B. Base Tool Changer QC-1210 Series—Robotic Tool Changer
Contents
1. Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 e www ati ia com e Email info ati ia com B 21 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 Symptom Cause Resolution R1 input RS1 and RS2 Master not in position Reprogram pick up point so sensors not on Master and Tool are parallel and within 1 mm of each other Sensor cable damage Check the RS1 and RS2 sensor faces and cables for damage Replace if necessary NOTE These sensors are wired in series in the cable harness Both sensors must be on to get the R1 RTL1 input on Check splitter cable from R1 connector at the control module to RS1 and RS2 sensors Replace as needed R2 input RS3 sensor not on Master not in position at Pick Reprogram pick up point so up Master and Tool are parallel and within 1 mm of each other Sensor cable damage Check the RS3 sensor face for damage Replace if necessary Check cable between RS3 sensor and the R2 connector at control module for damage and replace as needed Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 e www ati ia com e Email info ati ia com B 22 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 6 Recommended Spare Parts Assembly Part Numbe2. 3 Places Figure 4 5 QC 1210 Lock and Unlock Sensor Assemblies 4 2 4 RTL Sensor Replacement 8mm Threaded Barrel Style oe eR Saha Remove the sensor cable connector from the sensor Loosen the jam nut securing the sensor to the Master body Unscrew remove the sensor from the Master and discard Screw the new sensor cable assembly into the Master body until the face of the sensor is flush with the surrounding face of the Master body Turn the sensor back turn Use a crowfoot and a torque wrench to tighten the jam nut to 20 in lbs of torque Replace the sensor cable if needed Re attach the cable connector to the control signal module Confirm operation of the new sensor by bringing a metallic object into close proximity to the face of the sensor and watching for the LED in the body of the sensor to come on ATTENTION R1 consists of sensors RS1 and RS2 wired in series Therefore a metallic object has to be used at both Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 e www ati ia com e Email info ati ia com B 18 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 locations in order to view the LED indicator of either sensor See QC 1210 RTL Cabling in Section 3 4 Figure 4 6 Barrel style RTL sensor 4 2 5 Alignment Pin Replacement 1 1 8 Two Piece Pin Sub Assembly 1 Unscrew the alignment
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4. refer to the application drawing When the customer chooses to design and build an End effector Interface Plate the following should be considered e The interface plate should be designed to include bolt holes for mounting and dowel pins that mate with Tool body for accurate positioning e The thickness of the interface plate must be great enough to provide the necessary thread engagement for the mounting bolts e The plate design should take into account clearances required for Tool Changer module attachments and accessories e The End effector Interface Plate should be designed with a set of holes in the center of each of the three locking mechanisms to allow for manually returning the locking mechanisms to the unlocked position under adverse conditions i e unintended loss of power and or air pressure The center access holes should be kept small recommended hole diameter 25 4mm 1 to prevent debris from contaminating the locking mechanism while operating in dirty environments 2 3 Tool Stand Design 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 Z Compliance is required for the Tool Stand in order to ensure that the Master remains fully contacted with the Tool prior to issuing the Unlock command CAUTION During coupling and lock up the Tool Stand must allow
5. Master Plate 1 The locking mechanism must be in the unlock state before cleaning Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 e www ati ia com e Email info ati ia com B 15 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 2 Usea clean rag to thoroughly remove the existing lubricant and debris from the balls the male coupling the cam and the alignment pins Figure 4 1 Cleaning balls and outer surfaces of Figure 4 2 Cleaning balls cam and inner male couplina surfaces of male couplina 3 Check each ball to make sure it moves freely in the male coupling Additional cleaning may be necessary to free up any balls that are sticking in place re Figure 4 3 Checking balls to move freely Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 ewww ati ia com e Email info ati ia com B 16 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 4 Apply a liberal coating of lubricant to the balls the male coupling inside and out and the alignment pins Figure 4 4 Lubrication areas 4 2 2 Cleaning the Locking Mechanism and Alignment Pin Bushings Tool Plate 1 Use a clean rag to thoroughly remove any lubricant and debris from the bearing race and the bushings 2 Nore lubrication is necessary on the Tool plate component
