95402 Rev 00 Smart Change SMR-V Modules.pub
Contents
1. cccccssssssssssseseesseesesseseseesseseeseeeeeeeeeeseeeeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 6 Technical Specifications cccccccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 6 IS Alli o Po BR EEE 7 5 1 Module Mounting and Removal eee 7 3 2 Electric amp Pneumatic COmnec On ewes 8 tido to OPE pr AN EEE E 10 CO Maa E ET PA E o PO 10 6 2 Tool Drop Prevention ceccccccccesseseeeseeeeeeeeeeeeeeeeeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 10 6 3 Method to Manually Over ride Solenoid Valve ss 11 A A ee eee eee ee ee eee 12 7 1 Troubleshooting Guide 12 A e POE PIO o A E e CE E soe e 13 NE Fis SVAN Ca a o o oo In 14 TL IS MES a a sisas 14 A IAS o A a 14 AAA e E no A 16 OA Spare Part Replacement Proced reS datada 17 ra MM A E ea E E 20 SMR V A IN MIR N aar db 20 PMR SA ZN SINS VA a a au 20 SVIR V AGN SMR VAA id 20 SMR V A1C2N SMR V A1C2G strain it ins 21 SMR V A2C2N SMR V A2C2G csi reinicie 21 X Applied Robotics Solutions in reach SMR V Modules Manual 95402 Rev 00 System Description The SmartChange SMR V modules provide a compact easily integrated method to control the air supply for coupling and uncoupling the SmartChange system A 4 way single solenoid valve and all electrical and pneu matic connections are included The SMR V modules also include2. A2 2 air fittings A4 4 air fittings Coolant Fitting Options C2 2 coolant fittings Thread Type N NPT 1 2 G G1 2 BSPP Technical Specifications Valve Specifications Pass through fitting specifications Module Robot Tool Working Pressure SMR V A1N SMR V A2N SMR V A4N SMR V A1G SMR V A2G _ 4 6 Bar 93 Number of Thread Maximum fittings Working Pressure 250 psi SMR V A4G 60 90 psi SMR V A1C2N SMR V A2C2N SMR V A1C2G SMR V A2C2G X AppliedRobotics SMR V Modules Manual 95402 Rev 00 Installation 4 1 Module Mounting and Removal The SMR V modules include a male dovetail feature that match up to the six dovetail slots around the perimeter of the SmartChange robot adaptor assemblies Each module is located to the robot adaptor housings using the dovetail feature and retained by a single captivated fastener for easy installation and replacement Typical installation for this module is in posi tion 2 The following steps should be taken for proper installation 4 1 1 Module Mounting l PA 3 4 Determine the desired location for the utility module to be positioned The robot and tool adaptor housings are marked with a number and an arrow between each dovetail slot to designate module positions Ensure dovetail features on both the utility module and the robot or tool adaptor housings are free from burrs or raised material that would cause i
3. mature failure of the o ring and molded seals If excessive build up of dirt debris or hard scale is present or a lack of proper lubrication is found during the perform ance of visual checks the fittings should be cleaned and lubricated per Section 9 3 of this manual X Applied Robotics Solutions in reach SMR V Modules Manual 95402 Rev 00 16 9 3 Lubrication The following procedures will define the proper method for lubricating the Female and Male fittings utilized in the SMR V module to maximize the cycle life of your SmartChange system 9 3 1 Female fitting 1 Clean the inner cavity of the female fitting of on any existing grease dirt or debris using a clean lint free rag 2 Apply a liberal coating of Staburags NBU 30 grease ARI part 0903 P11N to the inner cavity of the fitting along the entire diameter The coupling of the female fitting to the male fitting will force the grease to the lower o ring and also lubricate the outer surfaces of the male fitting Inner Cavity Seal O rings This method allows for no direct lubrication being required for the male fitting X Applied Robotics Solutions in reach SMR V Modules Manual 95402 Rev 00 17 9 4 Spare Part Replacement The following procedures will explain the correct method for removing and replacing the recommended spare parts listed in Section 8 of this manual 9 4 1 4 way Solenoid Valve 1 Ensure air supply to tool changer is removed prior
