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ATI Technologies QC-850 Manual

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Manual, Tool Changer, QC-850
Document #9620-20-B-850-06
B. Base Tool Changer ..................................................................................................................B-3
QC-850 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 Plate Installation ........................................................................................................... B-7
2.2
Master Plate Removal ............................................................................................................... B-7
2.3
Tool Interface ............................................................................................................................. B-8
2.4
Tool Plate Installation (Bolt Down) .......................................................................................... B-9
2.5
Tool Plate Removal (Bolt Down) .............................................................................................. B-9
2.6
Tool Plate Installation (Bolt Up) ............................................................................................. B-10
2.7
Tool Plate Removal (Bolt Up) ..................................................................................................B-11
2.8
2.9
Electrical Connections ............................................................................................................ B-13
2.9.1
3.
Operation .............................................................................................................................B-14
3.1
Conditions for Coupling ......................................................................................................... B-15
3.2
Fail-Safe Operation ................................................................................................................. B-16
3.3
Conditions for Uncoupling ..................................................................................................... B-17
3.4
Tool Identification .................................................................................................................... B-17
3.5
Tool Storage Considerations ................................................................................................. B-18
4.
Maintenance .........................................................................................................................B-19
4.1
Preventive Maintenance ......................................................................................................... B-19
4.2
5.
Troubleshooting and Service Procedures ........................................................................B-22
5.1
Troubleshooting Procedures ................................................................................................. B-22
5.2
Service Procedures ................................................................................................................. B-24
5.2.1
Sensor Replacement Procedures .................................................................................B-24
5.2.2
Alignment Pin Replacement ..........................................................................................B-29
5.2.3
Master Side Self-Sealing Valve .....................................................................................B-31
5.2.4
Tool Side Self-sealing Valve ..........................................................................................B-34
5.2.5
V-ring Seal Replacement ...............................................................................................B-36
6.
Serviceable Parts ................................................................................................................B-37
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 •

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Summary of Contents for ATI Technologies QC-850

  • Page 1: Table Of Contents

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 Table of Contents B. Base Tool Changer ........................B-3 QC-850 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 Master Plate Installation ......................B-7 Master Plate Removal .......................
  • Page 2 Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 Master Plate Assembly ......................B-37 Master Fastener Kits ....................... B-37 Tool Plate Assembly ........................ B-39 Specifications ........................B-40 Drawings ..........................B-41 Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati‑ia.com...

  • Page 3: Base Tool Changer

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 B. Base Tool Changer QC-850 Series—Robotic Tool Changer 1. 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.

  • Page 4: Master Plate Assembly

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 1.1 Master Plate Assembly The QC‑850 Master plate assembly features: • An anodized aluminum body • A hardened stainless steel locking mechanism (a cam, male coupling, and chrome steel ball bearings) • Hardened steel alignment pins that mate with bushings on the Tool plate •...

  • Page 5: Tool Plate Assembly

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 1.2 Tool Plate Assembly The Tool plate assembly includes the following features: • An anodized aluminum body • A hardened stainless steel bearing race • Alignment bushings that mate with pins on the Master plate •...

  • Page 6: Installation

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 2. Installation 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 (for example: electrical, air, water, etc.) are turned off, pressurized connections are purged and power is discharged from circuits in accordance with the customer specific safety practices and policies.

  • Page 7: Master Plate Installation

    7. If equipped, connect the Lock, Unlock and RTL sensor connections. Figure 2.1—Master Plate Installation robot arm (1) 12 mm dowel pin (1) boss QC-850 Master plate (10) M12 socket head cap screw or use the larger counter bores for (10) M16 socket head cap screw 2.2 Master Plate Removal Tools required: 10 mm or 14 mm hex key 1.

  • Page 8: Tool Interface

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 2.3 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 to secure the Tool plate to customer tooling.

  • Page 9: Tool Plate Installation (Bolt Down

    6. If the installation is complete, the Tool plate may be put into normal operations. Figure 2.2—Bolt Down Tool Plate Installation (10) M12 socket head cap screw flat for tool stand module QC-850 Tool plate (2) 12 mm dowel pin (customer supplied) interface plate (customer supplied) 2.5 Tool Plate Removal (Bolt Down)

  • Page 10: Tool Plate Installation (Bolt Up

    Use either a 8 or 10 mm hex key to tighten the screws; for the recommended torque value, refer to Table 2.1. Figure 2.3—M12 Bolt Down Tool Plate Installation QC-850 Tool plate (10) hex nuts (customer supplied) (2) 12 mm dowel pin (customer supplied)

  • Page 11: Tool Plate Removal (Bolt Up

    Use either an 10 mm or 14 mm hex key to insert the screws into the customer tooling or interface plate and Tool plate; for the recommended torque value, refer to Table 2.1. Figure 2.4—M16 Bolt Down Tool Plate Installation QC-850 Tool plate (2) 12 mm dowel pin (customer supplied) interface plate (customer supplied)

  • Page 12: Pneumatic Connection And Valve Requirement For The Locking Mechanism

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 2.8 Pneumatic Connection and Valve Requirement For the Locking Mechanism Proper operation of the locking mechanism requires a constant supply of clean, dry, non‑lubricated air, with the following conditions: • Pressure range of 60 to 100 psi (4.1 ‑ 6.9 bar) Suggested 80 psi •...