6. Prior to Coupling Notes Maximum values shown Decreasing actual values will minimize wear during coupling uncoupling Actual allowable values may be higher in some cases but higher offsets will increase wear during coupling 2 3 1 Tool Locating Features The Tool must be positively and repeatably located in the Tool Stand A variety of methods may be used to accomplish this Whatever method is chosen it is important that the required compliance or float be built into the locating system A common method is to use tapered alignment pins in holes As the Tool plate is lifted during locking the taper lets the Tool float into its locked position even with small deviations in robot position Other Tool locating feature methods include balls and detents dowel pins in notched V grooves etc Please consult ATI for recommendations or assistance with locating feature design for your particular tooling Straight cylindrical dowel pins should not be used as they provide too much surface engagement During coupling and uncoupling the Tool can bind on these pins due to misalignment of the Master and Tool plates Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 e www ati ia com e Email info ati ia com B 8 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 Robot programming and location repeatability are vital in Tool pick up and drop off 2 3 2
7. Tool Stand Sensors It is highly suggested 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 fail safe 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 located 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 2 4 Pneumatic and Electrical Connections The air supply used for coupling and uncoupling the Tool Changer should be clean dry and non lubricated A supply pressure in the range of 70 to 100 psi is acceptable for operation of the locking mechanism with a setting of 80 psi suggested The air should be filtered 50 micron or better CAUTION Do not use the Tool Changer in the fail safe condition Do not transport the Tool Changer in the fail safe condition Possible damage to the locking mechanism could occur 3 Operation The Master locking mechanisms are pneumatically driven to couple and uncouple with the bearing races on the Tool plate The Master plate utilizes air ports from an air or valve adapter module to provide Lock and Unlock pressure to the locking mechanism supply of co
8. view SC gt Control Module U2 f 7 lt QC 1210 Master N TS T S de SS a i Junction de i TE Module CR Tt E s R1 R2 U and L S L2 RS3 U3 L3 U and L Figure 3 2 Connector view Figure 3 3 and Table 3 1 show the cables pertaining to the Lock and Unlock sensors From the factory the cables will be labeled to match where they are connected Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 ewww ati ia com e Email info ati ia com B 12 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 PELL EEE LLL L1 Ls SU Junction Module lt 4 gt ir Valve r Valve CRLLLLERE ELET 4 DRRRRRRRRRRR Eee Control Signal La Module LLC LL RE LECCE LETI Control Signal R2 Module Lock amp Unlock Sensor Cables RTL Sensor Cables Figure 3 3 Sensor Cable Routing Sensor Cable Routing 9121 XXX M Lock Unlock Sensor Junction Module Control Module ID Connector Connector RTL Sensor ID L1 lt 3 gt lt 4 gt L1 Cable from Fig 3 3 ATI Part Number PNP with LED Cables SL Models NPN with LED Cables SE Models lt 1 gt 9120 C 3PF 3PF 3PM90 9120 C 3PF 3PF 3PM90 NPN lt 2 gt 9120 C 3PF 3PM90 0030 9120 C 3PF 3PM90 0030 NPN lt 3 gt 9005 20 1613 9005 2
9. 0 1780 lt 4 gt 9120 C 3M5F 3PM90 0020 9120 C 3M5F 3PM90 0020 lt 5 gt 9120 C 3M5F 3PM90 0016 9120 C 3M5F 3PM90 0016 lt 6 gt 9120 C 3PF90 3PM90 0041 9120 C 3PF90 3PM90 0041 NPN Table 3 1 Cable Number Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 e www ati ia com e Email info ati ia com B 13 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 The QC 1210 Master has 3 RTL sensors They are designated as RS1 RS2 and RS3 Sensors RS1 and RS2 are wired in series by means of a splitter cable and in this way provide the control module with a single R1 signal Only when RS1 and RS2 are both triggered will a Tool presence signal occur at R1 The third RTL sensor RS3 is connected directly to the control module at R2 to give a second Tool presence signal Figure 3 3 and Table 3 1 show the cables pertaining to the RTL sensors The labels on the cables indicate which sensors the cables are connected to 4 Maintenance ATTENTION The cleanliness of the work environment strongly influences the trouble free operation of the changer The dirtier the environment the greater the need is 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 S
