ATI Pivoting Compliance Compensator Installation and Operation Manual

Compensator

Pivoting Compliance Compensator

Installation and Operation Manual

Document #: 9610-15-1002

December 2013

Engineered Products for Robotic Productivity

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: [email protected]

Pivoting Compliance Compensator Installation and Operation Manual

Document #9610-15-1002-02

Foreword

Please contact ATI Industrial Automation with any questions concerning your particular model.

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 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 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:

ATI Industrial Automation

1031 Goodworth Drive

Apex, NC 27539 USA

WWW.ati-ia.com

Tel: 919.772.0115

Fax: 919.772.8259

E-mail: [email protected]

Technical support and questions:

Application Engineering

Tel: 919.772.0115, Option 2, Option 2

Fax: 919.772.8259

E-mail: [email protected]

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: [email protected]

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Document #9610-15-1002-02

Table of Contents

1. Safety ......................................................................................................................................... 5

1.1 Explanation of Notifications ......................................................................................................... 5

1.2 General Safety Guidelines ............................................................................................................ 5

1.3 Safety Precautions ........................................................................................................................ 5

2. Product Overview ..................................................................................................................... 6

2.1 Compliance .................................................................................................................................... 7

3. Installation ................................................................................................................................ 8

3.1 Installing the Compensator to the Robot .................................................................................... 8

3.2 Removing the Compensator from the Robot .............................................................................. 9

3.3 Lock/Unlock Pneumatic Connections and Valve ....................................................................... 9

3.3.1 Air Requirements ................................................................................................................ 9

3.3.2 Valve Requirements and Connections ............................................................................... 9

3.4 Electrical Connections ................................................................................................................ 10

3.4.1 PNP Type Lock Sensors ................................................................................................... 10

4. Operation ................................................................................................................................ 10

4.1 Lock Position ............................................................................................................................... 10

4.2 Unlocked Position ....................................................................................................................... 10

4.3 Locked Position Sensing (Optional) .......................................................................................... 11

4.4 Operation of Pick Part ................................................................................................................. 11

5. Maintenance ............................................................................................................................ 12

5.1 Preventive Maintenance ............................................................................................................. 12

5.2 O-ring seal replacement, Cleaning, & Lubrication of the Locking Mechanism .................... 13

6. Troubleshooting ..................................................................................................................... 16

6.1 Sensor Replacement ................................................................................................................... 16

6.2 Coil Spring Replacement ............................................................................................................ 17

7. Recommended Spare Parts ................................................................................................... 19

8. Specifications ......................................................................................................................... 20

9. Drawings ................................................................................................................................. 21

10. Terms and Conditions of Sale ............................................................................................... 22


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Document #9610-15-1002-02

Term

Ball Cage

Definition

Glossary of Terms

Hardened steel ring attached to the Compensator Body that contains the balls that are engaged by the cam during the locking process.

Ball Lock Cam

Tool Mount Plate

End-effector

Lock Port

Compensator Body

Ball Pivot

Unlock Port

Pivot Cam

Lock Sensing

Circular disc attached to the piston that forces the locking balls inward during the locking process.

The part of the Ball Lock Compensator that attaches to the End-effector.

Tool used by the robot to perform a particular function.

Pneumatic port on the Compensator Body to which air is supplied to Lock the body to the lock plate.

The part of the Ball Lock Compensator that is mounted to a robot. The body contains the locking mechanism.

A ball end shaft that attaches to the Tool Mount Plate and is captive in the Compensator

Body. Part of the mechanism that provides angular and rotational compliance about the

Z axis.

Pneumatic port on the Compensator Body to which air is supplied to Unlock the body from the lock plate.

The Pivot Cam is part of the mechanism that provides angular and rotational compliance about the Z axis when the Compensator is in the Unlocked position. Is part of the mechanism that maintains the centered noncompliant position when the Compensator is in the Locked position.

Proximity sensor mounted in sensor fitting detects when Compensator is locked.


