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ATI Technologies QC-1510 Series Instruction Manual

Robotic tool changer
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Manual, Tool Changer, QC-1510
Document #9620-20-B-1510 Series Base Tool Changer-07
B. Base Tool Changer ................................................................................................................B-3
QC-1510 Series-Robotic Tool Changer ....................................................................................B-3
1.
Product Overview ..................................................................................................................B-3
1.1
Master Plate Assembly ............................................................................................................. B-4
1.2
Tool Plate Assembly .................................................................................................................. B-5
1.3
Optional Modules ...................................................................................................................... B-5
2.
Installation .............................................................................................................................B-6
2.1
Master Interface ......................................................................................................................... B-7
2.2
Master Plate Installation ........................................................................................................... B-7
2.3
Master Plate Removal ............................................................................................................... B-7
2.4
Tool Interface ............................................................................................................................. B-9
2.5
Tool Plate Installation ............................................................................................................... B-9
2.6
Tool Plate Removal ................................................................................................................. B-10
2.7
Pneumatic Connections ..........................................................................................................B-11
2.7.1
2.8
Electrical Connections ............................................................................................................ B-12
2.8.1
2.8.2
3.
Operation .............................................................................................................................B-13
3.1
Conditions for Coupling ......................................................................................................... B-14
3.2
Fail-Safe Operation ................................................................................................................. B-14
3.3
Conditions for Uncoupling ..................................................................................................... B-15
3.4
Tool Storage Considerations ................................................................................................. B-15
4.
Maintenance .........................................................................................................................B-16
4.1
Preventive Maintenance ......................................................................................................... B-17
4.2
4.3
Alignment Pin Replacement ................................................................................................... B-20
4.4
Seal Inspection and Replacement ......................................................................................... B-21
4.5
Pin Block Inspection and Cleaning ....................................................................................... B-22
5.
Troubleshooting ..................................................................................................................B-23
5.1
Lock and Unlock Sensor Assembly and Cable Replacement ............................................. B-24
5.1.1
Control Module to Junction Module Cable Replacement ..............................................B-24
5.1.2
5.1.3
5.1.4
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: +1 919-772-0115 • Fax: +1 919-772-8259 •

Table of Contents

B-1
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Summary of Contents for ATI Technologies QC-1510 Series

  • Page 1: Table Of Contents

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 Table of Contents B. Base Tool Changer ........................B-3 QC-1510 Series—Robotic Tool Changer ..................B-3 Product Overview ........................B-3 Master Plate Assembly ......................B-4 Tool Plate Assembly ........................B-5 Optional Modules ........................B-5 Installation ..........................B-6...
  • Page 2 Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 Ready-to-Lock Sensor and Cable Replacement ..............B-29 5.2.1 RTL Sensor Replacement (RS1/RS2) ................B-29 5.2.2 RTL Cable Replacement (R1 to RS1/RS2) ..............B-29 5.2.3 RTL Sensor Replacement (RS3) ...................B-31 5.2.4 RTL Cable Replacement (R2 to RS3) ................B-32 Serviceable Parts ........................B-33 Common Master Parts ......................

  • Page 3: Base Tool Changer

    Tool change applications, as well as manual Tool change operations. Robotic Tool Changers also provide a method for quick Tool change for maintenance purposes. For the most current product information and specifications on the QC-1510 Series of Tool Changers, please click the following link: QC-1510 Series.

  • Page 4: Master Plate Assembly

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 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).

  • Page 5: Tool Plate Assembly

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 1.2 Tool Plate Assembly The Tool Plate assembly includes an anodized aluminum body and a hardened stainless steel bearing races. The Tool Plate has (6) flat sides for mounting of optional modules. Proximity sensor targets are mounted to the body of the Tool Plate to verify Tool Plate presence when coupled.

  • Page 6: Installation

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 2. Installation All fasteners used to mount the Tool Changer to the robot and to customer’s tooling should be tightened to a torque value as indicated. Refer to Table 2.1. Furthermore, removable (blue) Loctite 242 must be used on these fasteners.

  • Page 7: Master Interface

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 2.1 Master Interface The Master Plate is attached to the robot arm. The Master Plate is designed with mounting features such as a bolt and dowel holes. These features are used to accurately position and secure the Master Plate to the robot arm or it may be necessary for a robot interface plate (RIP) to be utilized to adapt the Master Plate to a specific robot arm.
  • Page 8 Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 1. Remove the M10-1.5 SHCS connecting the Master Plate to the robot arm or RIP. Figure 2.1— Typical Master Plate Installation RIP Dowel Pin Robot Arm (Customer Supplied) Robot Interface Plate, RIP Mounting Hardware ATI or Customer Supplied (Customer Supplied)

  • Page 9: Tool Interface

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 2.4 Tool Interface The Tool Plate is attached to the customer’s tooling. The Tool Plate is designed with mounting features such as a recess and/or bolt and dowel holes. These features are used to accurately position and secure the customer’s tooling.