10. 90 NPN NPN RTL Cable RS1 amp RS2 to R1 9120 C 3PF 3PM90 0030 NPN NPN RTL Cable RS3 to R2 NPN L U Cable Picofast Female Right Angle to Picofast 9120 C 3PF90 3PM90 0041 NPN Male Right Angle 41 m Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 ewww ati ia com e Email info ati ia com B 23 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 7 Specifications Master and Tool Plates Ready To Lock Suggested Payload Limit 2980 Ibs The mass attached to the Tool Changer 1350 kg Operating Temperature Range 20 150 F 30 66 C Operating Pressure Range 70 100 psi Locking mechanism supply pressure operating 4 8 6 9 bar range Supply to be clean dry and filtered to 50 micron or better Coupling Force 80psi 21 000 Ibs Axial holding force 9 525 kg Static Moment Capacity X Y 48 000 in lb Maximum recommended working load for 5 423 Nm optimum performance of the Tool Changer Z 48 000 in lb Torsion 5 423 Nm Positional Repeatability 0 0006 in Repeatability tested at rated load at one million 0 015 mm cycles Weight coupled no access 62 Ibs Master 18 kg Tool 10 kg eK Does not include RIP or TIP assemblies Max Recommended distance 0 04in No Touch locking technology allows the between Master and Tool Plate 1 mm Master and Tool Plates to lock with separation when c
11. Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 Table of Contents B Base Belt E EEN 2 QC 1210 Series Robotic Tool Changer 1rrrrreee iii 2 T eet Ae Ee E aria 2 iL Master Plate Assen Vicaria 2 LS Tool Plate Assembly Leelee 3 1 3 Optional Medules s EE EE 4 2 TUE e EE 5 2 0 MASTS HMO AGE arri dele 5 2 2 Toolnieriace cieli 6 23 Joolsiand Designers loin iaia 7 2 3 1 Tool Locating NEE 8 2 3 2 Tool Stand Sensors EE 9 2 4 Pneumatic and Electrical Connections i 9 3 ole EE 9 3 7 Coupling Seguente EE 10 3 2 Fail Safe Operation eet reegen ele eege ok eerie 10 CN ae le EE 11 3 4 Integrated SEnsofrs Lul lella 12 4 Maintenance elle 14 4 1 Preventive Maintenance ennn 14 4 2 Cleaning Lubrication Adjustment and Replacement ssssessneeeeeeeeserrreree 15 4 2 1 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins Master E EE 15 4 2 2 Cleaning the Locking Mechanism and Alignment Pin Bushings Fool Plate ieri 17 4 2 3 Lock and Unlock Sensor Assembly Replacement Figure 4 5 17 4 2 4 RTL Sensor Replacement 8mm Threaded Barrel Style 18 4 2 5 Alignment Pin Replacement 1 1 8 Two Piece Pin Sub Assembly 19 Bee VT E e e WE 20 6 Recommended Spare Parts 23 TA A E 24 8 GRA WINGS E 25 Pinnacle Park e 1031 Goodworth Drive e A
12. S 90KSI M10 1 5 75 Nm Minimum thread engagement of 15mm 0 59 Class 12 9 55 ft lbs 1 5X fastener Tool Plate aluminum to End Effector Interface Plate M10 1 5 52 Nm 6061 NG Aluminum Class 12 9 38 ft lbs Minimum thread engagement of 15mm 0 59 1 5X fastener Tool Plate aluminum to End Effector Interface Plate M10 1 5 52 Nm AE Class 12 9 38 ft lbs Minimum thread engagement of 15mm 0 59 1 5X fastener 2 1 Master Interface The Master assembly is attached to the robot interface plate RIP and both are bolted to the 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 to the robot The RIP is utilized to adapt the Master plate to a specific robot flange that is not compatible with the Master plate mounting features Custom RIPs are available upon request Refer to drawings in Section 8 of this manual for technical information on mounting features Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 e www ati ia com e Email info ati ia com B 5 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 Robot Wrist Flange Robot Interface Plate With Fasteners and A Dowel Pins Master Plate with Fasteners to Robot Interface Plate Tool Plate with Fasteners to Tool Interface Plate
13. The Lock signal should read on true and the Unlock signals should read off false 3 2 Fail Safe Operation In the event of air supply loss to the locking mechanism the Tool Changer will not uncouple A slight separation between the Master and Tool plates occurs just after air loss but at this point the locking balls become trapped and cannot move without air pressure being applied to the Unlock port This feature provides the Tool Changer with a fail safe mechanism Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 e www ati ia com e Email info ati ia com B 10 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 ATP 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 CAUTION Do not use the Tool Changer in the fail safe condition Do not transport the Tool Changer in the fail safe condition Possible damage to the locking mechanism could occur 3 3 Uncoupling Verify that the Tool is FULLY secured and seated in the Tool Stand Z compliance is required for the Tool Stand in order to ensure reliable Unlocking sequence Once you have verified that the Tool is FULLY secured in the Tool Stan