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Document #9610-15-1002-02

1. Safety

The safety section describes general safety guidelines to be followed with this product, explanation of the notification found in this manual, and safety precaution that apply to the product. More specific notification are imbedded within the sections of the manual where they apply.

1.1

Explanation of Notifications

The notifications included here are specific to the product(s) covered by this manual. It is expected that the user heed all notifications from the robot manufacturer and/or the manufacturers of other components used in the installation.

DANGER:

Notification of information or instructions that if not followed will result in death or serious injury. 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.

WARNING:

Notification of information or instructions that if not followed could result in death or serious injury. 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.

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:

Notification of specific information or instructions about maintaining, operating, installation, or setup of the product that if not followed could result in damage to equipment. The notification can emphasize but is not limited to specific grease types, good operating practices, or maintenance tips.

1.2 General Safety Guidelines

Prior to purchase and installation, the customer should verify that the Ball Lock Compensator selected is

rated for the maximum loads moments expected during operation. Refer to

Section 8—Specifications

for specific ratings, or contact ATI for assistance. Particular attention should be paid to dynamic loads caused by robot acceleration and deceleration. These forces can be many times the value of static forces in high acceleration or deceleration situations.

All pneumatic fittings and tubing must be capable of withstanding the repetitive motions of the application without failing. The routing of electrical and pneumatic lines must minimize the possibility of stress/strain, kinking, rupture, etc. Failure of critical electrical or pneumatic lines to function properly may result in injury to personnel and equipment.

All electrical power, pneumatic and fluid circuits should be disconnected during servicing.

1.3 Safety Precautions

WARNING: Do not perform maintenance or repair on Ball Lock Compensator with power or air on. Injury or equipment damage can occur with power or air on. Turn off power and air before performing maintenance or repair on Compensator.

CAUTION: The Compensator is only to be used for intended applications and applications approved by the manufacturer. Using the Compensator in applications other than intended will result in damage to Compensator or end-of-arm tooling and could cause injury to personnel.


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2. Product Overview

The Pivoting Compliance Compensator is a compliance device that enhances the flexibility and reliability of a robot or assembly machine. Compensators are used in automated assembly applications to provide compliance for misalignment during assembly. The Compensator allows for angular offset for the assembling a pin into a bore in an approximate location without twisting or tilting the work piece.

The Ball Lock Compensator consists of two main components, an anodized aluminum Compensator Body assembly and an anodized aluminum Tool Mount Plate assembly. The Compensator Body assembly contains a hardened steel ball lock cam, ball bearings, and Ball Cage that is part of the locking mechanism. The Tool Mount

Plate assembly provides angular and rotational compliancy using a ball pivot and pivot cam with externally machined surfaces, when the locking mechanism is actuated the Tool Mount Plate assembly will return the centered and locked position. Extreme pressure grease is applied to the ball pivot and ball bearings to enhance performance and maximize the life of the assemblies.

Figure 2.1—Pivoting Compliance Compensator

Tool Mount Plate

Compensator Body

Locked Position

PNP Sensor

M5 Unlock Air Port

M5 Lock Air Port

The body is equipped with a circular mounting pattern and two locating dowel holes used to mount the

Compensator to the robot. The body has Lock and Unlock M5 air ports. The Compensator can also be equipped with Locked position PNP Sensor. The Tool Plate assembly has a circular mounting pattern and two locating dowel pin holes for mounting the tool.

Figure 2.2—Section View

Ball Bearing

Ball Cage

Ball Lock Cam

Pivot Cam

Locked Position

PNP Sensor

Compression Spring

Pivot Cap

Ball Pivot

Compensator Body

Assembly


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2.1 Compliance

The Compensator is designed to provide compliance in the X and Y Planes and rotational compliance about the

Z axis (see

Figure 2.3

and

Figure 2.4

)

.

The Tool Plate can rotate from the ball pivot providing a 13º angular compliance in the X and Y planes and can rotate 19º about the Z axis from its centered position.

Figure 2.3—Compliance in the X and Y Planes

Z Axis

13°

Figure 2.4—Compliance about the Z axis

19°


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3. Installation

The Compensator is mounted to the robot wrist (refer to

Figure 3.1

) using six mounting screws. The end-effector is

attached to the Compensator Lock Plate by using the tapped hole pattern with user supplied fasteners.

