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ATI Technologies QC-835 Series Manual

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Manual, Tool Changer, QC-835
Document #9620-20-B-835-06
B. Base Tool Changer ..................................................................................................................B-3
QC-835 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 for ISO 9409-1-125-10-M10 ............................................................. B-8
2.2
Master Plate Installation for ISO 9409-1-160-10-M10 ............................................................. B-9
2.3
Master Plate Installation for ISO 9409-1-160-10-M12 ............................................................. B-9
2.4
Master Plate Removal ............................................................................................................. B-10
2.5
Tool Interface ............................................................................................................................B-11
2.6
Tool Plate Installation (Bolt Down) ........................................................................................ B-12
2.7
Tool Plate Removal (Bolt Down) ............................................................................................ B-12
2.8
Tool Plate Installation (Bolt Up) ............................................................................................. B-13
2.9
Tool Plate Removal (Bolt Up) ................................................................................................. B-14
2.11 Electrical Connections ............................................................................................................ B-16
3.
Operation .............................................................................................................................B-16
3.1
Conditions for Coupling ......................................................................................................... B-18
3.2
Fail-Safe Operation ................................................................................................................. B-19
3.3
Conditions for Uncoupling ..................................................................................................... B-20
3.4
Tool Identification .................................................................................................................... B-20
3.5
Tool Storage Considerations ................................................................................................. B-21
4.
Maintenance .........................................................................................................................B-22
4.1
Preventive Maintenance ......................................................................................................... B-23
4.2
5.
Troubleshooting and Service Procedures ........................................................................B-27
5.1
Troubleshooting Procedures ................................................................................................. B-27
5.2
Service Procedures ................................................................................................................. B-29
5.2.1
Sensor Replacement Procedures .................................................................................B-29
5.2.2
Alignment Pin Replacement ..........................................................................................B-34
5.2.3
Master Side Self-Sealing Valve .....................................................................................B-36
5.2.4
Tool Side Self-sealing Valve ..........................................................................................B-39
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-835 Series

  • Page 1: Table Of Contents

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 Table of Contents B. Base Tool Changer ........................B-3 QC-835 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 for ISO 9409-1-125-10-M10 ............. B-8 Master Plate Installation for ISO 9409-1-160-10-M10 .............
  • Page 2 Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 5.2.5 V-ring Seal Replacement ....................B-40 Serviceable Parts ........................B-41 Master Plate Fastener Kits ..................... B-41 Master Plate Common Parts ....................B-43 Models 9128-835xM-0-0-0-0-SM ..................... B-44 Standard Tool Plate ........................ B-45 Specifications ........................B-46 Drawings ..........................B-47 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‑835 Document #9620‑20‑B‑835‑06 B. Base Tool Changer QC-835 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‑835 Document #9620‑20‑B‑835‑06 1.1 Master Plate Assembly • 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‑835 Document #9620‑20‑B‑835‑06 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‑835 Document #9620‑20‑B‑835‑06 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 (e.g. 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 Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 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 in Table 2.1. Table 2.1—Fastener Size, Class, and Torque Specifications Material (of Robot, ISO Standard...

  • Page 8: Master Plate Installation For Iso 9409-1-125-10-M10

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 2.1 Master Plate Installation for ISO 9409-1-125-10-M10 Tools required: 8 mm hex key, toque wrench Supplies required: Clean cloth, Loctite 242 1. Use a 8 mm hex key to remove the (10) M10 x 45 socket head cap screws and hex nuts from the 125 mm bolt circle pattern on the QC‑835 Tool Changer.

  • Page 9: Master Plate Installation For Iso 9409-1-160-10-M10

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 2.2 Master Plate Installation for ISO 9409-1-160-10-M10 Tools required: 8 mm hex key, toque wrench Supplies required: Clean cloth, Loctite 242 1. Wipe down the mounting surfaces with a clean rag. 2. Insert a 10 mm dowel pin into the 10 mm dowel pin hole on the robot mounting side of the Master plate. 3.

  • Page 10: Master Plate Removal

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 Figure 2.4—Typical Master Plate Installation robot arm (1) 12 mm dowel pin QC-835 Master plate (1) boss (10) M12 socket head cap screw 2.4 Master Plate Removal Tools required: 8 mm or 10 mm hex key 1.