4. the option to include up to four fluid fittings that work in conjunction with the SMT F fluid pass though modules See SMR T F Modules User Guide for more details on these modules Y Applied Robotics Solutions in reach SMR V Modules Manual 95402 Rev 00 Safety 2 1 Safety Notices READ MANUAL Do not start operate or service machine until you read and understand User s Manual Failure to do so could result in serious injury HAND CRUSH NOTICE Indicates the possibility for a crush force between components during coupling of the Robot and Tool adaptors DANGER NOTICE Indicates an imminently hazardous situation which if not avoided will result in serious injury or death WARNING NOTICE Indicates a potentially hazardous situation which if not avoided could result in serious injury or death Sites CAUTION NOTICE Indicates a potentially hazardous situation which if not avoided will or could result in minor or moderate injury also used where the risk applies only to property damage IGNORING INFORMATION ABOUT POTENTIAL HAZARDS CAN LEAD TO SERIOUS HARM TO PERSONNEL AND OR DAMAGE TO THE EQUIPMENT AND MAY RESULT IN THE X Applied Robotics Solutions in reach SMR V Modules Manual 95402 Rev 00 Ordering Information A2 C2 N SMR Robot Side Module SMT Tool Side Module Module Type V Control Valve with air and or fluid Air Fitting Options A1 1 air fitting
5. to performing the remainder of this procedure 2 Using a 3mm hex wrench remove the M4 screw that holds the Manual Uncouple cover in place 3 Remove the Manual Uncouple cover and set aside for installation once solenoid valve is replaced 4 Disconnect the M8 cord set from the solenoid valve and move cord set away from the valve to prevent the possibility of damage when installing the new valve 5 Using a No 2 Phillips screwdriver loosen and remove the two screws that hold the solenoid to the module base Remove solenoid valve and discard Ensure gasket is also removed and discarded Ensure the gasket surface on the module base is clean and free of debris 8 Place new solenoid valve into position ensuring that the gasket is in place and aligned to the solenoid valve body 9 Insert and tighten the two Phillips head screws to a torque value of 1 5 Nm 13 in lbs 10 Route the M8 cord set between the solenoid valve and module base 11 Connect female M8 connector to solenoid valve 12 Place Manual Uncouple cover in place so that it covers the manual over ride push button on the solenoid valve 13 Using a 3mm hex wrench insert the M4 screw through the Manual Uncouple cover and tighten to a torque value of 2 7 Nm 24 1n 1b 14 Restore air supply to the tool changer 15 Perform Initial Test procedure in Section 5 1 of this manual to verify proper operation of the new solenoid valve ZO T A REE M4 screw 4 way solenoid M8 Cord O Ph
6. LESS THE ATTACHED TOOL IS FULLY SUP PORTED PREFERABLY IN ITS TOOL STAND If the electrical signals to the SmartChange SMR V valve module are lost in a manner that prevents the system from un coupling under normal means we have included a feature in our design that allows the solenoid valve to be manually over ridden The following steps must be followed to ensure the SmartChange system is manually uncoupled in a safe manner 1 Ensure the attached tooling is safely supported preferably in its tool stand so that no damage or personal injury occurs when the tool is released Ensure all unnecessary personnel are clear of the tooling before going further in this procedure Using a 3mm hex wrench remove the M4 screw that holds the Manual Uncouple cover in place Remove the Manual Uncouple cover to expose the manual override button on the solenoid valve Press the manual over ride button to uncouple the tool changer and release the tool Once the tool is released and safely resting in its tool stand release the manual over ride button Re install the Manual Uncouple cover and tighten the M4 screw to a torque value of 2 7 Nm 24 in 1b AA AE A ad Applied Robotics Solutions in reach SMR V Modules Manual 95402 Rev 00 12 Troubleshooting 6 1 Troubleshooting Guide Tool Changer not within required distance for coupling 2mm be Adjust robot program to move Tool Changer will tween Robot and Tool Adaptor within the re