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

3.1 Installing the Compensator to the Robot

1. It may be necessary to clean the mounting surfaces of the robot and the Compensator in order to remove any debris that is present.

2. Apply Loctite 242® to the six user supplied M10 mounting screws and attach the Compensator to the robot.

Figure 3.1—Installing the Compensator to the Robot

Robot

Ball Lock Compensator

Lock Port Pneumatic

Connections

Unlock Port Pneumatic

Connections

Electrical sensor

Connection

(6) M10 Socket Head Cap Screw

(User Supplied)

3. Sensor cables and pneumatic hosing can be connected after attaching the Compensator to the robot.

CAUTION:

All pneumatic fittings and tubing must be capable of withstanding the repetitive motions of the application without failing. The routing of electrical and pneumatic lines must minimize the possibility of over stressing, pullout, or kinking the lines. Failure to do so can cause some critical electrical and/or pneumatic lines not to function properly and may result in injury to personnel or damage to equipment.

4. Once the Compensator is attached to the Robot the end-effector can be attached to the Compensator.

With the user supplied M8 mounting screw attach the end-effector to the mounting hole pattern on the

Tool Mount Plate. Refer to

Section 9—Drawings

for mounting details

.

Figure 3.2—Installing the End-effector to the Compensator

End-effertor

M8 Socket Head Cap Screws

(User Supplied)


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3.2 Removing the Compensator from the Robot

1.

Remove the screws securing the end-effector to the Compensator, and remove the end-effector.

2. Depending on the service being done, the electrical sensor and pneumatic connection may have to be removed.

3.

Remove the six M10 fasteners securing the Compensator to the robot and remove the Compensator.

3.3 Lock/Unlock Pneumatic Connections and Valve

CAUTION: The locking mechanism will not function properly when connected to a single 3-way valve as this type of valve is incapable of venting trapped air pressure from within the Tool Changer. Connect the Lock and Unlock supply air to a single

2-position 4-way or 5-way valve with either 4-port or 5-port configuration. This could result in damage to the product, attached tooling, or personnel.

Air must be supplied to the “Lock” air port on the Compensator Body to move the internal piston, which moves the cam, and forces the locking balls intward. The locking balls move intward until they contact the machine surface of the Pivot Cam. This will rigidly engage the Compensator Body and Lock Plate centering and locking the Compensator.

To unlock the Lock Plate from the Compensator Body, lock air must be vented and air supplied to the

“Unlock” air port on the Compensator Body.

3.3.1 Air Requirements

For proper operation of the Compensator, the air ports on the body must be supplied with clean, dry, non-lubricated air supplied between 65 and 80 psi (4.5–5.5 Bar) and filtered at 20 microns or better. Flow requirements are negligible, typically no more than 1/3 CFM at 70 PSI.

3.3.2 Valve Requirements and Connections

As with all pneumatic piston arrangements, smooth operation requires proper porting of the supplied and vented air. It is recommended that a single 4-way valve be used to actuate the locking mechanism in the Compensator Body. The valve may be of either 4-port or 5-port configuration. It is imperative that when air is supplied to the Lock or Unlock Port on the Compensator Body, that the opposite port be vented to atmosphere (i.e., when air is supplied to the Lock Port, the Unlock

Port must be open to the atmosphere.) Failure to vent trapped air or vacuum on the inactive port will negate the locking force of the Compensator mechanism. The Lock and Unlock Ports are threaded for M5 x 0.8 connections.

Figure 3.3—Lock and Unlock Pneumatic Connections

4 or 5 -way Valve

Unlock Port

Lock Port

Supply Clean, Dry,

Non-lubricated Air

65 – 80 psi (4.5 – 5.5 Bar)

Exhaust

Open to Atmosphere


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3.4 Electrical Connections

The Compensator Body has optional Lock PNP proximity sensors, with M8 quick disconnect connections.