14. The ball bearings and or cam Clean and lubricate as needed to the locking mechanisms are are not moving freely in the restore smooth operation see jammed male coupling Section 4 Maintenance The Master and Tool are not Check that the Tool is properly within the specified No Touch seated in the Tool Stand Re zone when attempting to Lock teach the robot to bring the Master and Tool closer together before attempting to Lock Master and Tool are not Check that the Tool is properly parallel all three RTL sensors seated in the Tool Stand Re are not on when trying to lock teach the robot to bring the Master and Tool closer together and parallel prior to attempting to Lock Verify RTLs RS1 RS2 and RS3 are all on Tool Drop off Distance is too Check that the Tool is properly large positioned in the Tool Stand and the Tool is fully seated Check that the UNLATCH command is not being issued with the Tool sitting above the Tool Stand and the robot is not trying to drop the Tool into the nest Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 e www ati ia com e Email info ati ia com B 20 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 Symptom Cause Resolution Unit is fully locked but Locked Individual Lock sensor cable Check LED light on each of the input to control module is not damag
15. Tool Interface Plate Fasteners and Dowel Pins Not Shown Figure 2 1 Typical Installation QC 1210 Shown If the customer chooses to design and build a robot interface plate the following should be considered e 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 e The thickness of the interface plate must be great enough to provide the necessary thread engagement for the mounting bolts e The interface plate must be properly designed to provide rigid mounting to the Master plate boss area e The plate design should take into account clearances required for Tool Changer module attachments and accessories 2 2 Tool Interface The Tool plate is attached to customer supplied tooling The Tool plate is designed with mounting features such as a bolt and dowel holes These features are used to accurately position and secure the end effector Most often an End effector Interface Plate EIP is utilized to adapt the Tool plate to an end effector that is not compatible with the Tool plate Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 ewww ati ia com e Email info ati ia com B 6 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 mounting features Custom End effector Interface Plates can be supplied by ATI to meet customer requirements see Figure 2 1
16. alls Alignment Pins Holes Bearing Race Inspect for lubrication and wear A NLGI 2 lithium based 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 4 2 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 Wear on the balls bearing race could be an indication of excessive loading Mounting Hardware Interface Connections Inspect for proper torque and interference or wear abrasions cuts of hoses and electrical cables Tighten and correct as required O rings Rubber Bushings Inspect for wear abrasion and cuts Exposed o rings and rubber bushings may be subject to damage during normal operation Replace damaged o rings and rubber bushings as needed Electrical Contacts Inspect for wear and abrasion Exposed contacts may be subject to damage during normal operation Clear debris from the area of the contacts using compressed air Do not directly clean contacts as abrasion may occur and the performance of the contact may be compromised 4 2 Cleaning Lubrication Adjustment and Replacement 4 2 1 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins
17. ature Only 2 M6 SHCS fasteners need to be unscrewed in order to remove the module from the Master Tool plate A secondary mounting support called a cleat is factory installed to the Master and Tool plate on each flat that is occupied with a module The cleats provide additional module support for those situations when hoses or cables may inadvertently be snagged or pulled and may otherwise result in damage to the module If modules are added to a tool changer in the field then the Master and Tool plates may have to be uninstalled to facilitate the cleat installation Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 e www ati ia com e Email info ati ia com B 4 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 2 Installation All fasteners used to mount the Tool Changer to the robot and to user Tools should be tightened to a torque value as indicated below Furthermore removable blue Loctite 242 must be used on these fasteners A CAUTION Care should be taken to select fasteners for mounting that are not too long such that a gap is formed at the interface Fastener Size and Ma umum Mounting conditions Recommended Property Class T orque Master Plate to RIP 6061 T6 aluminum M10 1 5 75 Nm Minimum thread engagement of 15mm 0 59 Class 12 9 55 ft lbs 1 5X fastener Master Plate to RIP Steel US