  • Page 13: Electrical Connections

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 2.9 Electrical Connections The Tool Changer is available with integrated lock/unlock sensors. If the sensors are not used, plugs will be provided to seal the locking mechanism. 2.9.1 PNP Type Lock and Unlock Sensors (-SM and -SMA sensor designation) This section applies to the following part number designators: (‑M) (‑MA).

  • Page 14: Operation

    Model (Max) (Max) (Max) (Max) 0.06” ±0.08” QC-850 ±0.7° ±1° (1.5 mm) (2 mm) 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.

  • Page 15: Conditions For Coupling

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 3.1 Conditions for Coupling The following conditions should be considered when operating the Tool Changer. For more details about programming the robot, refer to the Operation section of the Control/Signal Module Manual. CAUTION: Do not attempt to couple the Tool Changer when in locked position. The locking mechanism must be in the unlock position when attempting to couple the Tool Changer.

  • Page 16: Fail-Safe Operation

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 6. A sufficient delay must be programmed between locking valve actuation and robot motion so that the locking process is complete before moving the robot. If equipped with Lock and Unlock sensors, the Lock signal should read “ON” (true) and the Unlock signal should read “OFF” (false). NOTICE: If the locking mechanism has been actuated and both the Lock and Unlock signals are OFF, then a “missed tool”...

  • Page 17: Conditions For Uncoupling

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 3.3 Conditions for Uncoupling Refer to your Air/Valve Adapter and/or Control/Signal Module Manual’s Operation section for operation during coupling/uncoupling. 1. Move the robot to position the Tool plate in the tool stand. The position for coupling and uncoupling are the same.

  • Page 18: Tool Storage Considerations

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 3.5 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 19: Maintenance

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 4. 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 (for example: electrical, air, water, etc.) are turned off, pressurized connections are purged and power is discharged from circuits in accordance with the customer specific safety practices and policies.

  • Page 20: Cleaning And Lubrication Of The Locking Mechanism And Alignment Pins

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 4.2 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins ® Supplies required: Clean rag, MobilGrease XHP222 Special Grease 1. Place the Tool in a secure location. 2. Uncouple the Master and Tool plates. 3.
  • Page 21 Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 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 2.11—Check Ball Bearing Movement 7.

  • Page 22: Troubleshooting And Service Procedures

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 5. Troubleshooting and Service Procedures The following section provides troubleshooting and service information to help diagnose conditions and repair the Tool Changer or control/signal module. 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 (for example: electrical, air, water, etc.) are turned off, pressurized connections are purged and power is discharged from circuits in accordance with the customer specific safety practices and...
  • Page 23 Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 Table 3.1—Troubleshooting Symptom Cause Resolution Re-teach the robot to bring the Master plate and Tool plate closer Ready-To-Lock together prior to attempting to lock. Refer to Section 3—Operation. (RTL) does not Ready-To-Lock (RTL) sensors Check that both RTL sensors and cables are not damaged and read “on”...

  • Page 24: Service Procedures

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 5.2 Service Procedures Component replacement procedures are provided in the following section. 5.2.1 Sensor Replacement Procedures NOTICE: The lock and unlock sensor assemblies are precision aligned and permanently assembled at the factory. Do not attempt to disassemble and rebuild. Parts required: Refer to Section 6—Serviceable Parts Tools required: 2 mm and 2.5 mm hex key, torque wrench...
  • Page 25 Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 6. To replace the lock, unlock, and RTL (R2) sensors: Remove modules from Flat D (refer to the ATI module manual for removal instructions). Figure 3.2—Remove Modules From Flat D and Tabs Remove modules from Flat D. control module RTL (R1) connector RTL (R2) connector...
  • Page 26 Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 Replace the RTL (R2) sensor assembly Use a 2 mm hex key to remove the M3 socket flat head cap screw and remove the sensor assembly. ii. Apply Loctite 222 to the threads of the M3 socket flat head cap screw. iii.
  • Page 27 Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 7. Replace the RTL (R1) sensor: Bend the tabs and remove the cable along the cable channel in the bottom of the valve module. Detach the RTL (R1) sensor connector from the control signal module. Figure 3.5—Bend Tabs From the Valve Module RTL (R1) connector (2) M3 socket flat...
  • Page 28 Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 d. Reroute the RTL (R1) cable through the channel along the valve module. Attach the cable connectors to the R1 connection on the control and signal module. Verify the sensor operates correctly. 8. Safely resume normal operation. Pinnacle Park •...