3.4.1 PNP Type Lock Sensors

The PNP Lock sensors are 4mm cylindrical inductive proximity sensor.

Table 3.1—PNP (Current Sourcing)

Description

Voltage Supply Range

Output Current

Nominal Sensing Distance Sn

Output Circuit

Value

10-30 VDC

< 100 mA

0.8 mm

PNP make function (NO)

Figure 3.4—PNP Type Lock and Unlock Sensors

PNP (Current Sourcing)

Brown (1)

Connector

(4) Black

+Vs

PNP

Black (4)

Output

Blue (3)

Z

Brown (1) (3) Blue

0 V

4. Operation

The Compensator locking mechanism is pneumatically driven and requires a continuous supply of clean, dry nonlubricated air 65 - 80 psi (4.5 – 5.5 Bar) and filtered to 20 microns or better.

CAUTION: Safe, reliable operation of the Compensators locking mechanism is dependent on a continuous supply of compressed air at a pressure of 65 to 80 psi. Robot motion should be halted if the air supply pressure drops below 60 psi for any reason.

4.1 Lock Position

To lock the Compensator in the centered position air must be supplied to the “Lock” air port on the

Compensator Body to move the internal piston, which moves the Ball Lock Cam, and forces the locking balls inward. The locking balls move inward until they contact the external machine surface of the Pivot

Cam. This will rigidly engage the Compensator Body and Tool mounting Plate assemblies centering and locking the Compensator. Air from the Unlock port must be exhausted to the atmosphere. The Compensator is not compliant in the locked position.

4.2 Unlocked Position

To unlock the Compensator air must be supplied to the “Unlock” air port on the Compensator Body to move the internal piston, which moves the Ball Lock Cam, and releases the locking balls. The locking balls move outward releasing the Tool Mount Plate Assembly. Air from the Lock port must be exhausted to the atmosphere. In the Unlock position the Compensator is fully compliant.


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4.3 Locked Position Sensing (Optional)

The optional proximity Sensor provide verification of the Compensators is in the Locked position. When the locking piston moves within the Compensator Body the Locked proximity sensor will detect when the locking piston enters the sensing range sending a locked signal.

Figure 4.1—Lock Position Sensor

Tool Mount Plate Assembly

Ball Cage

Ball Bearing

Ball Lock Cam

Compensator Body

Assembly

Pivot Cam

Lock PNP Sensor

Unlock Air Port

Lock Air Port

Ball Pivot

4.4 Operation of Pick Part

The Compensator can be used in a part picking operation. The Compensator will allow for misalignment of the robot and work piece in the X-Y-Z and rotational directions. The Compensator can center the work piece for placement.

Figure 4.2—Pick Part Operation

Robot moves to pick part, positioned above work piece. Compensator

Unlock fully compliant

Gripper Closes, Compensator offsets to compensate for Robot and work piece positioning.

Compensator Unlock fully compliant

Robot removes work piece.

Compensator Locked not compliant.

Work piece centered and lock in position.


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5. Maintenance

Under normal conditions, no special maintenance is necessary, however it is recommended that periodic inspections be performed to assure long-lasting performance and to assure that unexpected damage has not occurred. Refer to

Section 5.1—Preventive Maintenance

for a schedule and items that should be visually inspected at regular intervals.

Spare parts are available from ATI. Please call for recommendations.

WARNING: Do not perform maintenance or repair on Compensator unless the tool is safely supported or removed and all energized circuits (e.g. electrical, air, water, etc.) have been turned off. Injury or equipment damage can occur with tool not supported or energized circuits on. Support or remove the tool and turn off all energized circuits before performing maintenance or repair on Compensator.

CAUTION: It is recommended, not to use fasteners with pre-applied adhesive more than three times. Fasteners used more than three times may come loose and cause equipment damage. Discard fasteners used more than three times and install new fasteners with preapplied adhesive.

5.1 Preventive Maintenance

The Compensator is designed to provide a long life with regular maintenance. A visual inspection and preventive maintenance schedule is provided in the

Table 5.1

below depending upon the application.

