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Quick-Change

High-Precision Robotic Tool Changer

QC-40 through QC-100

Installation and Operation Manual

Document #: 9610-20-2255

June 2015

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]

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

Foreword

This manual contains basic information applicable to all ATI Quick-Change robotic Tool Changers. Certain Quick-

Change models have their own manuals that contain more detailed information. Also, additional information about electrical, pneumatic, fluid, high-power and high-current modules and other options is available in other manuals and documents.

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]

2

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

Table of Contents

1. Safety ......................................................................................................................................... 6

1.1 Explanation of Notifications ......................................................................................................... 6

1.2 General Safety Guidelines ............................................................................................................ 6

1.3 Safety Precautions ........................................................................................................................ 7

2. Product Overview ..................................................................................................................... 8

2.1 Master Plate Assembly ............................................................................................................... 10

2.2 Tool Plate Assembly .................................................................................................................... 11

2.3 Master Plate/Tool Plate Locking Mechanism ............................................................................ 11

2.4 Optional Sensor Interface Plate (SIP) ........................................................................................ 12

2.5 Optional Modules ........................................................................................................................ 12

3. Installation .............................................................................................................................. 13

3.1 Robot Interface Plates (RIP) ....................................................................................................... 14

3.2 Master Plate Installation ............................................................................................................. 15

3.3 Master Plate Removal ................................................................................................................. 16

3.4 Tool Interface Plate ..................................................................................................................... 17

3.5 Tool Plate Installation ................................................................................................................. 18

3.6 Tool Plate Removal ..................................................................................................................... 18

3.7 Optional Module Installation ...................................................................................................... 19

3.7.1 QC-60 Flat A Optional K Series Module Installation ......................................................... 19

3.7.2 QC-60 Flat A Optional K Series Module Removal ............................................................ 19

3.7.3 QC-60 Flat B Optional Module Installation ....................................................................... 20

3.7.4 QC-60 Flat B Optional Module Removal .......................................................................... 20

3.7.5 QC-40. QC-41, QC-43, QC-71, and QC-100 Optional Module Installation ...................... 21

3.7.6 QC-40, QC-41, QC-43, QC-71, and QC-100 Optional Module Removal ......................... 21

3.8 Lock/Unlock Pneumatic Connections and Valving .................................................................. 22

3.8.1 Air Requirements .............................................................................................................. 22

3.8.2 Valve Requirements and Connections ............................................................................. 22

3.9 Electrical Connections ................................................................................................................ 24

3.9.1 PNP Type Lock and Unlock Sensors ................................................................................ 24

3.9.2 NPN Type Lock and Unlock Sensors ............................................................................... 24

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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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

4. Operation ................................................................................................................................ 25

4.1 Coupling Sequence ..................................................................................................................... 26

4.2 Fail-Safe Operation ..................................................................................................................... 26

4.3 Uncoupling Sequence ................................................................................................................. 26

4.4 Tool Identification ........................................................................................................................ 27

4.5 Tool Storage Considerations ..................................................................................................... 27

5. Maintenance ............................................................................................................................ 28

5.1 Preventive Maintenance ............................................................................................................. 28

5.2 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins ........................... 29

5.3 Optional Electrical Module Pin Block Inspection and Cleaning ............................................. 31

6. Troubleshooting and Service Procedures ........................................................................... 32

6.1 Troubleshooting .......................................................................................................................... 32

6.2 Service Procedures ..................................................................................................................... 33

6.2.1 1/8” and 1/4” Rubber Bushing Inspection & Replacement .............................................. 33

6.2.2 3/8” Rubber Bushing Replacement .................................................................................. 33

6.2.3 Optional Electrical Module Seal Inspection and Replacement ......................................... 34

6.2.4 QC-100 Alignment Pin Replacement ................................................................................ 35

6.2.5 Proximity Sensor Adjustment, Test, or Replacement ....................................................... 35

7. Serviceable Parts ................................................................................................................... 37

7.1 Models QC-40 .............................................................................................................................. 37

7.2 Models QC-41 .............................................................................................................................. 38

7.3 Models QC-43 .............................................................................................................................. 39

7.4 Models QC-60 .............................................................................................................................. 40

7.5 Models QC-71 .............................................................................................................................. 41

7.6 Models QC-100 ............................................................................................................................ 42

8. Drawings ................................................................................................................................. 43

8.1 QC-40 Tool Changer with J16 Module ....................................................................................... 43

8.2 QC-41 Tool Changer with R19 Module ...................................................................................... 44

8.3 QC-43 Tool Changer .................................................................................................................... 45

8.4 QC-60 Tool Changer with K19 Module ...................................................................................... 46

8.5 QC-71 Tool Changer with G19 Module ...................................................................................... 47

8.6 QC-100 Tool Changer with T19 and F02 Modules .................................................................... 48

9. Terms and Conditions of Sale ............................................................................................... 50

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

4

Term

Master Plate

Tool Plate

Cover Plate

Piston

Cam

Bearing Race

End-Effector

Tool Stand

RIP

Electrical Module

Pneumatic Module

Detection Shaft

Sensor Plate

Lock Port

Unlock Port

No-Touch™

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

Definition

Glossary of Terms

The half of the Tool Changer that is mounted to a robot. The Master Plate contains the locking mechanism.

The half of the Tool Changer to which various tools or end-effectors are mounted.

Simple, blank closure plate on standard Quick-Change Master Plates that closes the pneumatic chamber.

Piston located in the Master Plate that actuates the locking mechanism.

Circular cam attached to the piston that forces the locking balls outward during the locking process.

Hardened steel ring in the Tool Plate that is engaged by the locking balls during the locking process.

Tool used by the robot to perform a particular function.

Stand that holds Tools not being used by the robot. This is usually supplied by the customer and is specific to the application.

Robot Interface Plate – interface plate between the robot flange and Master Plate.

Any of a wide variety of modules that pass electrical power through the Master Plate to the Tool Plate and to the end-effector.

Any of a wide variety of modules that pass pneumatic power through the Master Plate to the Tool Plate and to the end-effector.

Threaded stem inserted into the back side (top) of the Piston, functions as a target to actuate the Lock/Unlock switches.

Cover plate for the back side of the Master plate, seals the pneumatic chamber and provides mounting points for the Lock/Unlock switches.

Pneumatic port on the Master Plate to which air is supplied to Lock the Master Plate to the Tool Plate.

Pneumatic port on the Master Plate to which air is supplied to Unlock the Master Plate from the Tool Plate.

Design feature of all ATI Quick-Change products that allows coupling the Master Plate and Tool Plate without physical contact prior to locking.

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

5

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

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 were 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 Tool Changer selected is rated for the maximum loads and moments expected during operation. Refer to product specifications section in each module of this manual 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.

The customer is responsible for ensuring that the area between the Master and Tool sides is clear of foreign objects during mating and subsequent coupling. Failure to do so may result in serious injury to personnel.

DANGER: The gap between the Master and Tool sides is a pinch point. All personnel should be prevented from placing any part of their body or clothing in the gap, especially during actuation of the locking mechanism.

The customer is responsible for understanding the function of the Tool Changer and implementing the proper hardware and/or software to operate the Tool Changer safely. The Tool Changer should be controlled such that there is no chance of locking or unlocking in a position that would endanger personnel and/or equipment. If the Tool Changer is specified with Lock/Unlock (L/U) and Ready-to-Lock (RTL) sensing capability, the status should be monitored and proper interlocks applied to prevent injury to personnel and equipment.

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

6

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

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: Remove all temporary protective materials (caps, plugs, tape, etc.) on locking face of Tool Changer and modules prior to operation. Failure to do so will result in damage to Tool Changers, modules, and end-of-arm tooling and could cause injury to personnel.

WARNING: Do not perform maintenance or repair on Tool Changer or modules unless the tool is safely supported or docked in the tool stand and all energized circuits (e.g. electrical, air, water, etc.) have been turned off. Injury or equipment damage can occur with tool not docked and energized circuits on. Dock the tool safely in the tool stand and turn off all energized circuits before performing maintenance or repair on Tool

Changer or modules.

WARNING: During operation, the area between the Master and Tool must be kept clear. Failure to keep area clear will result in damage to Tool Changer, modules, or endof-arm tooling and could cause injury to personnel.

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

CAUTION: The Master Plate locking mechanism must not be actuated without being mounted to the robot interface plate. Damage to the Cover Plate and O-ring may result.

Always attach the Master Plate to the Robot interface plate prior to attempting any operations.

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

7

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

2. Product Overview

QC models are available with different anodizing, pneumatic port sizes and quantities, refer to

Table 2.1

for specific part numbers.

The Quick-Change Tool Changer provides flexibility to robot applications by allowing the robot to change endeffectors (e.g., grippers, vacuum cup tooling, pneumatic and electric motors, weld guns, etc.) automatically. The

Quick-Change consists of a Master plate and a Tool plate.

The Master plate is installed on the robot arm and locks to the Tool plate with a pneumatically-driven locking mechanism. This locking mechanism uses a patented, multi-tapered cam with ball locking technology and a patented fail-safe mechanism. The Master allows for the passage of pneumatic and electrical connections to the

Tool plate. End-effectors such as grippers, material handlers, etc. are attached to one or more Tool Plates.

In operation, the robot can be programmed to select the desired end-effector by coupling the Master Plate to the

Tool Plate. Electrical signals, pneumatic power, and fluids can be transferred to the end-effector(s) through the

Master Plate and Tool Plate by optional modules and ports. See the respective manuals for these options for more details on their operation.

A Tool Changer enhances the flexibility and reliability of a robotic cell. Robotic Tool Changers are used in automated Tool-change applications, as well as manual Tool-change operations. Robotic Tool Changers also provide a method for quick Tool change for maintenance purposes.

Table 2.1—Standard QC Tool Changer Models and Features

Model

QC-40

QC-41

QC-43

Payload

110 lbs

110 lbs

110 lbs

Flats

(2) Flat

(1) Flat

(2) Flat

Plate

Master

Part No.

