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ATI Technologies 9150-CGV-900 Product Manual

Pneumatic angle grinder
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ATI Pneumatic Angle Grinder
(Model 9150‑CGV‑900)
Product Manual
Document #: 9610-50-1056
Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919-772-0115 • Fax: +1 919-772-8259 • www.ati-ia.com

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  • Page 1 ATI Pneumatic Angle Grinder (Model 9150‑CGV‑900) Product Manual Document #: 9610-50-1056 Engineered Products for Robotic Productivity Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: +1 919-772-0115 • Fax: +1 919-772-8259 • www.ati-ia.com...
  • Page 2 Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 Foreword 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.

  • Page 3: Table Of Contents

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 Table of Contents Glossary ............................5 Safety ............................6 1.1 Explanation of Notifications ......................6 General Safety Guidelines ......................6 Safety Precautions ........................6 Product Overview ........................7 Technical Description ........................8 2.1.1 Environmental Considerations ................... 8 2.1.1.1 Operation ......................
  • Page 4 Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 5.3.5 No Radial Loads ....................... 24 5.3.6 Program the Robot to Incorporate 50% Compliance Travel of the Tool ......24 Gravity Compensation ........................ 24 LEDs Normal Operation ......................25 RS485 Serial Console Interface .................... 26 Serial Console Commands ......................

  • Page 5: Glossary

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 Glossary Definition Term Device for removing contamination from air supply lines. Typically refers to removal Air Filter of particulates. A number that is related to the speed of data transmission in a system. The data Baud Rate indicates the number of electrical oscillations per second that occurs within a data transmission.

  • Page 6: Safety

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 1. Safety The safety section describes general safety guidelines to be followed with this product, explanations of the notifications found in this manual, and safety precautions that apply to the product. More specific notifications are embedded within the sections of the manual (where they apply).

  • Page 7: Product Overview

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 2. Product Overview ATI's Compliant Pneumatic Robotic Angle Grinder (CGV) is a compliant tool that is best for finishing, blending, and light grinding operations. The CGV can be a replacement for handheld grinders and is compatible with industry-standard grinding media such as flap wheels, sanding discs, and wire brushes.

  • Page 8: Technical Description

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 2.1 Technical Description A technical overview of the product is provided in the following tables and graphs. For additional technical specifications, refer to Section 10—Specifications. 2.1.1 Environmental Considerations 2.1.1.1 Operation Table 2.1—Operation Mounted to robot or fixed post/bench by various Installation position means, customer‑supplied tool holders/adapters.

  • Page 9: Compliance Unit Performance

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 2.2 Compliance Unit Performance The force from the compliance mechanism varies linearly with air pressure as shown in Figure 2.2. This shown compliance force does not include the friction or weight of the attached tooling. Therefore, when calculating this force, customers should include the weight of the motor assembly (5.1 lbs or 2.3 kg), additional accessories, and the tool's orientation.

  • Page 10: Guidelines For Transporting, Unpacking, And Storing The Cgv

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 3. Guidelines for Transporting, Unpacking, and Storing the CGV 3.1 Protection During Transportation The CGV arrives in packaging that secures and protects the tool during transportation. Always use this packaging to safely transport the CGV. 3.2 Inspect the Product Condition When Delivered Upon receipt, verify the following: •...

  • Page 11: Installation

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 4. Installation 4.1 General Guidelines: • Mount the tool onto a rigid fixture, prior to use. • Do not use the unit for handheld operations. • Supply the unit with clean air filtered (5) micron or better. The use of a coalescing filter is recommended to remove trace moisture from the air supply.
  • Page 12 Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 Figure 4.2—Bolt-up Top Surface (ATI Interface Plate Kit P/N 9005-50-6267) (2) M6 dowel pin* Interface plate ATI P/N 3700‑50‑9282 (4) M6 socket head cap screws* Compliance assembly (2) M6 dowel pin (4) M5 socket head cap screws *These dowel pins and screws are for mounting to a ISO50 bolt pattern on the robot or customer device.

  • Page 13: Installation Procedure

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 4.3 Installation Procedure Parts required: Refer to Section 9—Parts and Accessories Supplies required: Loctite ® 242, M5 or M6 socket head cap screws Tools required: 4 or 5 mm hex key wrench, torque wrench The CGV can be installed to a robot/interface plate using one of the three mounting patterns: bolt-up or bolt-down on the top of the compliance assembly;...