  • Page 11: Tool Interface

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 2.5 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 12: Tool Plate Installation (Bolt Down

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 2.6 Tool Plate Installation (Bolt Down) Tools required: 8 mm hex key, torque wrench Supplies required: Clean cloth, Loctite 242 1. Wipe down the mounting surfaces with a clean rag. 2. Insert (1) 10 mm dowel pin in the 10 mm dowel pin hole on the customer tool side of the Tool plate. 3.

  • Page 13: Tool Plate Installation (Bolt Up

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 2.8 Tool Plate Installation (Bolt Up) Tools required: 6 mm hex key for M10 socket flat head cap, 8 mm hex key for M10 socket head cap or M12 socket flat head, 10 mm hex key for M12 socket head cap, torque wrench Supplies required: Clean cloth, Loctite 242 1.

  • Page 14: Tool Plate Removal (Bolt Up

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 2.9 Tool Plate Removal (Bolt Up) Tools required: 6 mm hex key for M10 socket flat head cap, 8 mm hex key for M10 socket head cap or M12 socket flat head, 10 mm hex key for M12 socket head cap 1.

  • Page 15: Pneumatic Connection And Valve Requirement For The Locking Mechanism

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 2.10 Pneumatic Connection and Valve Requirement For the Locking Mechanism Air should be supplied at 60 to 100 psi (4.5 ‑ 6.9 Bar) and filtered to ISO 8573‑1:2010 {7:4:4}. To lock or unlock the Tool Changer, a constant supply of compressed air is required. If there is a loss of air pressure in the locked state, the cam profile prevents the master plate and tool plate from unlocking, and the Tool Changer goes into the fail‑safe condition.

  • Page 16: Electrical Connections

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 2.11 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. 2.11.1 PNP Type Lock and Unlock Sensors (-SM sensor designation) This section applies to the following part number designators: (‑SM).
  • Page 17 Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 Figure 3.1—Offset Definitions Master Plate Tool Plate Cocking Offset (About X and Y) X, Y, and Z Offset Twisting Table 3.1—Maximum Recommended Offsets Prior to Coupling No-Touch Zone Z X and Y Offset Cocking Offset Twisting Offset Offset Model...

  • Page 18: Conditions For Coupling

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 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 the locking mechanism is in locked position.

  • Page 19: Fail-Safe Operation

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 6. If equipped with lock and unlock sensors, the lock signal should read “ON” (true) and the unlock signal should read “OFF” (false). NOTICE: The locking mechanism must be in the unlock state before another attempt is made to couple or damage could occur to the robot and/or the Tool Changer.

  • Page 20: Conditions For Uncoupling

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 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 21: Tool Storage Considerations

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 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 22: Maintenance

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 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 23: Preventive Maintenance

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 4.1 Preventive Maintenance A visual inspection and preventive maintenance schedule is provided in table below. Detailed assembly drawings are provided in Section 7—Specifications of this manual. Refer to module sections for detailed preventive maintenance steps for all utility modules.

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

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 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 25 Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 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 4.3—Check Ball Bearing Movement 7.
  • Page 26 Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 8. Use a clean rag to thoroughly remove any lubricant and debris from the Tool plate bearing race and bushings. NOTICE: No application of lubrication is necessary on the Tool plate components. 9. Safely resume normal operation. Figure 4.5—Clean Tool Plate Surfaces of Locking Mechanism Clean Bushing Surfaces Clean Bearing Race...

  • Page 27: Troubleshooting And Service Procedures

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 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 28 Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 Table 5.1—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 29: Service Procedures

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 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 30 Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 6. To replace the lock, unlock, and RTL (R2) sensors: Remove modules from Flat D (refer to the ATI module manual for removal instructions). b. Retaining tabs are flexible and can be bent to remove cable from channel. Figure 5.2—Remove Modules From Flat D and Tabs Remove modules from Flat D.
  • Page 31 Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 d. Replace the RTL (R2) sensor assembly: Use a 2 mm hex key to remove the M3 socket flat head cap screw. ii. Remove the sensor assembly. iii. Apply Loctite 222 to the threads of the M3 socket flat head cap screw. CAUTION: Thread locker applied to fasteners must not be used more than once.
  • Page 32 Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 4. Replace the RTL (R1) sensor: Retaining tabs are flexible and can be bent to remove cable from channel. b. Detach the RTL (R1) sensor connector from the control signal module. Figure 5.5—Bend Tabs From the Valve Module RTL (R1) connector (2) M3 socket flat head cap screwand tab...
  • Page 33 Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 Figure 5.6—RTL (R1) Sensor Assembly Replacement M3 socket flat head cap screw RTL (R1) Sensor valve module control and signal module 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.