9120-040M-000-000

9120-040M-000-000-B

Tool

Master

(8) 1/8”-28 BSPP Pass-through ports

(2) 1/8”-28 BSPP Lock/Unlock air ports

Tool (8) 1/8”-28 BSPP Pass-through ports 9120-040T-000-000-E

9120-040M-000-000-R

Master

(8) 1/8” BSPT Pass-through ports

(2) 1/8” BSPT Lock/Unlock air ports

Tool (8) 1/8” BSPT Pass-through ports

Master

Tool

(6) 3/8” NPT Pass-through ports

(4) 1/8” NPT Pass-through ports

(2) 1/8” NPT Lock/Unlock air ports

(6) 3/8” NPT Pass-through ports

(4) 1/8” NPT Pass-through ports

9120-040T-000-000

9120-040T-000-000-B

9120-040M-000-000-E

9120-040T-000-000-R

9120-041M-000-000

9120-041M-000-000-B

9120-041T-000-000

9120-041T-000-000-B

9120-041M-000-000-E

Master

Tool

Pneumatic Ports

(8) 1/8” NPT Pass-through ports

(2) 1/8” NPT Lock/Unlock air ports

(8) 1/8” NPT Pass-through ports

(6) 3/8”-19 BSPP Pass-through ports

(4) 1/8”-28 BSPP Pass-through ports

(2) 1/8”-28 BSPP Pass-through ports

(6) 3/8”-19 BSPP Pass-through ports

(4) 1/8”-28 BSPP Pass-through ports

9120-041T-000-000-E

Master

Tool

(8) 1/8” NPT Pass-through ports

(2) 1/8” NPT Lock/Unlock air ports

(8) 1/8” NPT Pass-through ports

9120-043M-000-000

9120-043T-000-000

Master

(8) 1/8”-28 BSPP Pass-through ports

(2) 1/8”-28 BSPP Lock/Unlock air ports

9120-043M-000-000-E

Tool (8) 1/8”-28 BSPP Pass-through ports 9120-043T-000-000-E

Notes”

1. QC Tool Changer Master and Tool Plate Assemblies with (-B and -E) part numbers have black anodized bodies

2. Additional options are available upon request.

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

8

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

Table 2.1—Standard QC Tool Changer Models and Features

Model

QC-60

QC-71

QC-100

Payload

160 lbs

180 lbs

330 lbs

Flats Plate

Master

Tool

(2) Flat

(1) J16 pattern and

(1) K series

Master

(8) 1/8” NPT Pass-through ports

(8) 1/8”-28 BSPP Pass-through ports

(2) 1/8”-28 BSPP Lock/Unlock air ports

9120-060T-000-000

9120-060T-000-000-B

9120-060M-000-000-E

Tool (8) 1/8”-28 BSPP Pass-through ports 9120-060T-000-000-E

9120-060M-000-000-R

Master

(8) 1/8” BSPT Pass-through ports

(2) 1/8” BSPT Lock/Unlock air ports

Tool

Pneumatic Ports

(8) 1/8” NPT Pass-through ports

(2) 1/8” NPT Lock/Unlock air ports

Part No.

9120-060M-000-000

9120-060M-000-000-B

Master

Tool

(8) 1/8” BSPT Pass-through ports

(8) 1/4 NPT Pass-through ports

(2) 1/8 NPT Lock/Unlock air ports

(8) 1/4 NPT Pass-through ports

9120-060T-000-000-R

9120-071M-000-000

9120-071M-000-000-B

9120-071T-000-000

9120-071T-000-000-B

(2) Flats

(2) Flats

Master

(8) 1/4 BSPP Pass-through ports

(2) 1/8” BSPP Lock/Unlock air ports

(8) 1/4 BSPP Pass-through ports

9120-071M-000-000-E

Tool

Master

(8) 1/4 BSPT(R) Pass-through ports

(2) 1/8” BSPT Lock/Unlock air ports

9120-071T-000-000-E

9120-071M-000-000-R

Tool (8) 1/4 BSPT(R) Pass-through ports 9120-071T-000-000-R

9120-100M-000-000

Master

(8) 3/8 NPT Pass-through ports

(2) 1/8 NPT Lock/Unlock air ports

Tool (8) 3/8 NPT Pass-through ports 9120-100T-000-000

Master

Tool

(8) G 3/8 BSPP Pass-through ports

(2) G 1/8 BSPP Lock/Unlock air ports

9120-100M-000-000-E

(8) G 3/8 BSPP Pass-through ports 9120-100T-000-000-E

Notes”

1. QC Tool Changer Master and Tool Plate Assemblies with (-B and -E) part numbers have black anodized bodies

2. Additional options are available upon request.

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

9

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

2.1 Master Plate Assembly

The Master Plate assembly includes an anodized aluminum body, a hardened stainless-steel locking mechanism, and hardened steel alignment pins. The locking mechanism consists of a cam, a male coupling, and chrome-steel ball bearings. The Master Plate provides one or two flat sides for mounting of optional modules, depending on the model. Optional modules can be arranged to suit the application.

Master Plate Assembly

(QC-71 Shown)

Figure 2.1—Master Plate Assemblies

Cover Plate

Master Plate Assembly

(QC-40 Shown)

Cover Plate

Optional Module

Flat B

Optional Module

Flat A

1/8"NPT Lock,

Unlock Air Ports

Ball Bearings

1/8"NPT Lock,

Unlock Air Ports

Optional Module Flat B

Male Coupling

Ball Bearings

Male Coupling

(2) Alignment Bushings

Pass-Through

Air Ports

Optional Module

Flat A

(2) Alignment

Bushings

Pass-Through Air Ports

(8) 1/8" NPT Pass-Through Air Ports

(8) 1/4" NPT Pass-Through Air Ports

The air port provides Lock and Unlock air for the locking mechanism and pass through air for the end of arm tooling. An Adapter Plate Assembly provides a standoff for the air ports and a mounting pattern to attach to the robot arm.

Alignment pins mate with bushings to ensure repeatable alignment during the coupling process. An extreme pressure grease is applied to the cam, male coupling, ball bearings, and pins to enhance performance and maximize the life of the Master Plate assembly. In some models the Master plate is equipped with tapered alignment pins, other models such as the QC-43 Mater Plate have hardened stainless steel alignment bushings.

A cover plate is attached to the master to protect the internal locking mechanism during shipment. This cover plate can be removed during installation if replaced by a robot interface plate or Sensor interface plate.

Refer to

Section 3—Installation

for details.

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

10

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

2.2 Tool Plate Assembly

The Tool Plate assembly includes an anodized aluminum body and hardened stainless-steel bearing race.

The Tool Plate provides one or two flat sides for mounting of optional modules, depending on the model.

Optional modules can be arranged to suit the application. In some models the bearing race or Tool plate body has integrated alignment holes or bushings, other models such as the QC-43 Tool Plate have hardened steel alignment pins.

The Tool Plate is equipped with pass through air ports to supply end of arm tooling.

Tool Plate Assembly

(QC-71 Shown)

Optional Module

Flat A

Figure 2.2—Tool Plate Assemblies

Pass Through Air Ports

(2) Integrated Alignment Holes

(2) Integrated Alignment Holes

Optional Module Flat B

Tool Plate Assembly

(QC-40 Shown)

Pass Through

Air Ports

Harden Stainless Steel

Bearing Race

Harden Stainless Steel

Bearing Race

(8) 1/4" NPT Pass-Through Air Ports

Optional Module Flat B Optional Module Flat A

(8) 1/8" NPT

Pass-Through

Air Ports

2.3 Master Plate/Tool Plate Locking Mechanism

The coupling of the Master Plate and the Tool Plate is achieved through a patented, high-strength, highrepeatability, stainless steel mechanism. During locking, steel balls in the Master Plate are driven outward by a circular cam attached to a pneumatically actuated piston. The cam profile has three features: A lead-in angle (conical), a fail-safe surface (cylindrical) area, and a secondary angle (conical). The lead-in angle initiates the coupling process, the fail-safe surface assures the coupling will not be compromised in case of air loss (fail-safe feature), and the secondary angle provides rigid coupling during normal operation. The balls engage a bearing race (or “locking ring”) in the Tool Plate and lock the Master Plate and Tool Plate tightly together.

Figure 2.3—Locking Mechanism

Piston

Ball Bearings

Bearing Race

Circular Cam

Ball Cage

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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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

2.4 Optional Sensor Interface Plate (SIP)

The Sensor Interface Plate (SIP) system provides locking mechanism position signals to the customer’s process controller. These signals will indicate two possible conditions for the Quick-Change Master Plate:

Unlocked or Locked.

The SIP system utilizes sensors to detect the position of the pneumatically-actuated piston in the Master

Plate. These sensors are available in PNP, or NPN other option are available, contact ATI for more information. Quick-Change model, and sensor availability.

The SIP system consists of a SIP Plate (which is actually the interface plate between the Master Plate and the robot), a Detection Shaft, a Sensor Plate, Proximity Switches, and an O-Ring.

The Sensor Plate will replace the simple Cover Plate on the backside of the Quick-Change Master. The

Sensor Plate provides mounting locations for the Proximity Sensors and closes the pneumatic chamber of the Master. The SIP provides mounting holes for attaching the Master to the customer’s application and retains the Sensor Plate.

Figure 2.4—Optional Sensor Interface Plate

Detection Shaft

(Sensor Target)

Lock Sensor

Unlock Sensor

Sensor Interface Plate (SIP)

O-ring

Sensor Plate

2.5 Optional Modules

Tool Changers have one or two flats depending on the model. Optional modules support the pass-through of various utilities such as signal, fluid/air, and power. Refer to

Table 2.2

for more information. Some module may require an adapter plate.

For assistance in choosing the right modules for your particular application, visit the specific QC

model webpages by clicking on the links in

Table 2.2

to see what is available or contact an ATI Sales

Representative directly.