  • Page 14: Optional Installation Of Accessories

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 4.4 Optional Installation of Accessories 4.4.1 Exhaust Assembly (ATI P/N 9005-50-6273) Parts required: Refer to Section 9—Parts and Accessories Tools required: 2 mm hex key, spanner wrench or box wrench Supplies required: Magnalube 1.

  • Page 15: Position Sensing

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 4.4.2 Position Sensing 1. Connect a sensor cable such as ATI P/N 9105-C-ZC27-ZC28 to the M8 connector on the compliance housing. For connector pinouts, refer to Section 4.6—M8 Sensor Connection Section 4.7—Sensor Assembly Cable (P/N 9105‑C‑ZC27‑ZC28).

  • Page 16: 90° Mounting Bracket (Ati P/N 9005-50-6274)

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 4.4.3 90° Mounting Bracket (ATI P/N 9005-50-6274) Parts required: Refer to Section 9—Parts and Accessories ® Tools required: 2.5 mm, 5 mm hex key, T20 Torx bit, torque wrench ® Supplies required: Locite 222, 242, and 7649 1.
  • Page 17 Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 NOTICE: The 90° mounting bracket and main housing have a 50 mm bolt pattern for (4) M6 socket head cap screws and (2) M6 dowel pins. The bracket can be installed as shown or rotated 180°. 4.

  • Page 18: Pneumatic Connections

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 4.5 Pneumatic Connections Connect the CGV as outlined in Section 4.3—Installation Procedure. WARNING: All pneumatic fittings and tubing must be capable of withstanding the repetitive motions of the application without failing. The routing of pneumatic lines must minimize the possibility of over stressing, pullout, or kinking the lines.

  • Page 19: M8 Sensor Connection

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 4.6 M8 Sensor Connection Electrical connection pinouts and ratings are listed in the following table. Cable shielding is required. Figure 4.7—M8 8-Pin Connector Wiring (Face View Shown) (see also Figure 4.4) Table 4.3—M8 8-Pin Male Connector Wiring Signal name Description Voltage/Current Rating...

  • Page 20: Sensor Assembly Cable (P/N 9105-C-Zc27-Zc28)

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 4.7 Sensor Assembly Cable (P/N 9105-C-ZC27-ZC28) NOTICE: ATI can provide a sensor assembly cable to install from the position sensor connector on the CGV (ZC27 connector) to the customer interface (ZC28 connector). For cable electrical specifications, refer to Section 10—Specifications.
  • Page 21 Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 NOTICE: The name of the device may differ based on the name of the PC’s RS485 port or name of the third‑party RS485 device. Figure 4.8—Device Manager, Port Assignment 4. Open the console, for example: PuTTY. A window opens that allows the user to set the configuration for the session.
  • Page 22 Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 In the Serial Line field, enter the assigned COM port from step 3. In the Speed field, enter the default baud rate of 115200. NOTICE: If the baud rate that is set on the console configuration does not match the baud rate set on the CGV sensor, then the console terminal window will open but commands cannot be sent.

  • Page 23: Operation

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 5. Operation These operating instructions are intended to help system integrators program their robots and make a functional robotic work cell with a finishing tool. System integrators must be generally familiar with the task of surface finishing and have extensive knowledge of robots and robotic automation.

  • Page 24: Normal Operation

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 5.3 Normal Operation Recommended operating conditions for the CGV are described in the following sections. 5.3.1 Air Quality The motor's supply air should be clean, lubricated, dry, and filtered. Use a coalescing filter that has elements rated for 5 micron or better.

  • Page 25: Leds Normal Operation

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 5.5 LEDs Normal Operation CGVs with the sensor kit have LEDs on the side of the compliance assembly indicate the tool position and notify users of when the tool is in a safe travel zone. Figure 5.1—LEDs LED 3 LED 2...

  • Page 26: Rs485 Serial Console Interface

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 6. RS485 Serial Console Interface 6.1 Serial Console Commands These commands can be used to view the status, parameters, and adjust settings of the sensor assembly with a program like PuTTY (available online) at a default baud rate of 115200. For instructions on setting up a serial console, refer to Section 4.8—Set‑up of the RS485 Communication Interface.

  • Page 27: Help Command: "Help", "H", Or

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 Table 6.1—Serial Console Commands Command Operand(s) Description Compressed: The data is displayed in a formatted human‑readable > output, for example: lined‑up columns. “>” is the default setting. Formatted: The data is displayed in a compressed output that has no Stream leading zeros, trailing zeros, or unnecessary blanks.

