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Novanta ATI QC-161 Manual

Custom tool changer
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QC‑161
Custom Tool Changer
Manual
Document #: 9610‑20‑4446
Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati‑ia.com

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  • Page 1 QC‑161 Custom Tool Changer Manual Document #: 9610‑20‑4446 Engineered Products for Robotic Productivity Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati‑ia.com...

  • Page 2: Foreword

    Apex, NC 27539 USA www.ati‑ia.com Tel: 919.772.0115 Fax: 919.772.8259 Application Engineering Tel: 919.772.0115 Fax: 919.772.8259 E‑mail: Applications.Engineers@novanta.com 24/7 Support: +1 855 ATI-IA 00 (+1 855-284-4200) Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati‑ia.com...

  • Page 3: Table Of Contents

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 Table of Contents Foreword ............................2 Glossary ............................5 Safety ............................6 1.1 Explanation of Notifications ......................6 General Safety Guidelines ......................6 1.3 Safety Precautions ........................7 2. Product Overview ........................8 Master Plate Assembly ......................... 8 Tool Plate Assembly ........................
  • Page 4 Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 6.1 Troubleshooting .......................... 27 6.2 Service Procedures ........................28 6.2.1 Lock and Unlock Sensor Replacement ................28 6.2.2 M12 Connector Assembly Replacement ................30 6.2.3 V‑ring Seal Inspection and Replacement ................. 31 6.2.4 Alignment Pin Replacement ..................... 32 7. Serviceable Parts ........................

  • Page 5: Glossary

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 Glossary Term Definition A steel ring in the Tool plate that is engaged by the locking balls during the Bearing Race coupling of the Tool Changer. A multi tapered sliding cylinder attached to the piston that forces the locking balls outward during the locking process.

  • Page 6: Safety

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 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. Product specific notifications are imbedded within the sections of this manual (where they apply).

  • Page 7: Safety Precautions

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 1.3 Safety Precautions WARNING: Remove all temporary protective materials (caps, plugs, tape, etc.) on the locking face of the 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.

  • Page 8: Product Overview

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 2. Product Overview ATI Tool Changers enhance the versatility of a robot by enabling the use of multiple customer tools, such as: grippers, vacuum cup tooling, pneumatic and electric motors, weld guns, and more. The QC‑161 is a custom Tool Changer for a washdown environment in a food application.

  • Page 9: Tool Plate Assembly

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 2.2 Tool Plate Assembly The Tool plate includes a stainless steel body and a hardened stainless steel bearing race (refer to Figure 2.2). Alignment bushings are integrated in the Tool body to ensure proper, repeatable orientation with the Master plate.

  • Page 10: Installation

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 3. Installation All fasteners used to mount the Tool Changer to the robot and customer’s tooling should be tightened to the torque Additionally, Loctite 7649 values indicated in Table 3.1——Fastener Size, Class, and Torque Specifications. primer and removable Loctite 242 must be used on these fasteners.

  • Page 11: Master Interface

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 3.1 Master Interface The Master plate is typically attached to the robot arm. The QC‑161 is designed to mount directly to ISO 9409-1-125-10-M10 robot wrists to minimize stack height. An interface plate can adapt the Master plate to differing specific robot arm mounting patterns.

  • Page 12: Master Plate Installation

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 3.2 Master Plate Installation Refer to Figure 3.1. Tools required: 8 mm flat hex key (not a ball end), torque wrench Supplies required: Clean rag, Loctite 7649 and 242 ® 1. Wipe down the mounting surfaces with a clean rag. CAUTION: The (10) M10 socket flat head cap screws are stainless steel.

  • Page 13: Master Plate Removal

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 3.3 Master Plate Removal Tools required: 8 mm flat hex key 1. Place the Tool in a secure location. 2. Uncouple the Master and Tool plates. 3. Turn off and de-energize all energized circuits (for example: electrical, pneumatic, and hydraulic). 4.