Model

QC-40

QC-41

QC-43

QC-60

Table 2.2—Tool Changer Models and Features

For the most current list, information, and specifications for compatible

Optional Modules click the link below

QC-40 Web Page

and select the Compatible modules tab

QC-41 Web Page

and select the Compatible modules tab

QC-43 Web Page

and select the Compatible modules tab

QC-60 Web Page

and select the Compatible modules tab

QC-71

QC-100

QC-71 Web Page

and select the Compatible modules tab

QC-100 Web Page

and select the Compatible modules tab

Note: The ATI website provides information on the Standard compatible modules additional custom modules are available, contact an ATI Sales Representative directly

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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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

3. Installation

The Master Plate of the Tool Changer mounts to the robot arm using a robot Interface Plate (RIP) or a Sensor

Interface Plate (SIP). Custom interface plates are available from ATI upon request. Refer to

Section 3.1—Robot

Interface Plates (RIP)

or

Section 2.4—Optional Sensor Interface Plate (SIP)

for more information.

The end-effector is typically attached to the Tool Plate with a tool interface plate, standard and custom tool interface

plates are available from ATI upon request. Refer to

Section 3.4—Tool Interface Plate

for more information.

All fasteners used to mount the Tool Changer to the robot and to customer’s tooling should be tightened to a torque value as indicated. Refer to

Table 3.1.

Furthermore, fasteners should have pre-applied adhesive or be applied

with removable (blue) Loctite 222

®

.

Table 3.1

contains recommended values based on engineering standards.

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

WARNING:

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.

WARNING: Do not use lock washer under the head of the mounting fasteners or allow the mounting fasteners to protrude above the mating surfaces of the Master and Tool Plates.

Allowing fasteners to protrude above the mating surface will create a gap between the Master and Tool Plates and not allow the locking mechanism to fully engage, this can cause damage to equipment or personal injury. Make sure the mounting fasteners are flush or below the mating surfaces of the Master and Tool Plates.

Mating Surface

Head of Mounting Fastener Must Be Flush or

Below Mating Surface. (Do Not Use Lock

Washer under Head of Mounting Fastener).

CAUTION: Do not apply Lock or Unlock air pressure to the Tool Changer prior to installing a robot interface plate (RIP) or sensor interface plate (SIP). Applying air pressure can damage the cover plate, O-ring or may cause injury to personnel from flying debris. Always install an appropriate RIP or SIP and have the Tool Changer mounted securely to the robot before

applying air pressure. Refer to

Section 3.1—Robot Interface Plates (RIP)

and

Section 3.2—

Master Plate Installation

for more information.

CAUTION: Do not use fasteners that exceed the thread depth in the Tool Changer. Refer to

Section 8—Drawings

for details on mounting hole thread depth. Secure the Tool Changer with the proper length fasteners. This is true for both robot and tool interfaces.

CAUTION: Failure to follow the Robot Interface Plate or tool interface plate design

consideration in

Section 3.1—Robot Interface Plates (RIP)

and

Section 3.4—Tool Interface

Plate

may result in cover plate O-ring damage or loosening of the interface during operation.

Follow the guidelines provided when designing a RIP, TIP for the Tool Changer.

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Mounting Conditions

Table 3.1

—Fastener Size, Class, and Torque Specifications

Fastener Size and

Property Class

Recommended

Torque

QC-40, QC-41, and QC-43 Master Plate to Robot

Interface Plate or Sensor Interface plate, Supplied

Fasteners

QC-60 and QC-71 Master Plate to Robot Interface Plate or Sensor Interface plate, Supplied Fasteners

QC-100 Master Plate to Robot Interface Plate or Sensor

Interface plate, Supplied Fasteners

M5 x 0.8 Class 12.9

Socket head cap

M6 x 1.0 Class 12.9

Socket head cap

Socket flat head cap

M8 x 1.25 Class 12.9

Socket head cap

Tool Interface Plate to QC-40, QC-41, QC-43, QC-60 and

QC-71 Tool Plate Minimum thread engagement of 12 mm

[1.5X fastener Ø]. Do not exceed maximum available

thread depth of 14 mm as shown in Section 8—Drawings

M8 x 1.25 Class 12.9

Socket head cap

Socket flat head cap

Tool Interface Plate to QC-100 Tool Plate Minimum thread engagement of 15 mm [1.5X fastener Ø]. Do not exceed

maximum available thread depth as shown in Section 8—

Drawings

M10 x 1.5 Class 12.9

Socket head cap

Optional Module or Adapter Plate to Master or Tool Plate,

Supplied Fasteners

M3 x 0.5 Class 12.9

Socket head cap

Socket flat head cap

M4 x 0.7 Class 12.9

Socket head cap

Socket flat head cap

45 in-lbs (5.08 Nm)

90 in-lbs (10.2 Nm)

60 in-lbs (6.78 Nm)

140 in-lbs (15.82 Nm)

140 in-lbs (15.82 Nm)

85 in-lbs (9.6 Nm)

55 ft-lbs (75 Nm)

10 in-lbs (1.13 Nm)

8 in-lbs (0.9 Nm)

15 in-lbs (1.69 Nm)

10 in-lbs (1.13 Nm)

Thread

Locker

Pre-applied

Adhesive or

Loctite 222

Pre-applied

Adhesive or

Loctite 242

Pre-applied

Adhesive or

Loctite 222

3.1 Robot Interface Plates (RIP)

The Robot Interface Plate (RIP) is used to adapt the Master Plate to a specific robot arm. The RIP is designed with mounting features such as a boss and/or bolt and dowel holes. These features are used to accurately position and secure the Master Plate to the robot arm. Custom RIPs are available from ATI upon request.

If the customer chooses to design and build a robot interface plate, the following should be considered:

• The interface plate should be designed to include bolt holes for mounting, dowel pins, and a boss for accurate positioning on the robot and Master Plate. (Refer to robot manual) (The dowel and boss features are important to prevent anti-rotation)

• A piston cover plate is provided with each Quick-Change Master Plate. If the robot interface plate

provides sealing for the piston cylinder, then the cover plate can be removed. Refer to

Figure 3.1

• The robot interface plate must be properly designed to provide rigid mounting on the boss surfaces.

The interface plate should not contact the Master body outside of the boss. The recommended dimensions for the interface plate bore, with and without the cover plate, are provided in

Section 8—

Drawings

. The mating diameters must provide sufficient clearance so that mating corner radii do not

interfere.

• The thickness of the interface plate must be great enough to provide the necessary thread engagement for the mounting bolts.

• Mounting bolts should not be too long, such that a gap is formed at the interface.

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Figure 3.1

—RIP and SIP with Master Plate Configurations

Dowel Pin

Sensor Interface plate (SIP)

Master Plate Boss

Sensor Plate

O-ring

Sensor Plate (Cover Plate Removed)

Mounting Fasteners

(Supplied by Customer)

Detection shaft

O-ring

Master Plate Body

Cover Plate Left In Place

Mounting Fasteners

(Supplied by Customer)

RIP Boss

Robot Interface Plate

(RIP)

Master Plate Boss

Maintain a Gap

O-ring

Cover Plate Removed

Cover Plate Left in Place

Dowel Pin

RIP Boss

Mounting Fasteners

(Supplied by Customer)

Robot Interface Plate

(RIP)

Master Plate Boss

Maintain a Gap

Dowel Pin

O-ring

Master Plate Body

Master Plate Body

3.2 Master Plate Installation

The Tool Changer Master Plate is mounted to the robot flange using an SIP or RIP. A cover plate is attached to the Master Plate to protect the internal locking mechanism during shipment. The cover plate will have to be removed if an SIP is being used and may have to be removed if an RIP is being used. The RIP can be designed to accommodate the cover plate.

1. Make sure mounting surface of the Master Plate, RIP, or SIP and robot arm are clean and free of debris.

2. Align the Dowel Pin in the RIP or SIP to the corresponding holes in the robot arm and secure with supplied or customer supplied fasteners, refer to

Figure 3.1

. Refer to

Table 3.1

for proper fasteners and torque.

3. What type of interface plate being installed?

If an RIP that replaces the cover plate being installed, go to step

4

.

If an SIP or an RIP that incorporates the cover plate, go to step

6

.

4. Remove the two M3 socket Flat head screws and discard.

5. Remove the cover plate.

CAUTION: Make sure the O-ring is properly seated in the groove in the Master Plate. If the O-ring is not properly seated in the groove it can be cut or damaged, resulting in a leaking seal. Properly seat O-ring into groove in Master body.

6. Align the Dowel Pin in the RIP or SIP to the corresponding holes in the Master Plate and secure with

supplied fasteners, refer to

Figure 3.2

. Refer to

Table 3.1

for proper fasteners and torque.

7. Connect all Lock / Unlock and pass-through air connection to the connections on the Master Plate. For

Lock and Unlock air refer to

Section 3.8—Lock/Unlock Pneumatic Connections and Valving.

8. If equipped connected the Lock and Unlock sensor cables.

9. If equipped connect other utilities to the optional modules on the Master Plate.

10. If installation is complete, the Master plate may be put into normal operations.

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3.3 Master Plate Removal

WARNING: Do not perform maintenance or repair on Tool Changer or modules unless the Tool is safely supported or docked in the Tool Stand and all energized circuits (e.g., electrical, air, water, etc.) have been turned off. Injury or equipment damage can occur with Tool not docked and energized circuits on. Dock the Tool safely in the Tool Stand and turn off all energized circuits before performing maintenance or repair on Tool

Changer or modules.

NOTICE: Depending on maintenance or repair being performed, utilities to modules and Master

Plate may need to be disconnected.

1. Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to the

Master plate.

2. Turn off all energized circuits (e.g. electrical, air, water, etc.).

3. If equipped disconnect all utilities (e.g. electrical, air, water, etc.).

4. If equipped disconnect the Lock and Unlock sensor cables.

5. Remove the fasteners securing the Master Plate to the RIP or SIP. Refer to

Figure 3.2.