18. d turn the Latch output off CAUTION This Tool Changer may be equipped with a Tool Stand Interlock TSI feature that physically breaks the Unlatch solenoid circuit Use of the TSI will prevent any unwanted Unlatch software commands from being recognized until the circuit is made See user manual of the respective control module for details and troubleshooting Issue the Unlatch output Air is supplied to the locking mechanism to uncouple the Tool Changer A sufficient delay must be programmed between the Unlatch output being activated and reading the state of the Lock Unlock signals so that the coupling process is completed before checking the Locked state Read the Lock and Unlock signals The Unlock signal should read on true and the Lock signal should read off false Any other condition indicates a problem and the robot program should be halted Once the Lock and Unlock signals are verified to be in the proper state the Master plate may be moved away from the Tool plate in the axial direction Check to verify that the RTLs are all off false after the Master moves away from the Tool The robot and Master plate can now proceed to another Tool for coupling and subsequent operations Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 e www ati ia com e Email info ati ia com B 11 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series bas
19. e three Lock sensors ON If OFF check for cable damage and a secure connection to the junction module Replace sensor and or cable as needed Main Lock sensor cable If all individual Lock sensor LEDs damage are on check the main Lock cable connecting the junction module and control module NOTE Individual sensors are wired in series in the junction module All sensors must be on to get the main Lock input on Check for cable damage and a secure connection to control module Replace as needed Junction Module failure If individual Lock sensors cables and main Lock cable are found to be good replace junction module Unit is fully unlocked but Individual Unlock sensor cable Check LED light on each of the Unlock input to control module damage three Unlock sensors is not ON If OFF check for cable damage and a secure connection to the junction module Replace sensor and or cable as needed Main Unlock sensor cable If all individual Unlock sensor damage LEDs are on check the main Unlock cable connecting the junction module and control module NOTE Individual sensors are in series in the junction module All sensors must be on to get the main Unlock input on Check for cable damage and a secure connection to control module Replace as needed Junction Module failure If individual Unlock sensor cables and main Unlock cable are found to be good replace control module
20. e Tool Changer CALE Wer2 or3 41 4 TILE 5 INDUSTRIAL PROPEI orawn ey D Swanson 5 21 09 w M Gala 5 22 09 e PROJECT SCALE DRAWING NOTES UNLESS OTIIERWISE QC 1210 Master Assembl Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 e www ati ia com e Email info ati ia com B 26 NOILSIFC d Dee PU OIZ1 07 0 96 g EL Jee com EE a 371 E oun 2 Ae GO ZZ S BED W 149 03393H9 f 3 60 17 S Uosuems q AI Nuvuo 1 6uey9 00 aseg 01Z1 00 awa Sg ETA Auedwo9 pasa1s1Ba 006 OS NOILYWOLNY NI dav SNOISNIWIO NY WOD EI ME MMM 66Z8ZLL616 4 Xei TYIHASNONI ONIMVAG NYOS LON OG morel neBojus eu SLAOTLL 6164 101 aads VSN 6ESLZ ON odp BAG Y11OMPOOD LEOL ISIMYAI LO SSTINA SILON Iqw ssy OO 0LZL 90 Document 9620 20 b 1210 series base tool changer 08 Quick Change Installation and Operation Manual B 27 Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 e www ati ia com e Email info ati ia com
21. e edge The locking mechanisms allow the Master to pull up the Tool with certain gaps between the two sides It is recommended that the mating faces of the Master and Tool not be touching but be within 0 040 1 mm of each other when coupling to minimize stress and wear on the locking mechanism RTL Ready To Lock sensing is built into the Tool Changer providing the ability to sense Tool proximity to the Master prior to coupling The mating faces of the Master and Tool must be positioned within approximately 0 055 0 065 1 40 1 65mm of each other for the sensors to detect Tool presence RTL signals are not required to couple the Tool Changer but are essential as a further confirmation of coupling prior to removing the Tool from the tool stand 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 allowed just prior to coupling ONLY if Z compliance is built in to the Tool Stand Verify that all the RTL signals are read as on true Turn the Unlatch output off Turn the Latch output on Air is supplied to the locking mechanism to couple the Tool Changer A sufficient delay must be programmed between the Latch output being activated and reading the state of the Lock Unlock signals so that the coupling process is completed before checking the Locked state Read the Lock and Unlock signals
