regarding Operation: The air motor is supported by two guide rods attached to the front plate of the deburring tool.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 DANGER: Never use the VersaFinish in a manner to produce radial loads. Avoid using the VersaFinish for countersinking or drilling. 4.2 VersaFinish Working Environment As described in previous sections, the VersaFinish should only be used in an automated cell/chamber. The work cell must be secured by means of barriers to prohibit personnel from entering the cell.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 4.4 Media Considerations For instructions on how to replace the media, see Section 5.1. In most applications, no cooling or lubrication of the part or tool is necessary nor is it desirable. For some materials and situations, the addition of coolants or compressed air may aid the cutting process. Any application of coolant must be exercised with care to prevent fluids from entering the tool or its chuck. As mentioned in Section 4.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 4.6 Spindle Operation and Media Selection When used with flexible abrasive media, the VersaFinish will perform best when the rotating media approaches the burr in a direction that will fold the burr back on itself. This will allow the media to remove material rapidly without excessive force and without the creation of a secondary bur.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 5. Maintenance Instructions Important Note Regarding Operation: The air motor is supported by two guide rods attached to the front plate of the deburring tool. To prevent binding of the compliance, one of these guide rods is rigidly attached to the front plate. The second guide rod and the compliance piston rods are free to float in the front plate.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 4. Use the pick to lift the boot as necessary and slide it forward off the spindle end of the tool. 5. To refit the boot perform the following steps: Slip the first o-ring up and over the boss of the main housing, temporarily leaving the o-ring on the main housing. Slip the boot over the moving motor mount plate and onto the main housing.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 5.5 Sensor Replacement The VersaFinish may be outfitted with up to three (3) proximity sensors. These sensors may be monitored by the customer to determine the following information. 1. Option –F: The Forward Sensor. This sensor is included on all units. It is ON when the spindle is fully forward. 2. Option –R: The Retract Sensor. This sensor is ON when the spindle is fully Retracted. 3. Option –T: The Tachometer.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 5.5.2 Retract Sensor (Option -R) The retract sensor is mounted to the rear housing inside the tool. When the spindle is within approximately 1.5mm of being fully retracted the sensor will turn on. This may be utilized to indicate when excessive brush force is being applied (i.e., the brush has been pushed back so far and so hard that the end of compliance travel has been reached).
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 Using fingers, advance the tachometer sensor until there is a gap of 1mm between the sensor and the back of the target plate. Rotate the spindle through one complete revolution by turning the chuck. Observe the sensor to target gap and adjust the sensor position as necessary so the sensor does not hit the target nor has a gap greater than 1mm. The target will have some warpage causing axial runout. This is normal and acceptable.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 6. Troubleshooting 6.1 Troubleshooting Matrix Process development is an iterative, learning task. The following table is presented to assist in solving various problems.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 7. Recommended Spare Parts For repair and spare parts please contact ATI. For an exploded drawing showing all the components of the VersaFinish, see Section 7—Drawings. Suggested user replaceable, optional, and spare parts are listed in the tables below. All other repairs must be performed by ATI.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 8. Drawings Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: info@ati-ia.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: info@ati-ia.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: info@ati-ia.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 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.
VersaFinish™ Installation and Operation Manual Document: 9610-50-1012-14 10.Attachments Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email: info@ati-ia.