6. Remove the Master Plate. Note: RIP or SIP should not need to be removed.

Figure 3.2—Typical Master Plate Installation

Robot Arm

Dowel Pins

(Customer Supplied)

Sensor Interface Plate

Socket Head Cap Screws

(Customer Supplied)

Sensor Plate

(Replaces Cover Plate)

Dowel Pins

(Customer Supplied)

Robot Arm

Robot Interface Plate

(Customer Supplied)

Socket Head Cap Screws

(Customer Supplied)

(2) M3 Socket Flat Head

Screws to temporaraly hold cover plate in place

The Cover Plate can remain in place if RIP is designed to accomodate the plate

Master Plate Assembly

(QC-41 with FN2 module Shown)

(6) M6 Socket Head Cap Screws

Master Plate Assembly

(QC-60 with K19 and FR4 modules Shown)

(6) Socket Flat Head

Cap Screws

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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

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3.4 Tool Interface Plate

The end-effector is typically attached to the Tool Plate with a tool interface plate. The tool interface Plate is designed with mounting features such as a recess and/or bolt and dowel holes. These features are used to accurately position and secure the customer’s tooling. Most often a tool interface plate is utilized to adapt the Tool Plate to customer’s tooling that is not compatible with the Tool Plate mounting features. Custom tool interface plates can be supplied by ATI to meet customer’s requirements (see

Figure 3.3

) (Refer to

Section 8—Drawings

for specific mounting features for your model).

If the customer chooses to design and build a tool interface plate, the following should be considered:

• The tool interface plate should be designed to include bolt holes for mounting, dowel pins, and a boss that mates with Tool Plate recess for accurate positioning. (The dowel and boss features are important to prevent anti-rotation).

• The locating boss height should not exceed the customer interface depth specified on the drawing.

• The thickness of the interface plate must be great enough to provide the necessary thread engagement for the mounting bolts. Fasteners should be chosen to meet minimum recommended engagement lengths while not exceeding the maximum available thread depth. Use of bolts that are too long can cause damage to the tool side changer.

• The plate design should take into account clearances required for Tool Changer module attachments and accessories.

• The tool interface plate should be designed with a hole in its center to allow for manually returning the locking mechanism to the unlocked position under adverse conditions (i.e. unintended loss of power and/or air pressure). The center access hole should be kept small [minimum recommended hole diameter: 1” (25.4 mm)] to prevent debris from contaminating the locking mechanism while operating in dirty environments.

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3.5 Tool Plate Installation

The end-effector is typically attached to the Tool Plate with an interface plate designed refer to

Section 3.4—

Tool Interface Plate

for specific requirements for your application.

1. Make sure mounting surface of the Tool Plate and tool interface plate is clean and free of debris.

2. Align the Dowel Pins in the tool interface plate or customer tooling to the corresponding holes in the

Tool Plate and secure with customer supplied mounting fasteners. Apply Loctite 242

®

to threads or use

fasteners with pre-applied adhesive, refer to

Table 3.1

for proper thread engagement and torque. (Note:

Mounting fasteners are supplied with ATI custom tool interface plates).

3. Connect utilities to the appropriate module and Tool Plate connections.

4. If installation is complete, the Tool plate may be put into normal operations.

Figure 3.3—Typical Tool Plate Installation

Tool Plate Assembly

(QC-60 with FR4 and K19

Modules Shown) Tool Plate Assembly

(QC-41 with FN2 Module Shown)

Dowel Pin

(Customer Supplied)

Dowel Pin

(Customer Supplied)

Interface Plate

(Customer Supplied)

Interface Plate

(Customer Supplied)

(6) M8 Socket Head Cap Screws

(Customer Supplied)

(6) M8 Socket Head Cap Screws

(Customer Supplied)

Note: Mounting Fasteners and Dowel Pins included with ATI Interface Plates

3.6 Tool Plate Removal

WARNING: Do not perform maintenance or repair on Tool Changer or modules unless the Tool is safely supported or docked in the Tool Stand and all energized circuits (e.g., electrical, air, water, etc.) have been turned off. Injury or equipment damage can occur with Tool not docked and energized circuits on. Dock the Tool safely in the Tool Stand and turn off all energized circuits before performing maintenance or repair on Tool

Changer or modules.

NOTICE: Depending on maintenance or repair being performed, utilities to modules and Tool

Plate may need to be disconnected.

1. Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to the Tool plate.

2. If equipped disconnect all utilities (e.g. electrical, air, water, etc.).

3. Remove the fasteners securing the Tool Plate to the tool interface Plate or customer tooling. Refer to

Figure 3.3.

4. Remove the Tool Plate.

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3.7 Optional Module Installation

The optional modules are typically installed on tool changers by ATI prior to shipment. The steps below outline field installation or removal as required. Tool Changers are compatible with many different types of modules. Some modules will require an adapter plate to be installed to the Tool Changer.

3.7.1 QC-60 Flat A Optional K Series Module Installation

1. If the Tool Changer is in service, dock the Tool safely in the tool stand and uncouple the Tool

Changer to allow clear access to the Master and Tool plates. Leave the locking mechanism in the unlocked.

2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).

3.

Align optional module on flat A of Master or Tool Plate Assembly.

4.

If not using fasteners with pre-applied adhesive, apply Loctite 222

®

to M3 mounting fasteners.

5. Secure module with two M3 mounting fasteners. Refer to

Table 3.1

for proper torque for your

specific mounting fasteners.

6. Remove all protective caps, plugs, tape, etc from the module prior to operation.

7. If installation is complete, return circuits to normal operation.

Figure 3.4—QC-60 Flat A Optional K Series Module Installation

(2) M3 Socket Head

Cap Screws

Electrical Module

(9120-K19-M Shown)

Master Plate Assembly

(QC-60 Shown)

Tool Plate Assembly

(QC-60 Shown)

Electrical Module

(9120-K19-T Shown)

(2) M3 Socket Head

Cap Screws

3.7.2 QC-60 Flat A Optional K Series Module Removal

1. Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to the Master or Tool plate.

2. Turn off all energized circuits (e.g. electrical, air, water, etc.).

3. Disconnect any cables, air line, etc. if required.

4. Supporting the module, remove the two M3 socket head cap screws. Note: For the module

on the master, the Master Plate may have to be removed refer to

Section 3.3—Master Plate

Removal.

5. Remove the module from the Master or Tool Plate.

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3.7.3 QC-60 Flat B Optional Module Installation

1. If the Tool Changer is in service, dock the Tool safely in the tool stand and uncouple the Tool

Changer to allow clear access to the Master and Tool plates. Leave the locking mechanism in the unlocked.

2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).

3.

Align Adapter Plate to Flat B of the QC-60 Master or Tool Plate as shown in

Figure 3.5

.

4.

If not using fasteners with pre-applied adhesive, apply Loctite 222

®

to M4 socket flat head cap screws.

5. Secure Adapter Plate to the Tool Changer with two M4 socket head cap screws. Tighten to 10 in-lbs.

6. Align optional module on the Adapter Plate.

7. If not using fasteners with pre-applied adhesive, apply Loctite 222

®

to four M4 mounting fasteners.

8. Secure module with four M4 mounting fasteners. Refer to

Table 3.1

for proper torque for your specific mounting fasteners.

9. Remove all protective caps, plugs, tape, etc from the module prior to operation.

10. If installation is complete, return circuits to normal operation.

Figure 3.5—QC-60 Flat B Optional Module Installation

Adapter Plate (9005-20-1388 Shown)

(4) M4 Socket Head

Cap Screws

Master Plate Assembly

(QC-60 Shown)

(4) M4 Socket Head Cap Screws

Tool Plate Assembly

(QC-60 Shown)

Adapter Plate

(9005-20-1389 Shown)

(4) M4 Socket Head Cap Screws

Fluid/Air Module

(9120-FR2-T Shown)

Fluid/Air Module

(9120-FR2-M Shown)

(4) M4 Socket Head

Cap Screws

3.7.4 QC-60 Flat B Optional Module Removal

1. Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to the Master or Tool plate.

2. Turn off all energized circuits (e.g. electrical, air, water, etc.).

3. Disconnect any cables, air line, etc. if required.

4. Supporting the module, remove the four M4 socket head cap screws.

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5. Remove the module from the Adapter Plate.

6. Remove the two M4 socket head cap screws securing the adapter plate to the Master or Tool

Plate.

7. Remove the adapter plate.

3.7.5 QC-40. QC-41, QC-43, QC-71, and QC-100 Optional Module Installation

1. If the Tool Changer is in service, dock the Tool safely in the tool stand and uncouple the Tool

Changer to allow clear access to the Master and Tool plates. Leave the locking mechanism in the unlocked.

2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).

3. Align optional module on the Master or Tool Plate as shown in

Figure 3.6

.

4.

If not using fasteners with pre-applied adhesive, apply Loctite 222

®

to four M4 socket head cap screws.

5. Secure module with four M4 mounting fasteners. Refer to

Table 3.1

for proper torque for your specific mounting fasteners.

6. Remove all protective caps, plugs, tape, etc from the module prior to operation.

7. If installation is complete, return circuits to normal operation.

Figure 3.6—Optional Module Installation

(4) M4 Socket Head

Cap Screws

Master Plate Assembly

(QC-41 Shown)

(4) M4 Socket Head

Cap Screws

Tool Plate Assembly

(QC-41 Shown)

Fluid/Air Module

(9120-FR2-T Shown)

3.7.6 QC-40, QC-41, QC-43, QC-71, and QC-100 Optional Module Removal

1. Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to the Master or Tool plate.

2. Turn off all energized circuits (e.g. electrical, air, water, etc.).

3. Disconnect any cables, air line, etc. if required.

4. Supporting the module, remove the four M4 socket head cap screws.

5. Remove the module from the Master or Tool Plate.

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3.8 Lock/Unlock Pneumatic Connections and Valving

WARNING: The Quick-Change 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.