  • Page 14: Tool Interface

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 3.4 Tool Interface The Tool plate is attached to the customer’s tooling. An interface plate can adapt the Tool plate to customer tooling. Alignment features (dowel holes and a recess) accurately position and bolt holes secure the Tool plate to customer tooling.

  • Page 15: Tool Plate Installation

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 3.5 Tool Plate Installation Tools required: 8 mm hex key, torque wrench Supplies required: Clean rag, Loctite 7649 and 242 ® 1. Wipe down the mounting surfaces with a clean rag. 2. If required, install the tooling interface plate to the customer tooling, align using the recess and dowel pin(s).

  • Page 16: Optional Module

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 3.7 Optional Module The optional modules are typically installed on the Tool Changers by ATI prior to shipment. The following steps outline field installation or removal as required. Tool Changers are compatible with many different types of modules.

  • Page 17: Optional Module Removal

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 3.7.2 Optional Module Removal Refer to Figure 3.3 Tools required: 2.5 mm or 3 mm hex key 1. Place the Tool in a secure location. 2. Uncouple the Master and Tool plates. 3. Turn off and de-energize all energized circuits (for example: electrical, pneumatic, and hydraulic circuits).

  • Page 18: Electrical Connections

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 3.9 Electrical Connections Integrated lock/unlock sensors are available. The sensor assemblies are protected within an enclosure attached to the Master plate. For the pinout and wire call‑outs of the M12 4‑pin connector, refer to Section 3.9.2—M12 4-Pin Male Connector.

  • Page 19: Operation

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 4. Operation The Master plate locking mechanism is pneumatically driven to couple and uncouple with the Tool plate bearing race. CAUTION: Operation of the Tool Changer is dependent on the maintaining an air pressure of 60 to 100 psi (4.1–6.9 bar).

  • Page 20: Conditions For Coupling

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 4.1 Conditions for Coupling 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.

  • Page 21: Conditions For Uncoupling

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 4.3 Conditions for Uncoupling 1. Position Tool plate in the tool stand so 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 Changer is in the Unlocked position).

  • Page 22: Tool Storage Considerations

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 4.5 Tool Storage Considerations NOTICE: Improperly designed tool stands cause components to become stuck and causes excessive wear of components. Thus, carefully consider tool stand design for optimal operation of the Tool Changer. For assistance, contact an ATI representative. When Tool plates are not in use, store the Tool plate with attached customer tooling in a tool stand.

  • Page 23: Maintenance

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 5. Maintenance WARNING: Do not perform maintenance or repair(s) on the Tool Changer or modules unless the Tool is safely supported or placed in the tool stand, all energized circuits (e.g. electrical, air, water, etc.) are turned off, pressurized connections are purged and power is discharged from the circuits in accordance with the customer specific safety practices and policies.

  • Page 24: Cleaning And Lubrication Of The Locking Mechanism And Alignment Pins

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 5.2 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins Supplies required: Clean rag, food grade grease such as JET LUBE FMG 1. Place the Tool in a secure location. 2. Uncouple the Master and Tool plates. 3. Turn off and de-energize all energized circuits (for example: electrical, pneumatic, and hydraulic circuits).
  • Page 25 Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 6. 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 7.

  • Page 26: Pin Block Inspection And Cleaning

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 5.3 Pin Block Inspection and Cleaning Tools required: Nylon Brush (ATI part number 3690-0000064-60) 1. Place the Tool in a secure location. 2. Uncouple the Master and Tool plates. 3. Turn off and de-energize all energized circuits (for example: electrical, pneumatic, and hydraulic circuits).

  • Page 27: Troubleshooting And Service Procedures

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 6. Troubleshooting and Service Procedures The following section provides troubleshooting and service information to help diagnose conditions and repair the Tool Changer. WARNING: Do not perform maintenance or repair(s) on the Tool Changer or modules unless the Tool is safely supported or placed in the tool stand, all energized circuits (e.g.