  • Page 29: Alignment Pin Replacement

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 5.2.2 Alignment Pin Replacement Parts required: Refer to Section 6—Serviceable Parts Tools required: 5 mm and 6 mm hex key, torque wrench Supplies required: Clean cloth, Loctite 242, MobilGrease XHP222 1. Place the Tool in a secure location. 2.
  • Page 30 Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 8. Apply Loctite 242 to the threads of the M8 socket head cap screw. CAUTION: Thread locker applied to fasteners must not be used more than once. Fasteners might become loose and cause equipment damage. Always apply new thread locker when reusing fasteners.

  • Page 31: Master Side Self-Sealing Valve

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 5.2.3 Master Side Self-Sealing Valve Parts required: Refer to Section 8—Drawings Tools Required: 2.5 mm hex key, torque wrench Supplies Required: Clean cloth, Magnalube G lubricant, Loctite 7649 primer, Loctite 222 1. Place the Tool in a secure location. 2.
  • Page 32 Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 Figure 3.9—Master Self-Sealing Valve Use a 2.5 mm hex key Valve Stem O-ring O-ring (face seal) Check valve piston U-cup seal (Open side down) Spring 10. Reinstall components: Install the non‑lubricated O‑ring (face seal) into the check valve. NOTICE: Do not lubricate the O-ring face seal until after installation.
  • Page 33 Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 g. Install the spring into the bore in the module housing. h. Seat the check valve on the spring. Apply Loctite 7649 primer and then Loctite 222 to the threaded end of the valve stem. NOTICE: To properly install the threaded end of the valve stem, the check valve must be pushed down flush with the mating surface of the Master plate.

  • Page 34: Tool Side Self-Sealing Valve

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 5.2.4 Tool Side Self-sealing Valve Parts required: Refer to Section 8—Drawings Tools required: 18 mm socket, torque wrench, open‑end wrench Supplies required: Clean cloth, Magnalube G lubricant 1. Place the Tool in a secure location. 2.
  • Page 35 Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 10. Install the spring into the bore of the Tool plate. 11. Lubricate both O‑rings with Magnalube G (Teflon/Petroleum based grease). 12. Place the larger O‑ring on the seat of the bore. 13. Install the smaller O‑ring in the groove of the check valve piston. CAUTION: Do not use excess force when installing the piston retainer cap into the Tool plate.

  • Page 36: V-Ring Seal Replacement

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 5.2.5 V-ring Seal Replacement Parts required: Refer to Section 6—Serviceable Parts 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.

  • Page 37: Serviceable Parts

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 6. Serviceable Parts 6.1 Master Plate Assembly 6.2 Master Fastener Kits Table 4.1—QC-850 Master Fastener Kit for ISO 9409-1-200-10-M12 Robot Mounting Pattern Description Part Number QC-850 Master Fastener Kit, BC 160 9128-850M-FK-E180B15A Kit Contents M12 X 55 socket head cap screw, class 12.9, ISO4762/DIN912, ES-ATI-007,...
  • Page 38 Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 Table 4.3—Master Plate Serviceable Parts Item No. Part Number Description QC-850 Base Master Assembly, no boss, and no options (sensors not 9128-850AMX -0-0-0-0 included) QC-850 Base Master Assembly, no boss, PNP Lock and Unlock sensors, 9128-850AMX-0-0-0-0-SM...

  • Page 39: Tool Plate Assembly

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 6.3 Tool Plate Assembly Table 4.4—Tool Plate Item No. Part Number Description 9128-850DT-0-0-0-0 Tool with 125 mm Recess and no other options 3690-0000090-50 tab/cable retainer, vinyl coated steel M3x6 flat socket head cap screw, class 10.9, ISO10642/DIN7991, ES‑ATI‑007, pre‑ 3500-1258006-15A applied adhesive (YL M-Spheres/IFI 525) Integrated Checked Air Valve Components...

  • Page 40: Specifications

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 7. Specifications Table 5.1—Master and Standard Tool Plates Recommended Max Payload 1540 lbs (700kg) The mass attached to the Tool Changer. -20–150°F Operating Temperature Range Optimal operating temperature range. (-30–66°C) Locking mechanism supply pressure operating range. 60–120 psi Supply to be clean, dry, and filtered to 50 micron or Operating Pressure Range...

  • Page 41: Drawings

    Manual, Tool Changer, QC‑850 Document #9620‑20‑B‑850‑06 8. Drawings Drawings are available on the ATI website or by contacting an ATI representative. Drawing for tool changer 850 is 9630‑20‑850. Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati‑ia.com B-41...

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