Air must be supplied to the “Lock” air port on the Master Plate (robot-side) to move the internal piston, which moves the cam, and forces the locking balls outward. The locking balls move outward until they contact the bearing race on the mating Tool Plate. This will rigidly engage the Master Plate and Tool Plate providing high load capacity and positional accuracy. The patented cam profile prevents the Tool Plate from becoming disengaged in the event that there is a loss of air in the locked state.

To unlock the Tool Plate from the Master Plate, lock air must be vented and air supplied to the “Unlock” air port on the Master Plate.

3.8.1 Air Requirements

For proper operation of the Quick-Change system, the Master Plate must be supplied with clean, dry, non-lubricated air supplied between 65 and 100 psi (4.5–6.9 Bar) and filtered at 20 microns or better. Flow requirements are negligible, typically no more than 1/3 CFM at 70 PSI when cycled continuously.

CAUTION: Do not use the Tool Changer in the fail-safe condition for extended periods of time. Do not transport the Tool Changer in the fail-safe condition.

Possible damage to the locking mechanism could occur.

3.8.2 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 Master Plate. 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 Master Plate, 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 Quick-Change mechanism.

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.

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Figure 3.7—QC-40, QC-43 and QC-71 Lock and Unlock Pneumatic Connections

4 or 5 -way Valve

Lock Port

Unlock Port

Supply Clean, Dry,

Non-lubricated Air

65 – 100 psi (4.5 – 6.9 Bar)

Exhaust

Open to Atmosphere

Figure 3.8—QC-41 Lock and Unlock Pneumatic Connections

4 or 5 -way Valve

Lock Port

Unlock Port

Supply Clean, Dry,

Non-lubricated Air

65 – 100 psi (4.5 – 6.9 Bar)

Exhaust

Open to Atmosphere

Figure 3.9—QC-60 Lock and Unlock Pneumatic Connections

4 or 5 -way Valve

Lock Port

Unlock Port

Supply Clean, Dry,

Non-lubricated Air

65 – 100 psi (4.5 – 6.9 Bar)

Exhaust

Open to Atmosphere

Figure 3.10—QC-100 Lock and Unlock Pneumatic Connections

4 or 5 -way Valve

Lock Port

Unlock Port

Supply Clean, Dry,

Non-lubricated Air

65 – 100 psi (4.5 – 6.9 Bar)

Exhaust

Open to Atmosphere

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3.9 Electrical Connections

The Optional Lock and Unlock sensors are available in PNP and NPN type.

3.9.1 PNP Type Lock and Unlock Sensors

The PNP Lock and Unlock sensors are 8mm cylindrical inductive proximity sensor.

Table 3.2—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)

PNP

PNP (Current Sourcing)

Brown (1)

Figure 3.11—PNP Type Lock and Unlock Sensors

+Vs

Connector

(4) Black

Black (4)

Output

Blue (3)

Z

0 V

Brown (1) (3) Blue

3.9.2 NPN Type Lock and Unlock Sensors

The NPN Lock and Unlock sensors are 8mm cylindrical inductive proximity sensor.

Table 3.3—NPN (Current Sourcing)

Description

Voltage Supply Range

Output Current

Nominal Sensing Distance Sn

Output Circuit

Value

10-30 VDC

< 100 mA

0.8 mm

NPN make function (NO)

NPN

NPN (Current Sinking)

Brown (1)

Figure 3.12—NPN Type Lock and Unlock Sensors

+Vs

Connector

(4) Black

Black (4)

Z

Output

Blue (3)

0 V

Brown (1) (3) Blue

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4. Operation

The Master locking mechanism is pneumatically driven to couple and uncouple with the bearing race on the Tool

Plate. The Master Plate utilizes air ports to provide lock and unlock pressure to the locking mechanism.

CAUTION: Safe, reliable operation of the tool changer is dependent on a continuous supply of compressed air at a pressure of 65 to 100 psi. Robot motion should be halted if the air supply pressure drops below 60 psi for any reason.

NOTICE: All Tool Changers are initially lubricated using MobilGrease® XHP222 Special grease. The end user must apply additional lubricant to the locking mechanism components and alignment pins

prior to start of service (See

Section 5.2—Cleaning and Lubrication of the Locking Mechanism and

Alignment Pins

). Tubes of lubricant for this purpose are shipped with every tool changer. Note:

MobilGrease® XHP222 Special is a NLGI #2 lithium complex grease with molybdenum disulfide.

The robot should be programmed to minimize misalignment during coupling and uncoupling. Additionally, the Tool

Stand should be durable and not allow deflection, under uncoupled Tool weight that will take alignment of the Tool

Changer plates outside of accepted offsets. See

Figure 4.1

and

Table 4.1

for recommended maximum allowable

offsets prior to coupling. In some cases, greater offsets than shown in

Table 4.1

can be accommodated by the

Master and Tool Plates, but will increase wear.

Lock-up should occur with the Master Plate in the No-Touch™ Locking zone (see

Table 4.1

) but not touching the

Tool Plate. As locking occurs, the Master Plate should draw the Tool Plate into the locked position.

Figure 4.1

— Offset Definitions

Master Plate

Z

Tool Plate

Y

Cocking Offset

(About X and Y)

Twisting Offset

(About Z)

X

X, Y, and Z Offset

Model

Table 4.1—Maximum Recommended Offsets Prior to Coupling

No-Touch™ Zone Z

Offset (Max)*

(mm)

X and Y Offset (Max)†

(mm)

Cocking Offset

(Max)

(degrees)

Twisting Offset

(Max)

(degrees)

QC-40

QC-41

QC-43

QC-60

QC-71

+3

+3

±2

±2

±1.0

±0.6

QC-100 +3 ±2 ±0.7

Notes: *Maximum values shown. Decreasing actual values will minimize wear during coupling/uncoupling.

±2

±1

±1

†Actual allowable values may be higher in some cases but higher offsets will increase wear during coupling.

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4.1 Coupling Sequence

CAUTION: The locking mechanism must be in the unlock position when attempting to couple the Tool Changer. Failure to adhere to this condition may result in damage to the unit and/or the robot.

1. Prior to coupling and with air supplied to the Unlock Port (if equipped the Unlock sensor will indicate the Tool Change is Unlocked), position the Master Plate above the Tool Plate.

2. Move the Master Plate toward the Tool Plate so that the two Master Plate alignment pins enter the alignment holes on the Tool Plate. Take care to program the robot so that the Master Plate and Tool

Plate are aligned axially and are parallel to each other as closely as possible, refer to

Table 4.1.

This will minimize Tool movement and subsequent wear during lock-up.

CAUTION: No-Touch™ locking technology allows the unit to couple with a separation distance between the Master and Tool. Direct contact of the Master and Tool mating surfaces is not suggested or required just prior to coupling. Contact may result in damage to the unit and/or the robot.

3.

When the two faces are within the specified No-Touch™ distance (refer to

Table 4.1)

, release the pressure from the Unlock Port and supply air to the Lock Port. The Tool Plate will be drawn toward the Master Plate and coupled. Air must be maintained on the Lock Port during operation to assure rigid coupling (if equipped the Lock sensor will indicate the Tool Change is in the Locked position).

4.

A sufficient delay must be programmed between locking valve actuation and robot motion so that the locking process is complete before moving the robot.

5. ATI’s patented fail-safe design prevents the Tool Plate from being released in the event of air-pressure loss to the Lock port, thereby increasing safety and reliability. Positional accuracy may not be maintained during air loss, but will be regained once air pressure is re-established to the Lock port.

4.2 Fail-Safe Operation

A fail-safe condition occurs, when there is an unintended loss of lock air pressure to the Master Plate. When air pressure is initially lost, the tool changer relaxes and there may be a slight separation between the Master and Tool Plates. The lock sensor may indicate that the unit is not locked. ATI’s patented fail-safe feature utilizes a multi-tapered cam to trap the ball bearings and prevent an unintended release of the Tool Plate.

Positional accuracy of the tooling will not be maintained during this Fail Safe condition. The Tool Changer is not to be operated in the fail-safe condition. Once source air is lost to the unit, movement should be stopped until air is restored. Once air pressure is reestablished to the Master Plate, the locking mechanism will energize securely locking the master and Tool Plates together. If equipped, make sure the lock sensor indicate the Tool changer is in the locked position before resuming normal operations.

CAUTION: Do not use the Tool Changer in a fail-safe condition. Do not transport the

Tool Changer in a fail-safe condition. Possible damage to the locking mechanism could occur. Once air pressure is reestablished to the Master Plate, the locking mechanism will energize securely locking the master and Tool Plates together. Make sure the lock sensor indicate the Tool changer is in the locked position, it may be necessary to consult your Control and Signal Module Manual for specific error recovery information before resuming normal operations.

4.3 Uncoupling Sequence

1. Position the Tool Plate in the Tool Stand such that there is little or no contact force between the Tool

Plate and Tool Stand.

2. Release air on the Lock port and apply air to the Unlock Port (if equipped the Unlock sensor will indicate the Tool Change is in the Unlocked position). The air will cause the locking mechanism to be released and the weight of the Tool Plate and attached tooling will assist in its removal. (Note: Tool weight assists in uncoupling if the Tool is released in the vertical position only). Move the Master Plate axially away from the Tool Plate.

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3.

A sufficient delay must be programmed between unlocking valve actuation and robot motion so that the unlocking process is complete and the Tool Plate is fully released before moving the robot.

4. In automated Tool change applications, it is recommended that a Tool presence sensor(s) be used in the Tool Stand to verify that the Tool is present and to verify that the Tool remains in place as the robot moves away after the unlocking process.

4.4

Tool Identification

When using multiple Tools, it is good practice to implement a Tool-ID system that identifies each Tool with a unique code. This can be used to verify that the robot has picked up the proper Tool. This may be accomplished by using an optional electrical module (for power and signal pass-through) and uniquely jumpering pins on the Tool-side of the module. See electrical module documentation for more information.