Assembly details are provided in

Section 9—Drawings

of this manual.

Table 5.1—Preventative Maintenance Checklist

Application(s)

General Usage, Material Handling, Docking

Station

Tool Change Frequency Inspection Schedule

More than 1 per minute

Less than 1 per minute

Weekly

Monthly

Wet or Humid Environments

Welding/Servo/Deburring, Foundry Operations

(Dirty Environments)

All

All

Weekly

Weekly

Mounting Fasteners

□ Inspect mounting fasteners, verify they are tight and have the proper torque.

Interface Connections

□ Inspect pneumatic connections for cuts in hoses, abrasions, or wear. If signs of wear are apparent, tighten connections and secure lines so that they allow freedom of movement during operation and do not rub or obstruct other components.

□ Inspect electrical cables for cuts, abrasions, or wear. If signs of wear are apparent, check connections and secure cables so that they allow freedom of movement during operation and do not rub or obstruct other components.

Rubber O-rings

□ Inspect for wear, abrasion, and cuts. If worn or damaged, replace. Refer to

Section 5.2—O-ring seal replacement, Cleaning, & Lubrication of the Locking Mechanism.

Locking Mechanism - cleaned and lubricated every 1.5 million cycles.

□ Inspect and Lubricate Locking Mechanism (Alignment locking posts). Over time lubricants can become contaminated with process debris. Therefore, it is recommended to thoroughly clean the existing grease and replace with new as needed. Refer to

Section 5.2—O-ring seal replacement,

Cleaning, & Lubrication of the Locking Mechanism.

Note: Locking mechanism components are subject to corrosion from water. If these components get wet, they must be dried and greased immediately.


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5.2 O-ring seal replacement, Cleaning, & Lubrication of the Locking Mechanism

The O-ring seal should be replaced and the locking mechanism should be cleaned and lubricated every 1.5 million cycles.

1.

Turn off all energized circuits (e.g. electrical, air, water, etc.) before beginning maintenance.

2. Remove the end-effector from the Compensator and remove the Compensator from the robot. Refer to

Section 3.2—Removing the Compensator from the Robot

.

3.

Remove the four M6 socket head cap screws from the Tool Mount Plate. Refer to

Figure 5.1

. Remove

the Tool Mount Plate by carefully pulling it straight up and off the Pivot Cam. This may be difficult due to the close fit of the dowel pins. Set aside.

4. Remove the six M6 socket head cap screws from the Cap Plate. Remove the Cap Plate by carefully pulling it straight up and off the Compensator Body. This may be difficult due to the close fit of the dowel pins.

5. Remove the O-ring from the inner bore of the Cap Plate and discard O-ring. Set the Cap Plate aside.

6.

Remove the six M5 socket head cap screws securing the Ball Cage Assembly to the Compensator Body.

Remove the Ball Cage Assembly by carefully pulling it straight up and off the Compensator Body and set aside. Note: Be careful not to lose the ball bearing from the cage.

Figure 5.1—Disassemble the Compensator for O-ring replacement and Cleaning

( 4) M6 Socket Head Cap Screws

Tool Mount Plate

(6) M6 Socket Head Cap Screws

Cap Plate

O-Ring Seal

Ball Cage Assembly

O-Ring Seal

O-Ring Seal

O-Ring Seal

Ball Lock Cam

(8) Coil Springs

Compensator Body

Lock and Unlock Ports



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7. Remove the Ball Lock Cam by pulling it straight up out of the Compensator Body.

8. Remove the outer and inner O-rings from the Ball Lock Cam and discard O-rings.

9. Clean the lubrication from the Ball Lock Cam and set aside.

10.

Remove the O-ring from the top of the Compensator Body and discard.

11. Clean the lubrication from the Compensator Body and set aside. Note: Be careful not to lose any of the eight coil springs from the Compensator Body

12. Remove the six ball bearings from the Ball Cage Assembly, removed earlier. Clean the lubrication from all the ball bearings and set aside.

13.

Remove the six M5 socket head cap screws securing the Pivot Cap to the Ball Cage. Remove the Pivot

Cap from the Ball Cage.