22. e tool changer 08 3 4 Integrated Sensors The QC 1210 Master has a total of 6 proximity sensors for detecting the Lock and Unlock state of the Tool Changer For each locking mechanism there is one Lock sensor and one Unlock sensor Each sensor pair is distinguished by the corresponding locking mechanism For example locking mechanism 1 has L1 Lock sensor 1 and U1 Unlock sensor 1 Also to eliminate confusion the Master body sensor cables and junction module connectors are labeled the same way L1 U1 L2 U2 L3 and U3 a E lt QC 1210 Master gt gt lt gt U1 U3 RS1 De Be o E n ag RS3 Ue AUER gt KR J all Da e IS ae i Bok dd i L1 AL DN L3 Figure 3 1 Lock and Unlock sensors L2 and U2 not visible in this view Inside the junction module all 3 Lock sensors are wired in series which provides for one Locked signal via the connector labeled L The 3 Unlocked sensors are also wired in series within the junction module which provides for one Unlocked signal via the connector labeled U Cables connect the L and U connectors of the junction module to the L and U connectors of the control module U1 L1 U2 and L2 not visible in this
23. for movement float in a plane parallel to the mating surfaces of the Master plate and Tool plates and ina direction perpendicular to this plane towards the Master plate In most cases the tools are stored in a Tool Stand when not being used by the robot During coupling and lock up the Tool Stand must allow for movement float in a plane parallel with the mating surfaces of the Master plate and Tool plates X and Y directions Even slight misalignment between the Master plate and Tool plate can generate high forces during lock up if the Tool plate is not allowed to float into place during lock up These high forces can cause excessive wear and even jamming of the end effector and robot The degree of float required depends on the accuracy of the robot s positioning and the repeatability of the Tool location in the Tool Stand during lock up See Figure 2 2 and Table 2 3 for recommended maximum allowable float offsets prior to coupling The Tool Stand should be designed to minimize misalignment during coupling and uncoupling In some cases greater offsets than shown in Table 2 3 can be accommodated by the Master and Tool plates but will increase wear For the QC 1210 the tool stand should have compliance in the Z direction The robot should be programmed to fully seat the Tool in the Tool Stand before issuing the Unlock command The Unlock sensors need to be active before pulling the Master away It is possible to design Tool Stands that
24. 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 Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 e www ati ia com e Email info ati ia com B 7 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 Lock up should occur with the Master plate in the No Touch Locking zone see Table 2 3 but not touching the Tool plate As locking occurs the Master plate should draw the Tool plate into the locked position Tool Stands may also need to incorporate means for covering Tools and electrical modules to protect them in dirty environments such as grinding or welding Alternatively locating Tool Stands in areas shielded from weld spatter fluids adhesives or other debris would eliminate the need for Tool covers Get GOPA 109 8 wus 7 pu Ee li GG EIS Ot Cocking Offset L About X and Y X Y and Z Offset Figure 2 2 Offset Definitions Twisting No Touch Zone X and Y Offset Cocking Offset Twisting Offset Z Offset Max Max t Max Max degrees degrees mm mm Table 2 3 Maximum Recommended Offsets
25. includes an anodized aluminum body and 3 hardened stainless steel bearing races The Tool plate has 6 flat sides for mounting of optional modules Junction Module Proximity Sensor Adapter Target RTL Alignment Pin Bushing Common Ledge Feature For Module Mounting Proximity Sensor Flats A B C D E andF Target RTL Bearing Race Proximity Sensor Target RTL Figure 1 2 Tool Plate Assembly Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 ewww ati ia com e Email info ati ia com B 3 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 1 3 Optional Modules There are 6 flats available for mounting of the optional modules for support of various utility pass through such as signal fluid air and power For assistance in choosing the right modules for your particular application visit our website to see what is available or contact an ATI Sales Representative directly In general flat A is reserved for an air valve adapter module and a control signal module Flat D is reserved for a signal junction module however optional utility modules can still be added on flat D Modules for flats B C D E or F are interchangeable to suit the application or the dress out required The optional modules are mounted to the Master or Tool plate using a common ledge mounting fe