DeviceNet Tool-ID modules are also available.

4.5 Tool Storage Considerations

CAUTION: Tool Stand design is critical to proper operation of the Tool Changer.

Improperly designed Tool Stands can cause misalignments that will cause jamming and/or excessive wear of Tool Changer components.

The tools may be stored in a Tool Stand when not being used by the robot. ATI provides compatible Tool

Stands designed for durability, longevity, and maximum adaptability to fit most customers’ applications. The

ATI TSM (Tool Stand Medium) system is compatible with ATI Tool Changer sizes QC-20 to QC-110. The

TSM systems can be equipped with horizontal modules, clamp modules, and different types of tool sensing.

Visit the ATI Web Site

http://www.ati-ia.com/products/toolchanger/toolstand/medium/MediumStand.aspx

for products available for your specific application or contact ATI for recommendations and assistance.

If the customer is supplying the tool stand, it should be designed to provide a fixed, repeatable, level, and stable positions for tool pick-up and drop-off. The tool stand must support the weight of the Tool Changer

Tool Plate, Tool Interface Plate, optional modules, cables, hoses, and customer tooling without allowing deflection in excess of the offsets specified in

Section 4—Operation

.

Ideally, the Tool should be hanging vertically in the Tool Stand so that gravity assists to uncouple the Tool

Plate from the Master Plate during unlocking. It is possible to design Tool Stands that hold tools in the horizontal position, but care must be taken that the necessary compliance is provided during coupling and uncoupling. In general, “horizontal-position” Tool Stands cause more wear on the locking mechanism and locating features of the Tool and Tool Stand.

A variety of methods may be used to position the Tool in the Tool Stand. A common method is to use tapered alignment pins and bushings. Robot programming and positional repeatability are vital in tool pickup and drop-off, refer to

Section 4—Operation

.

It is highly recommended that the customer provide a sensor that detects the presence of a properly seated

Tool in the Tool Stand. The sensor may be used prior to coupling to ensure there is a Tool properly seated in the stand. Sensors may also be used as the robot starts to move away after uncoupling. This provides a safety measure in the event that a Tool should become jammed in the stand or if the Tool should fail to release properly from the robot.

Proximity sensors should be positioned so that the sensing face is vertical to prevent metal shavings, weld spatter, or other debris from falling on the sensor and creating false readings.

Tool Stands may also need to incorporate means for covering Tools and modules to protect them in dirty environments, such as grinding or welding. Alternatively, positioning Tool Stands in areas shielded from weld spatter, fluids, adhesives, or other debris would eliminate the need for tool covers.

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5. Maintenance

WARNING: Do not perform maintenance or repair on Tool Changer or modules unless the

Tool is safely supported or docked in the Tool Stand and all energized circuits (e.g., electrical, air, water, etc.) have been turned off. Injury or equipment damage can occur with Tool not docked and energized circuits on. Dock the Tool safely in the Tool Stand and turn off all energized circuits before performing maintenance or repair on Tool Changer or modules.

NOTICE:

The cleanliness of the work environment strongly influences the trouble free operation of the Tool Changer. The dirtier the environment, the greater the need for protection against debris.

Protection of the entire EOAT, the Master, the Tool and all of the modules may be necessary. Protective measures include the following: 1) Placement of Tools Stands away from debris generators. 2) Covers incorporated into the Tool Stands. 3) Guards, deflectors, air curtains, and similar devices built into the

EAOT and the Tool Stand.

5.1 Preventive Maintenance

The Tool Changer and optional modules are designed to provide a long life with regular maintenance. A visual inspection and preventive maintenance schedule is provided in the table below depending upon the application. Detailed assembly drawings are provided in

Section 8—Drawings

of this manual.

Table 5.1—Preventive Maintenance Check List

Application(s) Tool Change Frequency Inspection Schedule

General Usage Material Handling Docking Station > 1 per minute

< 1 per minute

Weekly

Monthly

Welding/Servo/Deburring, Foundry Operations (Dirty Environments) All Weekly

Checklist

Mounting Fasteners

г

Inspect fasteners for proper torque, interference or wear. Tighten and correct as required. Refer to

Section 3—

Installation.

Balls/Alignment Pins/Holes/Bearing Race

г

Inspect for lubrication and wear. MobilGrease® XHP222 Special a NLGI #2 lithium complex grease with molybdenum disulfide additive is suggested for locking mechanism and alignment pin lubrication. 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. See

Section 5.2—Cleaning and Lubrication of the

Locking Mechanism and Alignment Pins

.

г

Inspect for excessive alignment pin/bushing wear may be an indication of poor robot position during pickup/ drop-off. Adjust robot position as needed. Check tool stand for wear and alignment problems. The QC-100 model has replaceable alignment pins, refer to

Section 6.2.4—QC-100 Alignment Pin Replacement

г

Inspect for wear on the balls/bearing race could be an indication of excessive loading.

Sensors and Cables

г

Inspect sensor cable connectors for tightness, if loose tighten connections. г

Inspect sensor cables for any damage, cuts, and abrasion. Replace as necessary.

Hoses

г

Inspect hose connection for tightness and leaks. If leaking or loose secure hose connection.

г

Inspect hoses for interferences, abrasions, cuts, and leaks. Replace as required.

Seals Pass Through Air and Optional Modules

г

Inspect for wear, abrasion, and cuts. Replace damaged seals, or rubber bushings as needed. Refer to

Section 6.2.1—1/8” and 1/4” Rubber Bushing Inspection & Replacement, Section 6.2.2—3/8” Rubber Bushing

Replacement,

or

Section 6.2.3—Optional Electrical Module Seal Inspection and Replacement

Electrical Contacts/Pin Block (Modules)

г

Inspect for damage, debris, and stuck/burnt pins. Clean pin blocks as required, refer to

Section 5.3—Optional

Electrical Module Pin Block Inspection and Cleaning.

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5.2 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins

1. Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to the

Master and Tool plates. Leave the locking mechanism in the unlocked.

1.

Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).

2. The locking mechanism must be in the unlock state before cleaning.

3.

Use a clean rag to thoroughly remove the existing lubricant and debris from the ball bearings, the male coupling, the cam and the alignment pins.

Figure 5.1— Cleaning Ball Bearings and Outer Surfaces of Male Coupling

4.

Use a clean rag to thoroughly remove the existing lubricant and debris from the inner surface of the male coupling and the cam.

Figure 5.2— Cleaning Ball Bearings, Cam and Inner Surfaces of Male Coupling

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5. Check each ball bearing to make sure it moves freely in the male coupling. Additional cleaning may be necessary to free up any ball bearings that are sticking in place.

Figure 5.3— Check Ball Bearing Movement

6.

Apply a liberal coating of MobilGrease® XHP222 Special grease to the ball bearings, the male coupling (inside and out), and the alignment pins.

Figure 5.4— Apply Lubricant to Locking Mechanism

Apply Lubricant on Alignment

Pins and Outer Surface

of Male Coupling

Apply Lubricant on Inner

Surface of Male Coupling

7. Use a clean rag to thoroughly remove the any lubricant and debris from the bearing race and the bushings from the Tool Plate.

Figure 5.5— Clean Tool Plate Surfaces of Locking Mechanism

Clean Bushing Surfaces

Clean Bearing

Race Surfaces

8. No application of lubrication is necessary on the Tool Plate components.

9. After repair is complete, return all circuits to normal operation (e.g. electrical, air, water, etc.).

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5.3 Optional Electrical Module Pin Block Inspection and Cleaning

1. Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to the

Master and Tool plates. Leave the locking mechanism in the unlocked.

2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).

3. Inspect the Master and Tool pin blocks for any debris or darkened pins.

Figure 5.6—Inspect Master and Tool Pin Blocks

Blackened Pins

Note: Pin blocks shown are for

illustration purposes only.

Tool Module Pin Block

Master Module Pin Block

4.

If debris or darkened pins exist, remove debris using a vacuum, and clean using a nylon brush (ATI part number 3690-0000064-60).

NOTICE: Do not use an abrasive media, cleaners, or solvents to clean the contact pins. Using abrasive media, cleaners, or solvents will cause erosion to the contact surface or pins to stick.

Clean contact surfaces with a vacuum and non-abrasive media such as a nylon brush (ATI part number 3690-0000064-60)

Figure 5.7—Clean Pin Blocks with a Nylon Brush

5. Inspect the Master and Tool pin blocks for stuck pins or severe pin block damage.

Figure 5.8—Stuck Pin and Pin Block Damage

Note: Pin blocks shown are for

illustration purposes only.

Stuck Pins

Severe Pin Block Damage

6.

If stuck pins or severe pin block damage exists, contact ATI for possible pin replacement procedures or module replacement.

7. After maintenance is complete, return all circuits to normal operation (e.g. electrical, air, water, etc.).

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6. Troubleshooting and Service Procedures

The following section provides troubleshooting information to help diagnose conditions with the Tool Changer and service procedures to help resolve these conditions.

WARNING: Do not perform maintenance or repair on Tool Changer or modules unless the

Tool is safely supported or docked in the tool stand and all energized circuits (e.g., electrical, air, water, etc.) have been turned off. Injury or equipment damage can occur with Tool not docked and energized circuits on. Dock the Tool safely in the tool stand and turn off all energized circuits before performing maintenance or repair on Tool Changer or modules.

6.1 Troubleshooting

The troubleshooting table is provided to assist in diagnosing issues that may cause the Tool Changer not to function properly.

Symptom

Tool Changer will not lock and/ or unlock (or

Lock sensor does not indicate

Tool Changer is

Locked)

Cause

Pneumatic connections loose or damaged.

Table 6.1—Troubleshooting

Air pressure trapped in deenergized Lock or Unlock ports.

Resolution

Debris caught between the

Master and Tool plates.