14. Clean the lubrication from the Pivot Cap and set aside.

15. Using a lint free rag, carefully remove the lubrication from the Ball Cage, Pivot Cam and Ball Pivot. Set all parts aside.

Figure 5.2—Disassemble the Ball Cage Assembly for Cleaning

Pivot Cam

Notch

(6) Ball Bearings

Ball Cage

Ball Pivot

Pivot cap


NOTICE: Use MobilGrease

®

XHP222 Special grease to lubricate the locking mechanism and O-rings. Note: MobilGrease® XHP222 Special is a NLGI #2 lithium complex grease with molybdenum disulfide.

16. Apply MobilGrease

®

XHP222 Special to the new O-rings and assemble to the outer diameter and inner bore of the Ball Lock Cam.

17. Ensure the eight coil springs are in the Compensator Body and in the proper location. Insert the Ball

Lock Cam into the Compensator Body aligning the coil springs with the holes in the bottom of the Ball

Lock Cam


®

XHP222 Special to the spherical surface of the Ball Pivot.

19. Assemble the Pivot Cap to the Ball Cage using the six M5 socket head cap screws. Tighten to 52 in-lbs.

Note: Make sure Pivot Cam moves freely, if not disassembly, clean, and apply lubrication again.


®

XHP222 Special to the spherical surface of the eight Ball Bearings. Insert the Ball

Bearings into the Ball Cage.

21. Assemble the Ball Cage to the Compensator Body, Align the notch in the Pivot Cam to the Lock and

Unlock ports in the Compensator Body. Refer to

Figure 5.1

and

Figure 5.2.

Secure with the six M5


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socket head cap screws. Tighten to 52 in-lbs.


®

XHP222 Special to the new O-ring and assemble in the top of the Compensator

Body.


®

XHP222 Special to the new O-ring and assemble to the inner bore of the Cap

Plate.

24. Assemble the Cap Plate to the Compensator Body, aligning the Sensor with the Lock and Unlock ports.

Secure using the six M6 socket head cap screws. Tighten to 89 in-lbs.

25. Assemble the Tool Mounting Plate to the Pivot Cam, using the dowel pin to align the notch in the Tool

Mounting Plate to the Sensor. Secure using the four M6 socket head cap screws. Tighten to 89 in-lbs.

26. Install Compensator to robot, refer to

Section 3.1—Installing the Compensator to the Robot

.


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6. Troubleshooting

The system contains few components and provides trouble-free operation once properly installed. The following table is provided to assist with troubleshooting the system.

Symptom

If Compensator is not operating properly check the following conditions prior to any further troubleshooting.

Sensor not functioning, do not report Locked position

Pneumatic connections incorrect or air supplied is insufficient.

Table 6.1—Troubleshooting

Possible Cause Correction

Ensure that the Compensator has proper pneumatic connections and air is supplied at a minimum of 65

psi (4.5 bar). Refer to

Section 3.3—Lock/Unlock

Pneumatic Connections and Valve.

Air or vacuum trapped in a de-energized

Lock or Unlock Port or incorrect Valve type.

O-ring seals are worn and leaking air.

Ensure that no air or vacuum can be trapped in a deenergized Lock or Unlock Port and 4 way type valve is used (pressure must be vented to atmosphere). Refer to

Section 3.3—Lock/Unlock Pneumatic Connections and Valve.

Replace O-ring seals, refer to

Section 5.2—O-ring seal replacement, Cleaning, & Lubrication of the

Locking Mechanism.

Sensor cable damaged or loose connection

Inspect sensor cable for damage or loose connection, if loose re-connect, if damaged replace.

Sensor not functioning

Replace Sensor, refer to

Section 6.1—Sensor

Replacement

6.1 Sensor Replacement

1.


2. Disconnect the sensor cable.

3. Using a 3mm Allen wrench, remove the two M3 socket head cap screws.

4. Pull the Sensor Assembly straight out and discard.

5. Clean out sensor hole with compresses air.

6.

Insert new sensor and secure with the two M3 socket head cap screws. Tighten to 12 in-lbs.