7. X Applied Robotics Solutions in reach SMR V Modules Control Valve with Air and or Fluid Pass through fittings SmartChange Tool Change System Manual 95402 Rev 00 November 16 2009 648 Saratoga Road Glenville NY 12302 USA Phone 518 384 1000 Fax 518 384 1200 www appliedrobotics com SMR V Modules Manual 95402 Rev 00 vision Revision Date Author Description 00 11 16 2009 GV Initial release All rights reserved Copyright O 1986 2009 Applied Robotics Inc The use of this document is reserved exclusively for the use of Applied Robotics Incorporated customers and personnel The information and drawings contained herein are the sole property of Applied Robotics Incorporated and shall not be divulged to any third party without the prior written consent of Applied Robotics Inc The information in this document 1s subject to change without notice Applied Robotics makes no warranty of any kind with regard to this user s guide including but not limited to implied warranties or fitness for a particular purpose Applied Robotics Inc shall not be liable for any errors contained herein or for incidental or consequential damages in connection with the performance or use of this material X Applied Robotics Solutions in reach 2 l SMR V Modules Manual 95402 Rev 00 ntents SA a 4 A a ETENE E ENE ETE S E T E A dames nosis N TE E E 5 A e eee A E A EAE O E N A E E cr eee eee 5 Ordering Information
8. arked with a U Couple fittings Bulkhead fitting Uncouple fittings Solenoid supply fitting 4 way Solenoid Valve SMR V Module PNEUMATIC PRESSURE SHOULD NEVER BE SUPPLIED TO THE SMARTCHANGE SYSTEM UNLESS THE POSITION OF THE VALVE SUPPLYING THE AIR IS KNOWN AND HAS BEEN CONFIRMED DANGER FAILURE TO DO SO CAN RESULT IN SERIOUS INJURY OR DEATH FROM A DROPPED TOOL THE ROBOT SHOULD NEVER BE RUN WITHOUT AIR PRESSURE SUPPLIED TO THE TOOL CHANGER PRESSURE TO THE TOOL CHANGER MUST BE AT LEAST 4 BAR 60 PSIG FOR PROPER OPERATION X AppliedRobotics Solutions in reach SMR V Modules Manual 95402 Rev 00 10 Guide to Operation 5 1 Initial Test To perform an initial functionality test of the solenoid valve the electrical and pneumatic connections should be verified against the installation instructions in Section 4 of this manual Once this verification is complete the following steps should be followed for the test l Verify the Robot Adaptor Assembly is clear of any obstruction and not coupled to the Tool Adaptor Assembly 2 Turn on supply air to the control valve and verify cams move to the extended position This will verify the single sole noid 4 way valve is plumbed correctly 3 Supply control power to the solenoid valve and supply the signal from the controller PLC to move the valve to the Uncouple Solenoid energized position The cams should retract to the Uncoupled position and the input from the Unc
9. e ensuring there is enough length to allow for the cable to bend around and the female end connected Connect the female end of the M8 cord set to the solenoid valve Place Manual Uncouple cover in place so that it covers the manual over ride push button on the solenoid valve Using a 3mm hex wrench insert the M4 screw through the Manual Uncouple cover and tighten to a torque value of 2 7 Nm 24 1n 1b Restore air supply to the tool changer Perform Initial Test procedure in Section 5 1 of this manual to verify proper operation of the solenoid valve with the new M8 cord set M4 screw Manual Uncouple cover 4 way solenoid valve Module base M8 Cord set M8 Cord set Female end Male end X AppliedRobotics Solutions in reach SMR V Modules Manual 95402 Rev 00 19 9 4 4 Female fluid fittings l 2 3 4 5 Ensure air and fluid lines for the fittings are shut off and drained 1f necessary Using a 27mm open end wrench loosen and remove the female fluid fitting The adaptor bulkhead and at tached tube hose will be free from the module Ensure the M24 x 1 5 threads on the fitting and in the bulkhead adaptor are clean and free of dirt and debris Also ensure seal o ring is also clean and free from dirt debris or hard scale Insert the new female fluid fitting into the adaptor bulkhead through the module base and tighten the fitting using a 27mm open end wrench to a torque value of 5 Nm 45 in 1b Ensure fi
10. h is wired via an M12 connector to our tool side electrical mod ule and the circuit is passed via spring probes to the robot side electrical module to complete the circuit The combination of these two switches provides the following OR logic function The actuation valve will not receive the signal to uncouple unless a tool side is not present OR the tool is resting in the tool stand In other words the uncouple signal will not reach the actuation valve unless one of the following two conditions are met 1 A tool side of the tool changer is not connected The normally closed Tool Present switch in the robot side signal module is in its normally closed position allowing the uncouple