26. mpressed air at a pressure of 70 100 psi Robot motion should be halted if i CAUTION Safe reliable operation of the Tool Changer is dependent on a continuous the air supply pressure drops below 70 psi for any reason ATTENTION 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 4 2 Tubes of lubricant for this purpose are shipped with every Tool Changer Note MobilGrease XHP222 Specialis a NLGI 2 lithium complex grease with molybdenum disulfide Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 ewww ati ia com e Email info ati ia com B 9 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 3 1 Coupling Sequence d 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 Position the Master above the Tool and move the Master into locking position The mating surfaces of the Master and Tool should be parallel and not touching Make sure that the tapered alignment pins from the Master enter the alignment holes on the Tool The alignment pins should be relatively concentric with the alignment holes such that they do not rub against th
27. multiple locking mechanism design the proximity sensors are grouped such that 3 sensors are for Lock and 3 are for Unlock The Lock Unlock signal at each locking mechanism is routed to the signal junction module The junction module provides the control signal module with the Lock Unlock state of the Master plate See the cable routing illustrations in Section 3 4 to understand the relationship between the sensors junction module and control module Three proximity sensors are mounted in the body of the Master plate to verify Tool plate presence when coupled The sensors provide 2 Ready To Lock RTL signals to the control signal module To accomplish a dual RTL signal 2 of the sensors are wired in series See Section 3 4 for more explanation of the RTL layout Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 e www ati ia com e Email info ati ia com B 2 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 Ball Bearings 36 Junction Module Proximity Sensor Cam RTL Signal Alignment Pin Male Coupling Common Ledge Feature For Module Mounting Flats A B C D E andF Proximity Sensor RTL Signal Cable Retaining Tabs Lock Unlock Air Supplied through Ja Proximity Sensor Air Valve Adapter Mounted to Flat A RTL Signal Figure 1 1 Master Plate Assembly 1 2 Tool Plate Assembly The Tool base assembly Tool plate
28. oupling Sensor Information signal L U Internal proximity sensors 6 with cable and name Lock Unlock connector to indicate locking mechanism position RTL Proximity sensors 3 with cable and connector for direct wiring to control signal module to indicate Master and Tool mating surfaces within close proximity of each other Mounting Customer Interface Master Plate Tool Plate See Section 8 See Section 8 Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 e www ati ia com e Email info ati ia com B 24 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 8 Drawings OlZL 02 0 96 a FL go 13355 Lara mee O mea azs nyos 09 er Rpe MMM woverge ozur eu 6410ZLL6164 ei YSN SOL ON xedy AJIA YOMPOO9 LEOL Jafueyo oo eseg O1Z1 00 GONZZIS geg W148 0210349 aw Auedwo9 pasa1s18a4 1006 OS 6SZ87LL E16 4 m 60 17 9 uosuems 0 NOILLYWOLNY TVIBASNONI WOCH Ne PIE D e SAILIWTIW NI JAV SNOISNIWIA NY ONIMVAd TIYOS LON OG ISMAJ LO SSTINA SALON siosuas ywxosd Buisn 4907 0 Apeay LY Buoajap jo alqedeo saHueyo joo e WsIUBYDEW Bupjoo YoRa 104 90jun pue 4907 Buljoajap jo ajqedeouaHueyo joo Z Ajddns Jie yoojun pue Mon uowwoo e aJeys pue swsjueyosw Huyo 8314 Jo S sisuod JaBUeYD JOO L 99 ON
29. pex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 e www ati ia com e Email info ati ia com B 1 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 B Base Tool Changer QC 1210 Series Robotic Tool Changer 1 Product Overview 1 1 Master Plate Assembly The Master base assembly Master plate includes an anodized aluminum body a set of hardened stainless steel locking mechanisms and hardened steel alignment pins see Figure 1 1 The Master plate has 6 flat sides for mounting of optional modules Flat A is dedicated for mounting of the control signal module along with tool changer supply air that is provided through an air or valve adapter Flats B C D E and F are fully interchangeable and optional modules can be arranged to suit the application or robot dress as required The Master plate is comprised of 3 locking mechanisms Each locking mechanism consists of acam male coupling and chrome steel balls Tapered pins located on the Master plate mate with holes in the Tool plate to ensure repeatable alignment during the coupling process Extreme pressure grease is applied to the cams male couplings ball bearings and pins to enhance performance and maximize the life of the Master assembly Proximity sensors 6 total are designed into the body of the Master plate to verify the locked unlocked position of each locking mechanism Due to the