  • Page 28: Service Procedures

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 6.2 Service Procedures Component replacement and adjustment procedures are provided in following section. 6.2.1 Lock and Unlock Sensor Replacement The proximity sensors are dependable and normally do not need to be replaced. Exhaust all other possible solutions before choosing to replace the proximity sensors, including: checking continuity, air supply, lubrication, and pneumatic components prior to replacing the sensor.
  • Page 29 Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 6. Install the new sensor assemblies on the Tool Changer. Be sure that new O-rings are installed around the sensor bodies. Using a 2.5 hex key, install the (4) M3 socket head cap screws that secure the sensor assemblies to the Master plate.

  • Page 30: M12 Connector Assembly Replacement

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 6.2.2 M12 Connector Assembly Replacement Parts required: Refer to Section 7.1—Master Plate Tools required: 17 mm wrench, torque wrench Supplies required: Loctite ® Section 6.2.1—Lock and Unlock Sensor Replacement. 1. Complete steps through from 2. Disconnect the Molex sensor connectors from the connector plugs in the sensor cover.

  • Page 31: V-Ring Seal Inspection And Replacement

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 6.2.3 V-ring Seal Inspection and Replacement The seal protects the electrical connection between the Master and Tool module. Replace the seal if it becomes worn or damaged. 1. Place the Tool in a secure location. 2. Uncouple the Master and Tool plates. 3.

  • Page 32: Alignment Pin Replacement

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 6.2.4 Alignment Pin Replacement Parts required: Refer to Section 7—Serviceable Parts Tools required: 4 mm hex key, 5 mm hex key socket, torque wrench Supplies required: Loctite 7649 and 242, Jet Lube Food Machine Grease (FMG) 1.

  • Page 33: Serviceable Parts

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 7. Serviceable Parts 7.1 Master Plate Table 7.1—QC‑161 Master Plate Item No. Part Number Description QC‑161 Master, Increased Corrosion Resistant Locking Mechanism, 9120‑161AM‑000‑000‑SG 304 SS Body, Sealed for Wash Down Environments, PNP Sensing with M12 Connector 9005‑20‑9273 QC‑161 Lock/Unlock Sensors with Cover and M12 Connector, PNP...

  • Page 34: Lock And Unlock Sensor Assembly

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 7.1.1 Lock and Unlock Sensor Assembly Table 7.2—Sensor Assembly Kit (P/N 9005‑20‑9273) Item No. Part Number Description 3560‑0862035‑23 M4 X 35 Hex Head Cap Screw, SS 18‑8, Self Sealing, Viton 3700‑20‑11783 QC‑161 Sensor Cover Block with PG9 Tapped Hole 3410‑0001020‑01 O‑Ring, Round, AS568‑030, Buna‑N, 70A 9015‑20‑1267...

  • Page 35: Specifications

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 8. Specifications Table 8.1—QC-161 Specifications Specification Value Description Recommended Max Payload 210 kg (463 lb) The mass attached to the Tool Changer. ‑30–55°C Operating Temperature Range Operational temperature (‑20–150°F) Locking mechanism supply pressure operating 4.1–6.9 Bar Operating Pressure Range range.

  • Page 36: Drawings

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 9. Drawings Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati‑ia.com...
  • Page 37 Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati‑ia.com...
  • Page 38 Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati‑ia.com...
  • Page 39 Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati‑ia.com...

  • Page 40: Terms And Conditions Of Sale

    Manual, Robotic Tool Changer, QC‑161 Document #9610‑20‑4446‑03 10. Terms and Conditions of Sale The following Terms and Conditions are a supplement to and include a portion of ATI’s Standard Terms and Conditions, which are on file at ATI and available upon request. ATI warrants to Purchaser that robotic Tool Changer products purchased hereunder will be free from defects in material and workmanship under normal use for a period of three (3) years from the date of shipment.

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