signal to reach the actuation valve This switch is necessary to allow for the tool changer to maintain itself in the Uncoupled state when moving to pick up the next tool 2 The tool side of the tool changer is connected and the tool is safely resting in its tool stand With a tool adap tor coupled up to the robot adaptor the normally closed Tool Present switch will open Now the uncouple signal will not reach the actuation valve unless the Tool in Stand switch on the EOAT is actuated by its magnetically coded actuator on the tool stand X Applied Robotics Solutions in reach SMR V Modules Manual 95402 Rev 00 11 5 3 Method to Manually Over ride Solenoid Valve THE SMR V SOLENOID VALVE SHOULD NEVER BE MANUALLY DANGER OVER RIDDEN UN
11. illips head screw 2 ot Module base X Applied Robotics Solutions in reach SMR V Modules Manual 95402 Rev 00 18 9 4 2 90 degree Tube fittings l AA NO Ensure air supply to tool changer is removed prior to performing the remainder of this procedure Remove 6mm air line from fitting to be replaced Using a 12mm open end wrench loosen remove and discard the tube fitting being replaced Ensure G1 8 BSPP threads are clean and free of dirt and debris Insert and tighten new fitting using a 12mm open end wrench until the seal is compressed to the robot adap tor housing Re install the corresponding 6mm tube into this fitting Restore the air supply to the tool changer and ensure the replaced fitting does not leak 6mm tube AT fittings 4 9 4 3 M8 Cord set l A A 11 BP 13 Ensure air supply to tool changer is removed and tool side of tool changer is disconnected Using a 3mm hex wrench remove the M4 screw that holds the Manual Uncouple cover in place Remove the Manual Uncouple cover and set aside for installation once the M8 cord set is replaced Disconnect the female end of the M8 cord set from the solenoid valve Disconnect the male end of the M8 cord set from the SMR E electrical module Discard the existing M8 cord set Connect the male end of the new M8 cord set to the SMR E electrical module Route the M8 cord set between the solenoid valve and the module bas
12. n the included solenoid valve and the SMR E electrical module using a double ended M8 cord set If an SMR E module is not required for the application an M8 cord set can be connected directly to the solenoid to provide the control signal The pneumatic supply to the solenoid valve is typically tapped off of the existing air line being passed through the tool changer This is accomplished using two 6mm tube fittings The first is connected to the bulkhead of the first pass through air fitting The second is connected to the module base and is ported directly to the supply of the solenoid valve The output lines from the solenoid valve are connected directly to the couple and uncouple ports of the SmartChange robot adaptor via 6mm tube and fittings The following conditions must be adhered to when supplying air to the SmartChange system To ensure proper operation air must be supplied to both the Couple and Uncouple ports via a pneumatic control valve 1 A single solenoid spring return 4 way pneumatic valve should be utilized to control the air supply to the Couple and Uncouple ports When the valve is in the de energized state and air is supplied to the valve the air being supplied from the valve in this condition should be plumbed to the couple port This condition will ensure air is maintained to the couple port on a loss of power to the solenoid valve 2 Supply air must be maintained between 4 6 Bar 60 90 psig The following procedures will explai
13. n the specific method for connecting both the electrical signals and air supply to the SMR V module and in turn to the SmartChange robot adaptor 4 2 1 Electrical Connection for Solenoid Valve 1 Attach female end of the 0 5 meter M8 cord set included with the SMR V module to the male 3 pin connec tor on the solenoid valve Using a 3mm hex wrench loosen and remove the M4 screw holding the Manual Uncouple cover Remove Manual Uncouple cover Route M8 cord set between the solenoid valve and the module base Connect male M8 connector to the female M8 receptacle on SMR E module Place Manual Uncouple cover back into position Using a 3mm hex wrench insert and tighten The M4 screw removed in step 2 to a torque value of 2 7 Nm 24 in Ib w a Get ae ex Y O Manual Uncouple Cover a MES 5 CP D gt 4 way solenoid M8 connector on valve SMR E module M8 Cord set IS M8 Cord set female end male end FEE Female MB SS ES i SMR V Module SMR E Module X AppliedRobotics Solutions in reach SMR V Modules Manual 95402 Rev 00 4 2 2 Pneumatic Connection for Solenoid Valve 1 Ensure 6mm tube between the bulkhead air fitting and solenoid supply fitting is installed This tube is typi cally installed at the factory 2 Connect the 6mm tubing between the corresponding couple and uncouple ports on both the SMR V module and robot adaptor The Couple ports are marked with a C and the uncouple ports are m