  • Page 28: Mancal Command

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 6.3 MANCAL Command The MANCAL command calibrates the CGV more precisely than the FASTCAL command. However, the process is more intricate and takes more time to complete. To calibrate with the MANCAL command, follow these steps: 1.

  • Page 29: Flow Command: "Flow

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 6.6 Flow Command: “flow” During a step of the main flow, users can observe the following parameter data (the content may vary among CGV sensor assemblies): flow user: response: >flow Accelerometer 17 mg 985 mg -2 mg Filtered Accl 25 mg...

  • Page 30: Status Command: "Status

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 6.7 Status Command: “status” If there could be an underlying problem within the CGV sensor assembly hardware, the “status” command can be used to retrieve detailed information or for the user to send the information to ATI for troubleshooting.

  • Page 31: Reset Command: "Reset

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 6.8 Reset Command: “reset” The “reset” command resets the MCU. “reset” command example format (the content may vary among CGV sensor assemblies): user: reset response: ======================================================================= ATI Compliant Angle Grinder Version: 1.0.6-next+5906-ge7978addf => BL=3 =>...

  • Page 32: Stream Command: "Stream [Hdbxyztp%Or]

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 6.9 Stream Command: "stream [HDBXYZTP%OR]" The following is an example of the “stream” command with specifiers "d" (decimal), "#" (line counter), "x" (raw acceleration X axis), "y" (raw acceleration Y axis), and "z" (raw acceleration Z axis): Note that the content may vary among CGV sensor assemblies.

  • Page 33: Set/Cal Commands

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 6.10 Set/Cal Commands The following fields can be called after entering "Set" or "Cal" to read the current value of a field or write a new value to writable fields. Table 6.2—Set/Cal Commands User Example Field...

  • Page 34: Filter "Filtc" Parameters

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 Table 6.2—Set/Cal Commands User Example Field Long Name Type Description Default Value Read/ Contents Write Lin0 Lin1 Lin2 Lin3 Lin4 1100 1100 Lin5 1375 1375 Linearization Position sensor Read/ Lin6 Uint16 1650 1650 Values calibration data Write...

  • Page 35: Baud Rate Command: "Set Baud

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 6.12 Baud Rate Command: “set baud The user can set the baud rate of the CGV sensor assembly. The default baud rate is 115200. “set baud” read and write command format: user: set baud response: Field Value...

  • Page 36: Maintenance

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 7. Maintenance 7.1 Routine Operational Maintenance When keeping to normal use, the CGV provides many hours of operation before service or repair is necessary. When under high shock loading or periods of continuous service without interruption, the CGV requires service or repair sooner than normal.

  • Page 37: Troubleshooting And Service Procedures

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 8. Troubleshooting and Service Procedures Troubleshooting guidance is in the following section to help resolve issues that might arise. Service procedures are provided for recommended replacement components. 8.1 Troubleshooting for Material Finishing For assistance when solving finishing problems, refer to the following table: Table 8.1—Troubleshooting Material Finishing Symptom Cause...

  • Page 38: Media Installation

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 8.3.1 Media Installation Refer to Figure 8.1. Parts required: Refer to Section 9—Parts and Accessories. Tools required: spanner wrench or box wrench, clean rag 1. Disconnect power and air supply lines to the CGV. 2.

  • Page 39: Parts And Accessories

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 9. Parts and Accessories for exploded drawings that show the user replaceable components of the CGV. Refer to Section 11—Drawings Available accessories, tools, and replacement parts are listed in the following section. All other repairs must be performed by ATI.

  • Page 40: Specifications

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 10. Specifications Table 10.1—Specifications for the CGV Parameter Rating 9.00 lbs (4.08 kg) Weight total (w/o adapter) .98" / 25 mm Compliance travel .49" / 12.5 mm Compliance travel recommended 0 –14 lbf (f) Compliance Force 0 –...

  • Page 41: Terms And Conditions Of Sale

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 12. 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 the compliant tool product will be free from defects in design, materials and workmanship for a period of one (1) year from the date of shipment and only when used in compliance with manufacturer’s specified normal operating conditions.

  • Page 42: Motor Life And Service Interval Statement

    Manual, Pneumatic Angle Grinder (CGV) Document #9610-50-1056-02 12.1 Motor Life and Service Interval Statement The air motors that are used in ATI deburring/finishing tools are subject to wear and have a finite life. Motors that fail, during the warranty period, will be repaired or replaced by ATI as long as there is no evidence of abuse or neglect and that the normal operating practices outlined in this manual have been observed.

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