Clean debris from between Master and Tool Plates. Verify mounting hardware is secure and does not protrude above the mating surfaces.

Insufficient or no air pressure supply to the lock or unlock ports.

Verify proper air pressure and pneumatic valve is supplied. Refer to

Section 3.8—Lock/Unlock Pneumatic

Connections and Valving.

Air pressure must be vented to the atmosphere

properly, refer to

Section 3.8—Lock/Unlock Pneumatic

Connections and Valving.

Inspect hose connection for tightness and leaks. If leaking or loose secure hose connection.

Inspect hoses for interferences, abrasions, cuts, and leaks. Replace as required.

The ball bearings and/or cam are not moving freely in the male coupling.

Clean and lubricate as needed to restore smooth operation (see

Section 5.2—Cleaning and Lubrication of the Locking Mechanism and Alignment Pins

).

The Master plate and Tool plate are not within the specified No-Touch zone when attempting to lock.

Lock sensor/cable is out of adjustment or damaged.

Check that the Tool is properly seated in the tool stand.

Refer to

Section 4.5—Tool Storage Considerations.

Re-teach the robot to bring the Master plate and Tool plate closer together prior to attempting to lock.

Adjust or replace the lock sensor assembly as necessary.

Refer to

Section 6.2.5—Proximity Sensor Adjustment,

Test, or Replacement.

Unit is locked but

Lock signal does not read “on”

(true).

Unit is unlocked but Unlock signal does not read

“on” (true).

Unlock sensor/cable is out of adjustment or damaged.

Adjust or replace the unlock sensor assembly as

necessary. Refer to

Section 6.2.5—Proximity Sensor

Adjustment, Test, or Replacement.

Units Equipped with Electrical/Servo/Control/Signal Modules

Loss of

Communication

Debris in and around contact pins. Contact Pin worn or damaged.

Cable connections loose or cables damaged

Inspect V-ring seal for damage, replace damaged seal.

Refer to

Section 6.2.3—Optional Electrical Module Seal

Inspection and Replacement

Check that cable connection are secure and cables are not damaged.

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6.2 Service Procedures

The following service procedures provide instructions for inspection, adjustment, test or replacement of components.

WARNING: Do not perform maintenance or repair on Tool Changer or modules unless the Tool is safely supported or docked in the tool stand and all energized circuits (e.g., electrical, air, water, etc.) have been turned off. Injury or equipment damage can occur with Tool not docked and energized circuits on. Dock the Tool safely in the tool stand and turn off all energized circuits before performing maintenance or repair on Tool

Changer or modules.

6.2.1 1/8 and 1/4 Rubber Bushing Inspection & Replacement

The rubber bushings seal the air passage from the Master plate to the Tool plate. If the bushing become cut or damaged they need to be replaced.

1. Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to the Master and Tool plates. Leave the locking mechanism in the unlocked.

2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).

3.

Remove damaged rubber bushing by grasping with fingers and pulling the bushing out of the body.

4. Dip new bushing in water to aid in installation.

5. Insert the beveled (chamfered) end of the rubber bushing into the bore, leaving ribbed end of the bushing facing outward.

6. Press the bushing in by hand until it is seated completely in the bore. If necessary, use a plastic or rubber soft-faced mallet to tap the bushings into place.

7. After maintenance is complete, return all circuits to normal operation (e.g. electrical, air, water, etc.).

Figure 6.1 —1/8 and 1/4 Rubber Bushing Replacement (QC-41 Shown)

Rubber Bushing

6.2.2 3/8 Rubber Bushing Replacement

1. Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to the Master and Tool plates. Leave the locking mechanism in the unlocked.

2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).

3. Using needle nose pliers grasp the rubber bushing and pull it out of the Master body. Refer to

Figure 6.2.

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4. If the collar remains in the Master body, remove it.

5. Lightly lubricate the new rubber bushing and push into the Master body (refer to

Figure 6.2)

.

6. Insert the new collar into the rubber bushing, make sure the bushing is pressed all the way in.

7. After maintenance is complete, return all circuits to normal operation (e.g. electrical, air, water, etc.).

Figure 6.2— 3/8 Rubber Bushing Replacement (QC-41 Shown)

Collar

Rubber Bushing

6.2.3 Optional Electrical Module Seal Inspection and Replacement

The seal protect the electrical connection between the Master and Tool module. If the seal becomes worn or damaged it needs to be replaced.

1. Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to the Master and Tool plates. Leave the locking mechanism in the unlocked.

2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).

3.

To remove the existing seal, pinch edge of seal with fingers and gently pull the seal away from the pin block on the Master.

4. Pull the seal off the pin block.

5. To install a new seal, stretch the new seal over the shoulder of the pin block.

6.

Push the seal’s hub down against the pin block using finger tip.

7. After maintenance is complete, return all circuits to normal operation (e.g. electrical, air, water, etc.).

Figure 6.3—V-Ring Seal Replacement

Stretch seal over shoulder of pin block and push seal hub down against the pin block with finger tip

V-ring Seal

V-ring Seal

Pinch edge of seal with fingers and gently pull away from pin block

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6.2.4 QC-100 Alignment Pin Replacement

Excessive alignment pin/bushing wear may be an indication of poor robot position during pickup/ drop-off. Adjust robot position as needed. Check tool stand for wear and alignment problems. If necessary replace the alignment pins.

1. Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to the Master plate.

2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).

3.

Using a 2.5mm allen wrench remove the alignment pin and discard

4.

Apply loctite 242 to the treads of the new alignment pin and thread into the Master Plate assembly. Tighten to 18 in-lbs.

5. Apply a liberal coating of MobilGrease® XHP222 Special grease to the alignment pins.

6. After maintenance is complete, return all circuits to normal operation (e.g. electrical, air, water, etc.).

Figure 6.4—QC-100 Alignment Pin Replacement

2.5mm Allen Wrench

Alignment Pin

6.2.5 Proximity Sensor Adjustment, Test, or Replacement

The proximity sensors are very reliable and normally do not need to be replaced. Exhaust all other possible solutions, check continuity, air supply, lubrication, and pneumatic components prior to testing or replacing the sensor

1. Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to the Master plate.

2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).

3. If you are testing or replacing the Lock sensor make sure the QC is in the locked position, if you are replacing the Unlock sensor make sure the QC is in the unlocked position before continuing.

4.

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

5. Disconnect any cables, air line, etc. if required.

6. Remove the mounting fasteners securing the Master Plate Assembly to the sensor interface plate. Refer to

Figure 6.5

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7. Disconnect the sensor cable.

8. Loosen the hex nut and unscrew the proximity sensor from the Master Plate Assembly. Retain the washer from the sensor.

9. To test the suspect sensor, connect the sensor cable and place a ferrous target in front of the

Proximity Sensor to confirm that the sensor is functional. The sensor lock or unlock signal should read “on”(true) and the sensor LED should illuminate.

10.

If the proximity sensor is not functioning properly replace. Disconnect the sensor cable and discard.

11.

Back the sensor hex nut to the connector end of the new sensor.

12. Thread the proximity sensor into the Master Plate Assembly until it touches the Detection

Shaft, then back the sensor off 1/2 turn.

CAUTION: Do not operate locking mechanism with sensor touching the detection shaft. Operating the locking mechanism with the sensor touching the detection shaft will damage the sensor. Back off the sensor ½ turn and secure with the set screw before operating the locking mechanism.

13.

Connect the sensor cable. The Proximity Sensor LED should be illuminated.

14.

Holding the sensor in position apply Loctite 222

®

to the proximity sensor threads between the hex nut and the Master Plate Assembly. Tighten the hex nut and torque to 20 in-lbs.

15. Attach the Master Plate to the sensor interface plate using the mounting fasteners. Refer to

Table 3.1

for torque and thread locker specifications.

16. If required, connect other utilities to the optional modules on the Master Plate.

17. Confirm the operation of the replaced sensor by issuing the Lock command to lock a Tool to the Master and then checking to see that the LED in the replaced Sensor body is on.

Figure 6.5—Replace Proximity Sensor

Sensor Interface Plate (SIP)

Washer

Lock Sensor

Sensor LED

Sensor Cable

Unlock Sensor

Detection Shaft

Master Plate

(QC-41 Shown)

Mounting Fasteners

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7. Serviceable Parts

The following items are commonly used as spare parts for the QC-40 through QC-100 Tool Changers.

7.1 Models QC-40

6

5

4

1

2

3

ITEM NO.

QTY

1 1

PART NUMBER

9120-040M-000-000

2 6 3500-1064035-12

QC-40 Master Plate

DESCRIPTION

QC-40 Master, no options

SHCS, M5x35, ZN

QC-40 Tool Plate

QC-40 Tool, no options

1/8” NPT Rubber Bushing, Nitrile

3

4

1

8

9120-040T-000-000

4010-0000013-01

5

5

6*

2

2

2

QC-40 SIP Assemblies

PNP Sensors - 9120-040M-SIP-B-XXXX

8590-9909999-04 PNP Prox Switch Hardwired

PNP Sensors - 9120-040M-SIP-D-XXXX and 9120-040M-SIP-G-XXXX

8590-9909999-08 PNP Prox Switch

8590-9909999-07

High-flex cable w/ straight snap-on connector, 5M long flying leads (Type-BU)

NPN Sensors - 9120-040-SIP-A-XXXX

8590-9909999-02 NPN Prox Switch Hardwired 5 2

NPN Sensors - 9120-040M-SIP-E-XXXX and 9120-040M-SIP-F-XXXX

5

6*

2

2

8590-9909999-14 NPN Proximity Sensor w/ LED

8590-9909999-07

High-flex cable w/ straight snap-on connector, 5M long flying leads (Type-BU)

Note: *Sensor cables for 9120-040M-SIP-D-XXXX and 9120-040M-SIP-F-XXXX models.

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

37

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

7.2 Models QC-41

8

7

1

2

3

5

6

4

QC-41 Master Plate

ITEM NO.