Figure 6.1—Sensor Replacement

3 mm Allen Wrench

M3 Socket Head Cap Screw

Lock Sensor Assembly


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6.2 Coil Spring Replacement

1.


2. Remove the end-effector from the Compensator and remove the Compensator from the robot. Refer to

Section 3.2—Removing the Compensator from the Robot.

3.

Remove the four M6 socket head cap screws form the Tool Mount Plate. Refer to

Figure 6.2.

Remove the Tool Mount Plate by carefully pulling it straight up and off the Pivot Cam. This may be difficult due to the close fit of the dowel pins. Set aside.

4. Remove the six M6 socket head cap screws from the Cap Plate. Remove the Cap Plate by carefully pulling it straight up and off the Compensator Body. This may be difficult due to the close fit of the dowel pins.

5. Remove the six M5 socket head cap screws securing the Ball Cage Assembly to the Compensator Body.

Remove the Ball Cage Assembly by carefully pulling it straight up and off the Compensator Body and set aside. Note: Be careful not to lose the ball bearing from the cage.

6.

Remove the Ball Lock Cam by pulling it straight up out of the Compensator Body.

7. Remove the eight coil springs from the Compensator Body and discard.

Figure 6.2—Replace the Coil Springs

( 4) M6 Socket Head Cap Screws

Tool Mount Plate


Cap Plate

Ball Cage Assembly

(8) Coil Springs

Ball Lock Cam

Compensator Body



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8. Install eight new coil springs in the Compensator Body,

9. Ensure the eight coil springs are in the Compensator Body and in the proper location. Insert the Ball

Lock Cam into the Compensator Body aligning the coil springs with the holes in the bottom of the Ball

Lock Cam

10. Assemble the Ball Cage to the Compensator Body, Align the notch in the Pivot Cam to the Lock and

Unlock ports in the Compensator Body. Refer to

Figure 6.2.

Secure with the six M5 socket head cap screws. Tighten to 52 in-lbs.

11. Assemble the Cap Plate to the Compensator Body, aligning the Sensor with the Lock and Unlock ports.

Secure using the six M6 socket head cap screws. Tighten to 89 in-lbs.

12. Assemble the Tool Mounting Plate to the Pivot Cam, using the dowel pin to align the notch in the Tool

Mounting Plate to the Sensor. Secure using the four M6 socket head cap screws. Tighten to 89 in-lbs.

13. Install Compensator to robot, refer to

Section 3.1—Installing the Compensator to the Robot

.


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7. Recommended Spare Parts

6

19

6

9

1

2

4

3

5

5

ITEM NO. QTY. PART NUMBER

1 1 3410-0001111-01

4

5

2

3

6

9

19

1 3410-0001166-01

1 3410-0001172-01

DESCRIPTION

AS568A-155 O-Ring Buna 3/32x4" IDx 4 3/16 OD

1 3410-0001358-01 O-Ring, AS568-146 Buna N

12 3500-1064016-15A M5 x 16mm SHCS, Blue Dyed Magni, ND Microspheres

10 3500-1066016-15A M6 x 16mm SHCS Blue Dyed Magni ND Microspheres

8 3610-4281001-21

1 9005-15-5003

O-RING, 3.5 x 3/32 (-153)

Buna-N Oring Dash 154

Coil Spring, Tapered, OD .343 x .421, FL .810, SS

BLC Prox Sensor Carrier Assembly


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Document #9610-15-1002-02

8.

Specifications

Specifications such as payload, moment capacity, repeatability, and weight for each model may be found in the product catalog and on our website. Drawings may also be found in the product catalog and on our website. 2-D and 3-D models are also available on our website.

Contact ATI for specific information and drawings regarding your installation. We encourage you to use our applications department to review your designs and answer your questions.

Specification

Compliance in the X and Y

Planes

Compliance about Z Axis

Table 8.1

—Specifications

Value Description

±13 degrees Unit complies laterally about X-Y plane and rotates about the Z axis simultaneously.