30. pin sub assembly from the Master plate using a 5mm hex key Note If for any reason the pin cannot be removed using the hex socket in the tip it may be necessary to remove it by other means such as Vise Grip pliers Another approach is to use the access hole in the back side of the Master plate In this case a 4 mm hex key will be needed Once the alignment pin has been removed verify that the sub assembly pin and set screw is intact If the set screw portion of the sub assembly did not come out it will be necessary to remove it separately using the access hole in the back side of the Master plate Apply Loctite 242 or similar thread locking compound to the M8 set screw in the new alignment pin Install the alignment pin into the bushing and screw it into place Apply 60 in lb of torque to fully tighten it Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 e www ati ia com e Email info ati ia com B 19 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 5 Troubleshooting Check these conditions for all symptoms prior to troubleshooting e Proper pneumatic and electrical connections have been made to the Tool Changer e Airis supplied at a minimum of 70 psi e No air or vacuum can be trapped in a de energized Lock or Unlock port pressure must be vented to atmosphere Symptom Cause Resolution Unit will not Lock or Unlock or
31. r Description Master Plate 9121 1210AM 0 0 0 0 0 0 Complete QC 1210 Master Plate No Options 9005 20 1569 1 1 8 Two Piece Alignment Pin 9005 20 1198 Master Cleat Assy See Section 8 for Additional Information Tool Plate 9121 1210AT 0 0 0 0 0 0 Complete QC 1210 Tool Plate No Options 9005 20 1199 Tool Cleat Assy See Section 8 for Additional Information Other 9005 20 1605 Tool Junction Module Adapter PNP with LED Cables SL 8590 9909999 34 PNP Proximity Sensor RTL 9005 20 1604 PNP Master Signal Junction Module 9005 20 1613 PNP Lock Unlock Sensor Assembly VS e x L U Cable Pentafast Female Straight to Picofast Male Right 9120 C 3M5F 3PM90 0016 Angle 0 16 m e 3 x L U Cable Pentafast Female Straight to Picofast Male Right 9120 C 3M5F 3PM90 0020 Angle 0 20 m 9120 C 3PF 3PF 3PM90 PNP RTL Cable RS1 amp RS2 to R1 9120 C 3PF 3PM90 0030 PNP RTL Cable RS3 to R2 PNP L U Cable Picofast Female Right Angle to Picofast 9120 C 3PF90 3PM90 0041 Male Right Angle 41 m NPN with LED Cables SE 8590 9909999 34 PNP Proximity Sensor RTL 9005 20 1780 NPN Lock Unlock Sensor Assembly 9005 20 1781 NPN Master Signal Junction Module Ra L U Cable Pentafast Female Straight to Picofast Male Right 9120 C 3M5F 3PM90 0016 Angle 0 16 m i x i L U Cable Pentafast Female Straight to Picofast Male Right 9120 C 3M5F 3PM90 0020 Angle 0 20 m 9120 C 3PF 3PF 3PM
32. s 4 2 3 Lock and Unlock Sensor Assembly Replacement Figure 4 5 1 Unscrew the sensor cable connector from the extension cable 2 Remove the two 2 M3 socket head cap screws that secure the assembly to the Master body 3 Slide the sensor assembly out and discard CAUTION The Lock and Unlock sensor assemblies are precision aligned and permanently assembled at the factory Do not attempt to adjust the position of the sensor or severe damage to the Master may occur 4 Apply Loctite 222MS to the new M3 socket head cap screws supplied with the new sensor assembly Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 eFax 919 772 8259 e www ati ia com e Email info ati ia com B 17 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 di Lock Sensor Assembly 3 Places Check that the new sensor assembly has the o ring present and that the old o ring came off of the Master with the old sensor assembly Attach the new assembly to the Master by tightening the M3 screws to 12 in lbs Re attach cables and modules Confirm operation of the Unlock sensor by issuing the Unlatch command and then checking to see that the LED in the Unlock sensor body is on Confirm operation of the Lock sensor by issuing the Latch command to lock a Tool to the Master and then checking to see that the LED in the Lock sensor body is on a Unlock Sensor ia Assembly
33. tands away from debris generators 2 covers incorporated into the Tool Stands see Section 2 3 and 3 guards deflectors air curtains and similar devices built into the EOAT and the Tool Stand 4 1 Preventive Maintenance The Tool Changer and optional modules are designed to provide a long life with regular maintenance A visual inspection and preventative maintenance schedule is provided in the table below depending upon the application Detailed assembly drawings are provided in Section 8 of this manual ATTENTION 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 4 2 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 Pinnacle Park e 1031 Goodworth Drive e Apex NC 27539 e Tel 919 772 0115 e Fax 919 772 8259 ewww ati ia com e Email info ati ia com B 14 Quick Change Installation and Operation Manual Document 9620 20 b 1210 series base tool changer 08 KEE Tool Change Inspection Weekly gt 1 per minute General Usage Material Handling Docking Station Welding Servo Deburring Foundry Operations Dirty Environments lt 1 per minute Monthly All Checklist B
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