QTY PART NUMBER DESCRIPTION

3

4

1

2

5

6

4

1 9120-041M-000-000

6 4010-0000010-01

6

3700-20-2000

4010-0000013-01

3500-1064035-12

QC-41 Master Assembly, No Options

3/8” Rubber Bushing. Nitrile

Collar for 3/8” Bushing

1/8” NPT Rubber Bushing, Nitrile

M5 x 35mm SHCS Zinc

6 1 9120-041T-000-000

QC-41 Tool Plate

QC-41 Tool Assembly, No Options

QC-41 SIP Assemblies

PNP Sensors - 9120-041M-SIP-D-XXXX and 9120-041M-SIP-G-XXXX

8590-9909999-08 PNP Prox Switch

8590-9909999-12 Straight Picofast Cordset, 2 Meter

7

8*

2

2

7

8*

2

2

NPN Sensors - 9120-041M-SIP-E-XXXX and 9120-041M-SIP-F-XXXX

8590-9909999-14

8590-9909999-12

NPN Proximity Sensor w/ LED

Straight Picofast Cordset, 2 Meter

Note: *Sensor cables for 9120-041M-SIP-D-XXXX and 9120-041M-SIP-F-XXXX models.

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

38

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

7.3 Models QC-43

6

5

1

4

2

3

QC-43 Master Plate

ITEM NO.

QTY PART NUMBER DESCRIPTION

1

2

1 9120-043M-000-000

6 3500-1064035-15

QC-43 Master, no options

M5 x 35mm SHCS, Blue Dyed Magni

3

4

1

8

9120-043T-000-000

4010-0000013-01

QC-43 Tool Plate

QC-43 Tool, no options

1/8” NPT Rubber Bushing, Nitrile

QC-43 SIP Assemblies (uses the QC-40 SIP Assemblies)

PNP Sensors - 9120-040M-SIP-B-XXXX

8590-9909999-04 PNP Prox Switch Hardwired 5 2

5

6*

2

2

PNP Sensors - 9120-040M-SIP-D-XXXX and 9120-040M-SIP-G-XXXX

8590-9909999-08 PNP Prox Switch

8590-9909999-07

High-flex cable w/ straight snap-on connector, 5M long flying leads (Type-BU)

NPN Sensors - 9120-040-SIP-A-XXXX

8590-9909999-02 NPN Prox Switch Hardwired 5 2

NPN Sensors - 9120-040M-SIP-E-XXXX and 9120-040M-SIP-F-XXXX

5

6*

2

2

8590-9909999-14 NPN Proximity Sensor w/ LED

8590-9909999-07

High-flex cable w/ straight snap-on connector, 5M long flying leads (Type-BU)

Note: *Sensor cables for 9120-040M-SIP-D-XXXX and 9120-040M-SIP-F-XXXX models.

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

39

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

7.4 Models QC-60

6

5

1

2

4

3

QC-60 Master Plate

ITEM NO.

QTY PART NUMBER DESCRIPTION

1

2

3

4

1

8

1 9120-060M-000-000

6 3500-1266040-15

9120-060T-000-000

4010-0000013-01

QC-60 Master, no options

M6 x 40mm SFHCS, Blue Dyed Magni-565

QC-60 Tool Plate

QC-60 Tool, no options

1/8” NPT Rubber Bushing, Nitrile

5

6*

2

2

QC-60 SIP Assemblies

PNP Sensors - 9120-060M-SIP-D-XXXX and 9120-060M-SIP-G-XXXX

8590-9909999-08 PNP Prox Switch

8590-9909999-07

High-flex cable w/ straight snap-on connector, 5M long flying leads (Type-BU)

NPN Sensors - 9120-060-SIP-A-XXXX

8590-9909999-02 NPN Prox Switch Hardwired 5 2

NPN Sensors - 9120-060M-SIP-E-XXXX and 9120-060M-SIP-F-XXXX

5

6*

2

2

8590-9909999-14 NPN Proximity Sensor w/ LED

8590-9909999-07

High-flex cable w/ straight snap-on connector, 5M long flying leads (Type-BU)

Note: *Sensor cables for 9120-060M-SIP-D-XXXX and 9120-060M-SIP-F-XXXX models.

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

40

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

7.5 Models QC-71

6

5

1

3

4

2

QC-71 Master Plate

ITEM NO.

QTY PART NUMBER DESCRIPTION

1

2

3

1 9120-071M-000-000

6 4010-0000021-01

6 3500-1066040-12

QC-71 Master Assembly, No Options

1/4” NPT Rubber Bushing, Nitrile

M6 x 40mm SHCS Zinc

QC-71 Tool Plate

QC-71 Tool Assembly, No Options 4 1 9120-071T-000-000

5

6*

2

2

QC-71 SIP Assemblies

PNP Sensors - 9120-071M-SIP-D-XXXX and 9120-071M-SIP-G-XXXX

8590-9909999-08 PNP Prox Switch

8590-9909999-07

High-flex cable w/ straight snap-on connector, 5M long flying leads (Type-BU)

NPN Sensors - 9120-071M-SIP-E-XXXX

8590-9909999-14 NPN Proximity Sensor w/ LED 5 2

NPN Sensors - 9120-071M-SIP-F-XXXX

5

6*

2

2

8590-9909999-09 NPN Prox Switch

8590-9909999-07

High-flex cable w/ straight snap-on connector, 5M long flying leads (Type-BU)

Note: *Sensor cables for 9120-071M-SIP-D-XXXX and 9120-071M-SIP-F-XXXX models.

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

41

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

7.6 Models QC-100

8

7

1

5

6

2

3

4

QC-100 Master Plate

ITEM NO.

QTY PART NUMBER DESCRIPTION

1

2

3

1

2

6

9120-100M-000-000

3700-20-1373

3500-1068055-15

QC-100 Master, no options

Monolithic Alignment Pin, QC-100, A2

M8 x 55mm SHCS, Blue Dyed Magni-565

4

5

6

1

8

8

9120-100T-000-000

4010-0000010-01

QC-100 Tool Plate

QC-100 Tool, no options

3/8” Rubber Bushing. Nitrile

7 2

3700-20-2000 Collar for 3/8” Bushing

QC-100 SIP Assemblies

PNP Sensors - 9120-100M-SIP-B-XXXX

8590-9909999-04 PNP Prox Switch Hardwired

7

8*

2

2

PNP Sensors - 9120-100M-SIP-D-XXXX and 9120-100M-SIP-G-XXXX

8590-9909999-08 PNP Prox Switch

8590-9909999-07

High-flex cable w/ straight snap-on connector, 5M long flying leads (Type-BU)

PNP Sensors - 9120-100M-SIP-L-XXXX

7 2 8590-9909999-23 PNP Hall Effect Sensor Switch for QC-100

NPN Sensors - 9120-100M-SIP-E-XXXX and 9120-100M-SIP-F-XXXX

7

8*

2

2

8590-9909999-14 NPN Proximity Sensor w/ LED

8590-9909999-07

High-flex cable w/ straight snap-on connector, 5M long flying leads (Type-BU)

Note: *

Sensor cable for 9120-100M-SIP-D-XXXX and 9120-100M-SIP-F-XXXX models.

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

42

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

8. Drawings

8.1 QC-40 Tool Changer with J16 Module

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

43

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

8.2 QC-41 Tool Changer with R19 Module

1/8 NPT Unlock Port

40.1 R19

1/8 NPT Lock Port

SHCS Provided Equally Spaced

44.9 R19-M

4X 1/8 NPT Pneumatic Thru Ports 6X 3/8 NPT Pneumatic Thru Ports

Part Numbers Shown: (A) Master: 9120-041M-R19-000 (B) Tool: 9120-041T-R19-000

30.1 Master Plate

Amphenol Connector PT02E-14-19P

Warning: Do not apply lock/unlock air pressure without master cover pl

4X 1/8 NPT Pneumatic Thru Ports (15.1 From 6X 3/8 NPT Pneumatic Thru Ports (14.1 From

33.3 R19-T

Pneumatic Port I.D.

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

60.2 R19

55.8 R19

57.6 (Typ.)

Notes: 1. Master mounting hardware provided. 2. Cover plate is not necessary if robot interface plate provi sealing. The recommended interface plate bore depth with a cover plate is 2.5mm. 3. Orientation marks are provided to assist in robot teaching. 4. Shown with optional R19 Electrical Modules. For other modu see the Modules and Options section of the catalog.

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

44

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

8.3 QC-43 Tool Changer

Cover Plate

1/8 NPT Lock Port

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

Master Plate

h7, Boss Customer Interface

6X Thru Hole for M5 x 35

SHCS Provided Equally Spaced

(Odd #s 15.1 From Mating Surface)

8X 1/8 NPT Pneumatic Thru Ports (Even #s 10.1 From Mating Surface)

1/8 NPT Unlock Port

NOTES: UNLESS OTHERWISE SPECIFIED.

DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS.

18.1 Male

27 Tool Plate

8X 1/8 NPT Pneumatic Thru Ports

15° (Typ.)

20° (Typ.)

3X 15.5 Alignment

30° (Typ.)

Pneumatic Port I.D.

Part Numbers Shown: (A) Master: 9120-043M-000-000 (B) Tool: 9120-043T-000-000

Warning: Do not apply lock/unlock air pressure without master cover pl Notes: 1. Master mounting hardware provided. 2. Cover plate is not necessary if robot interface plate provi a cover plate is 2.5mm, with a cover plate is 5.6mm. 3. Orientation marks are provided to assist in robot teaching.

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

45

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

8.4 QC-60 Tool Changer with K19 Module

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

46

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

8.5 QC-71 Tool Changer with G19 Module

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

47

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

8.6 QC-100 Tool Changer with T19 and F02 Modules

10 deep Customer Interface

+ 0-

(6) M10, 20 deep Customer Interface

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

48

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

+ 0

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

49

Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual

Document #9610-20-2255-02

9. 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.

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

50

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