±19 degrees

Moment Breakaway

Rated Life

Positional Repeatability

Weight

Operating Pressure Range

Air Supply Port Size

Mounting

Sensing

Construction

600 in-lbs

1 Million

At 80 psi

Compliance Cycles

±0.0035 in. (0.089 mm) Repeatability tested at rated load at one million cycles.

5.86 lbs. (2.66 kg) Compensator without Sensors

65–80psi

(4.5–5.5bar)

65–80psi

4.5–5.5bar)

M5

125 mm BC, (6) M10,

(2) M10 Dowel

100 mm BC, (6) M8,

(2) M8 Dowel

Locking mechanism supply pressure operating range. Supply to be clean, dry, and filtered to 50 micron or better.

Position Hold supply pressure operating range. Supply to be clean, dry, and filtered to 50 micron or better.

For Lock, and Unlock

Robot Mounting

Center Position Lock &

Unlock

Tool Mounting

(Custom tooling plates available upon request)

Sensor options

SG – 3 wire DC PNP, 8 inch lead, M8 Quick

Connect

SE – 3 wire DC NPN, 8 inch lead, M8 Quick

Connect

Anodized Aluminum Housing and Tool plate

Hardened Stainless Steel Internal compliance components


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9. Drawings


Document #9610-15-1002-02

1031 Goodworth Drive, Apex, NC 27539, USA Tel: +1.919.772.0115 Email: [email protected] Fax: +1.919.772.8259 www.ati-ia.com ISO 9001 Registered Company

Ball Lock Compensator, XYZ Rotation, 125 BC, with 2072 Tooling Plate

10 Slip Fit 8mm

From Other Side For M10 SHCS Equally Spaced

NOTES: UNLESS OTHERWISE SPECIFIED.

DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS.

8 Slip Fit 8mm

6X M8X1.25 THRU PLATE

3 Pin Male M8 Connector on 8 inch Lead Optional Sensor to Detect Center Position


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Document #9610-15-1002-02

10. Terms and Conditions of Sale

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 Tool Changer products purchased hereunder will be free from defects in material and workmanship under normal use for a period of three (3) years 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 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 operations.

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.


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ATI Pivoting Compliance Compensator Installation and Operation Manual

Assistant Bot

Compensator

Pivoting Compliance Compensator

Installation and Operation Manual

Document #: 9610-15-1002

Engineered Products for Robotic Productivity

Foreword

How to Reach Us

Table of Contents

Glossary of Terms

1. Safety

1.1

Explanation of Notifications

1.2 General Safety Guidelines

1.3 Safety Precautions

2. Product Overview

Tool Mount Plate

Compensator Body

Locked Position

PNP Sensor

M5 Unlock Air Port

M5 Lock Air Port

2.1 Compliance

3. Installation

3.1 Installing the Compensator to the Robot

3.2 Removing the Compensator from the Robot

3.3 Lock/Unlock Pneumatic Connections and Valve

3.3.1 Air Requirements

3.3.2 Valve Requirements and Connections

3.4 Electrical Connections

3.4.1 PNP Type Lock Sensors

PNP (Current Sourcing)

Brown (1)

Connector

(4) Black

+Vs

PNP

Black (4)

Output

Blue (3)

Z

Brown (1) (3) Blue

0 V

4. Operation

4.1 Lock Position

4.2 Unlocked Position

4.3 Locked Position Sensing (Optional)

4.4 Operation of Pick Part

5. Maintenance

5.1 Preventive Maintenance

5.2 O-ring seal replacement, Cleaning, & Lubrication of the Locking Mechanism

Pivot Cam

Notch

(6) Ball Bearings

Ball Cage

Ball Pivot

Pivot cap

(6) M5 Socket Head Cap Screws

6. Troubleshooting

6.1 Sensor Replacement

3 mm Allen Wrench

M3 Socket Head Cap Screw

Lock Sensor Assembly

6.2 Coil Spring Replacement

7. Recommended Spare Parts

6

19

6

9

1

2

4

3

5

5

8.

Specifications

9. Drawings

10. Terms and Conditions of Sale