14. nterference Slide the male dovetail feature of the utility module into the desired female dovetail of the robot or tool adaptor housing until 1t bottoms out on the threaded male feature of the robot or tool adaptor housing Using a 4mm hex wrench insert and tighten the M5 captivated socket head cap screw to a torque value of 5 5 Nm 481n 1bs 4 1 2 Module Removal Using a 4mm hex wrench loosen the M5 captivated socket head cap screw in the male dovetail feature of the utility module until it is free from the threads in the robot or tool adaptor housing Do not continue loosening this screw out of the utility module so that it will remain captivated Slide the male dovetail feature of the utility module out of the female dovetail slot of the robot or tool adap tor housing l X AppliedRobotics Solutions in reach SMR V Modules Manual 95402 Rev 00 4 2 Electrical amp Pneumatic Connections The SMR V module includes all of the fittings tubing and electrical cable required to operate the included single solenoid spring return valve in order to control the operation of the double acting cylinder of the SmartChange robot adaptor assem bly The single solenoid valve included with these modules has been specified to provide the appropriate amount of air and includes other features required for simple installation and safe operation as an integral part of our Tool Stand Monitoring circuit The electrical connection is made betwee
15. olyurethane tubing aty in feet 0 5M M8 cord set Additional Spares for SMR V module with A air fitting option Description Part Number Quantity Female Fitting LPF 08F SS EXTENDED 0509 C38A 1 41 Additional Spares for SMR V module with C coolant fitting option Description Part Number Quantity Male Fitting LPF O8M SS EXTENDED 0509 C39A Female Fitting LPF O8F SS EXTENDED 0509 C38A Quantity required based on specific SMR V module Quantity required will match the number following A in the module part number For example SMR V A4N requires 4 female fittings and SMR V A2C2G requires 2 female fittings for the air pass through X Applied Robotics Solutions in reach SMR V Modules Manual 95402 Rev 00 14 Maintenance FAILURE TO FOLLOW THE MAINTENANCE SCHEDULE DESCRIBED BELOW COULD ALTER OR VOID THE WAR RANTY PROVIDED BY APPLIED ROBOTICS 9 1 Maintenance Schedule Maintenance Frequency of Maintenance Items SMR V Module Female Fittings Male Fittings Every 2 weeks gt 1000 cycles per day MISURE CACCE Every 4 weeks lt 1000 cycles per day Lubrication N A 250 000 cycles or as necessary based on visual inspections Fitting Replacement 1 000 000 cycles 9 2 Visual Checks 9 2 1 SMR V Module 1 Inspect 4 way solenoid valve and M8 cord set signal cable for damage 2 Inspect all 6mm tube fittings for damage or air leaks 3 Inspect air coolant tube or hose fittings for damage or leakage a
16. oupled sensor should be received by the robot controller PLC 4 Change the state of the solenoid valve by turning off the Uncouple signal solenoid de energized The cams should extend back to the Coupled position and the Uncoupled sensor signal should turn off and the Coupled Signal should turn on at the robot controller PLC 5 Repeat steps 3 and 4 several times The cam action should be smooth and quick DURING TESTING KEEP YOUR FINGERS CLEAR OF THE ME CHANICAL COUPLING MECHANISM 5 2 Tool Drop Prevention The prevention of accidental uncoupling is of utmost importance when setting up your SmartChange system for operation As a minimum level of prevention Applied Robotics recommends the use of one of our SMR T E Electrical modules that includes our Tool Stand Monitoring Circuit The Tool Stand Monitoring Circuit incorporates two switches that are wired in line parallel to each other with the uncouple signal controlling the actuation valve of the tool changer 1 The first switch Tool Present is a normally closed proximity switch located inside the Robot side electri cal module with its target embedded in the tool side electrical module This switch is necessary to allow for the tool changer to maintain itself in the Uncoupled state when moving to pick up the next tool 2 The second switch Tool in Stand a magnetically coded switch is mounted on the end of arm tool with its actuator mounted to the tool stand This switc