  • Page 10: Tool Plate Removal

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 2.6 Tool Plate Removal WARNING: Do not perform maintenance or repair on Tool Changer or modules unless the Tool is safely supported or docked in the Tool Stand and all energized circuits (e.g., electrical, air, water, etc.) have been turned off.

  • Page 11: Pneumatic Connections

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 2.7 Pneumatic 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.

  • Page 12: Electrical Connections

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 2.8 Electrical Connections Tool Changer is available with integrated lock/unlock sensors. If sensors are not used, plugs will be provided to seal the locking mechanism. If a control/signal module is to be utilized on Flat A when ordered, the sensors will be connected to the module prior to shipping.

  • Page 13: Operation

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 3. Operation The Master locking mechanism is pneumatically driven to couple and uncouple with the bearing race on the Tool Plate. The Master Plate utilizes air ports from an air or valve adapter module to provide lock and unlock pressure to the locking mechanism.

  • Page 14: Conditions For Coupling

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 3.1 Conditions for Coupling Refer to your Air Valve Adapter and/or Signal/Control module manual’s Operation section for operation during coupling/uncoupling. CAUTION: The locking mechanism must be in the unlock position when attempting to couple the Tool Changer.

  • Page 15: Conditions For Uncoupling

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 3.3 Conditions for Uncoupling Refer to your Air Valve Adapter and/or Signal/Control module manual’s Operation section for operation during coupling/uncoupling. • The Tool Changer should be positioned in the Tool Stand in the same location as that when coupling took place.

  • Page 16: Maintenance

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 4. Maintenance WARNING: Do not perform maintenance or repair on Tool Changer or modules unless the Tool is safely supported or docked in the Tool Stand and all energized circuits (e.g., electrical, air, water, etc.) have been turned off.

  • Page 17: Preventive Maintenance

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 4.1 Preventive Maintenance The Tool Changer and optional modules are designed to provide a long life with regular maintenance. A visual inspection and preventive maintenance schedule is provided in the table below depending upon the application.

  • Page 18: Cleaning And Lubrication Of The Locking Mechanism And Alignment Pins

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 4.2 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins 1. The locking mechanism must be in the unlock state before cleaning. 2. Use a clean rag to thoroughly remove the existing lubricant and debris from the ball bearings, the male coupling, the cam and the alignment pins.
  • Page 19 Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 4. 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 4.3—...

  • Page 20: Alignment Pin Replacement

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 6. Use a clean rag to thoroughly remove the any lubricant and debris from the bearing race and the bushings from the Tool Plate. Figure 4.5— Clean Tool Plate Surfaces of Locking Mechanism Clean Bushing Surfaces Clean Bearing Race Surfaces...

  • Page 21: Seal Inspection And Replacement

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 2. Another approach would be to use the access hole in the back side of the Master Plate. In this case, a 4mm Allen Wrench will be needed (see Figure 4.7).

  • Page 22: Pin Block Inspection And Cleaning

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 4.5 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 23: Troubleshooting

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 5. Troubleshooting Check these conditions for all symptoms prior to troubleshooting: Proper pneumatic and electrical connections have been made to the Quick-Change. • • Air is supplied at a minimum of 70 psi (4.8 Bar). •...

  • Page 24: Lock And Unlock Sensor Assembly And Cable Replacement

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 5.1 Lock and Unlock Sensor Assembly and Cable Replacement The proximity sensors are very reliable and normally do not need to be replaced. Exhaust all other possible solutions, check continuity, air supply, lubrication, and pneumatic components prior to testing or replacing the sensor WARNING: Do not perform maintenance or repair on Tool Changer or modules unless the Tool is safely supported or docked in the Tool Stand and all energized circuits (e.g.,...

  • Page 25: Lock\Unlock Sensor Assemblies (L1/U1) And Cable Replacement

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 13. If optional modules were installed on Flats E and/or Flat F, install modules. 14. If fasteners do not have pre-applied adhesive, apply Loctite 242® to the M6 SHCS fasteners. Install the two (2) M6 socket head screws securing the module to the Tool Changer body and tighten to 70 in-lbs (7.9 Nm).

  • Page 26: Lock And Unlock Sensor Assemblies (L2/U2) And Cable Replacement

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 9. Install the new Lock and/or Unlock sensor assembly, routing the cable into the cable channel of the Tool Changer body. 10. Connect the Lock and/or Unlock sensor cable connectors to the proper cable connections on Flat C.