17. quired distance not couple Assemblies Air Supply to tool changer has Verify all air connections are in been lost place and air supplied to robot cell Air Supply to tool changer has Verify all air connections are in been lost place and air supplied to robot cell Verify all connections are in place and that valve is not damaged and operating correctly Solenoid for control valve has Replace 4 way solenoid valve per failed Section 9 4 1 Dirt Debris or hard scale fouling Clean fitting and lubricate per Sec sealing surfaces tion 9 3 of this manual Fitting Leak i Replace fitting per Section 9 4 of Damage to sealing surfaces this manual For troubleshooting issues not covered in this guide please contact the Applied Robotics Technical Support Department at 518 384 1000 or techsupport appliedrobotics com Tool Changer will Electrical Connection to actuation not uncouple valve has been lost X Applied Robotics Solutions in reach SMR V Modules Manual 95402 Rev 00 Spare Parts The spare parts listed below are recommended to be maintained in stock for the life of the unit These quantities are based on a single unit If higher quantities are purchased please contact our Technical Support Department at 518 384 1000 or techsupport appliedrobotics com to determine the quantity of spares we recommend for the size of your installation Recommended Spares for SMR V 4 way Solenoid Valve 90 degree 6mm tube fittings 6mm p
18. the point where they connect to the adaptor bulkheads 4 way M Solenoid 8 Cord set Valve Adaptor bulkheads 6mm Tube 1 4 fittings 4 If damage is found that prevents these items from operating correctly they should be replaced following the procedures in Section 9 4 of this manual Hose and tube fittings are typically supplied by the customer Applied Robotics Solutions in reach SMR V Modules Manual 95402 Rev 00 15 9 2 2 Female Fittings 1 Inspect fitting surfaces adjacent to o ring seals for excessive wear or raised material that could cause dam age to sealing surfaces on the corresponding male fitting 2 Inspect seal o rings and molded seal for damage or excessive build up of dirt debris or hard scale 3 Inspect o rings for proper lubrication Seal O rings 2 Fitting surfaces Molded seal 9 2 3 Male Fittings 1 Inspect outer sealing surfaces for excessive wear or raised material that could cause damage to seal o rings or molded seal in the corresponding female fitting 2 Inspect outer sealing surfaces for excessive build up of dirt debris or hard scale 3 Ensure outer sealing surface is properly lubricated Outer Sealing Surfaces If excessive wear or damage is found in any of the surfaces of the male or female fitting they should be replaced following the procedures in Section 9 4 of this manual Leaving the fittings in place with damaged interface surfaces will lead to pre
19. tting in properly lubricated per Section 9 3 of this manual before use Female fluid Module base fittings 1 4 Adaptor bulkhead 1 4 9 4 5 Male fluid fittings l 2 3 4 J Ensure air and fluid lines for the fittings are shut off and drained if necessary Using a 27mm open end wrench loosen and remove the male fluid fitting The adaptor bulkhead and at tached tube hose will be free from the module Ensure the M24 x 1 5 threads on the fitting and in the bulkhead adaptor are clean and free of dirt and debris Also ensure seal o ring is also clean and free from dirt debris or hard scale Insert the new female fluid fitting into the adaptor bulkhead through the module base and tighten the fitting using a 27mm open end wrench to a torque value of 5 Nm 45 in lb Ensure fitting in properly lubricated per Section 9 3 of this manual before use Male fluid fitting Adaptor bulkhead X AppliedRobotics Solutions in reach SMR V Modules Manual 95402 Rev 00 20 Module Variations SMR V AIN SMR V A1G SMR V A2N SMR V A2G SMR V A4N SMR V A4G X AppliedRobotics SMR V Modules Manual 95402 Rev 00 SMR V A1C2N SMR V A1C2G X AppliedRobotics 21
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