  • Page 27: Lock And Unlock Sensor Assemblies (L3/U3) And Cable Replacement

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 Figure 5.3— Lock and Unlock Sensor Assemblies (L2/U2) Replacement Connects to "L2" Connects to "U2" M6 Socket Head Cap Screws L2 Lock Sensor Assembly U2 Unlock Sensor Assembly M3 Socket Head Cap Screws Junction Module Cable Connections on Flat D...
  • Page 28 Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 8. Remove the Lock and/or Unlock sensor assembly from the cable channel of the Tool Changer body. There is an O-ring around the cylinder barrel, ensure O-ring came off with old sensor before continuing.

  • Page 29: Ready-To-Lock Sensor And Cable Replacement

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 5.2 Ready-to-Lock Sensor and Cable Replacement The proximity sensors are very reliable and normally do not need to be replaced. Exhaust all other possible solutions, check continuity, air supply, lubrication, and pneumatic components prior to testing or replacing the sensor WARNING: Do not perform maintenance or repair on Tool Changer or modules unless the Tool is safely supported or docked in the Tool Stand and all energized circuits (e.g.,...
  • Page 30 Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 Figure 5.5— RTL Cable Replacement (R1 to RS1/RS2) Remove Module M6 Socket Head Cap Screws on Flat F M3 Socket Head Flat Screws M3 Socket Head Flat Screws M6 Socket Head Cap Screws Cable Retaining Tabs Remove Module Control Module...

  • Page 31: Rtl Sensor Replacement (Rs3

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 21. Connect all cable connection to corresponding connectors on the Junction Module, as previously marked. 22. Confirm the operation of the RTL 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 light up.

  • Page 32: Rtl Cable Replacement (R2 To Rs3

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 5.2.4 RTL Cable Replacement (R2 to RS3) 1. If there is an optional module on Flat B, remove the two M6 socket head cap screws securing the module(s) to the Tool Changer body. Refer to Figure 5.6 2.

  • Page 33: Serviceable Parts

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 6. Serviceable Parts 6.1 Common Master Parts Common Master Parts ITEM PART NUMBER DESCRIPTION 9121-1510xM-0-0-0-0 Complete QC-1510 Master Plate, No Options 9005-20-1569 Alignment Pin, Two Piece, 1-1/8” Dia., Stepped Notes: x = A, B, C, D, E, or F for boss size designation.

  • Page 34: Models 9121-1510Xm-0-0-0-0-Sl And 9121-1510Xm-0-0-0-0-Se

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 6.2 Models 9121-1510xM-0-0-0-0-SL and 9121-1510xM-0-0-0-0-SE 9121-1510xM-0-0-0-0-SL ITEM PART NUMBER DESCRIPTION 8590-9909999-34 True 2 PNP Proximity Sensor 9005-20-1604 QC-1510 Master Junction Module Assembly,Potted 9005-20-1613 Lock/Unlock Sensor Assembly, QC-1510 (PNP) 9121-1510xM-0-0-0-0-SE ITEM PART NUMBER DESCRIPTION 8590-9909999-120...

  • Page 35: Cables For Models 9121-1510Xm-0-0-0-0-Sl And 9121-1510Xm-0-0-0-0-Se

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 6.3 Cables for Models 9121-1510xM-0-0-0-0-SL and 9121-1510xM-0-0-0-0-SE 9121-1510xM-0-0-0-0-SL ITEM PART NUMBER DESCRIPTION CONNECTIONS L1 to L1, U1 to U1, 9120-C-3M5F- Cordset, Pentafast 3-Pin Straight Female to Picofast 3-Pin 3PM90-0020 Male Right Angle Threaded to, 0.2 m L3 to L3, U3 to U3 L2 to L2, 9120-C-3M5F-...

  • Page 36: Tool Plate

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 6.4 Tool Plate Tool Plate ITEM NO. PART NUMBER DESCRIPTION 9121-1510xT-0-0-0-0 QC-1510 Base Tool Assembly, No Options 9005-20-1605 QC-1510 Tool Junction Module Adapter Assembly Notes: x = A, B, C, D, E, or F for boss size designation. Pinnacle Park •...

  • Page 37: Specifications

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 7. Specifications Master and Standard Tool Plates Table 5.1—Specifications Recommended Max Payload 2980 lbs. (1350kg) The mass attached to the Tool Changer. -20–150°F Operating Temperature Range (-30–66°C) Locking mechanism supply pressure 70–100 psi Operating Pressure Range operating range.

  • Page 38: Drawings

    Manual, Tool Changer, QC-1510 Document #9620-20-B-1510 Series Base Tool Changer-07 8. Drawings Drawings are available on the or by contacting an ATI representative. ATI website Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: +1 919-772-0115 • Fax: +1 919-772-8259 • www.ati-ia.com B-38...