  • Page 34: Alignment Pin Replacement

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 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 35 Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 Figure 5.9—Install the Alignment Pin Apply Loctite 242 to the alignment pin bore Apply Loctite 242 to the socket head cap screw 6. Use a clean cloth to remove debris from the alignment pin bore. 7.

  • Page 36: Master Side Self-Sealing Valve

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 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 37 Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 Figure 5.10—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: Lubricate the bore in the module housing with Magnalube G (Teflon/ Petroleum based grease).
  • Page 38 Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 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 39: Tool Side Self-Sealing Valve

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 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 40: V-Ring Seal Replacement

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 d. Replace components that are damaged or worn. 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.

  • Page 41: Serviceable Parts

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 6. Serviceable Parts 6.1 Master Plate Fastener Kits Figure 6.1—QC-835 Master Fastener Kit for BC125 Robot Mounting Pattern, 10.4mm Engagement Part Number Description 9128-835M-FK-E104A15A QC-835 Master Fastener Kit, BC125, 10.4mm Engagement Kit Contents 3500-1070060-15A SHCS, M10 X 60MM, ST 12.9, CPC, PRE-APP, DIN 912 ISO 4762 3540-0710025-11 DOWEL PIN, PULL OUT, 10MM X 25MM, ST 1050-1095, DIN 7979D-m6...
  • Page 42 Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 Figure 6.5—QC-835 Master Fastener Kit for BC160 Robot Mounting Pattern, 15mm Engagement Part Number Description 9128-835M-FK-E150B15A QC-835 Master Fastener Kit, BC160, 15mm Engagement Kit Contents 3500-1070055-15A SHCS, M10 X 55MM, ST 12.9, CPC, PRE-APP, DIN 912 ISO 4762 3700-20-11593 Hardened Flat Washer, 10.5mm ID, 18mm OD, 2mm Thick, 1095 Steel, Zinc Finish 3540-0710025-11...

  • Page 43: Master Plate Common Parts

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 6.2 Master Plate Common Parts Figure 6.7—Master Plate Common Parts Item No. Part Number Description Refer to Section 6.2—Models 9128‑835xM‑0‑0‑0‑0‑SM M8x25 Socket Head Cap Screw, 12.9, ISO4762/DIN912, Corrosion 3500-1068025-15A Protection Coating , YL M-spheres/IFI 525 3700-20-11494 SERIES 8 ALIGNMENT PIN, END TAP SS Spring 7/8 O.D, 15#/in, -LC055K1SS...

  • Page 44: Models 9128-835Xm-0-0-0-0-Sm

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 6.3 Models 9128-835xM-0-0-0-0-SM Figure 6.8—QC-835 Master Plates Item No. Part Number Description 9128-835xM-0-0-0-0-SM QC-835 Master and PNP lock/unlock and RTL Sensing, LED Cables Inductive Sensor, 16 x 8 x 4.7 (mm), PNP, .33m Potted Cable with 90 deg Male 8590-9909999-244 M8 3-Pin Connector, Sn = 2.00 mm QC-835 L/U Sensor Carrier Subassembly, Single-Screw, 0.677”...

  • Page 45: Standard Tool Plate

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 6.4 Standard Tool Plate Table 6.1—Standard Tool Plate Item No. Part Number Description 9128-835CT-0-0-0-0 QC-835 Tool Base Assembly, 100 mm Recess 3410-0001071-01 O-Ring 18 mm X 1 mm Buna-N D70 3610-6401501-21 SS Spring 14 mm O.D, 13.5#/in 3700-20-2303 Check valve on Tool F02/F04 3410-0001067-01...

  • Page 46: Specifications

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 7. Specifications Table 7.1—Master and Standard Tool Plates Recommended Max Payload 661 lbs (300kg) 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 47: Drawings

    Manual, Tool Changer, QC‑835 Document #9620‑20‑B‑835‑06 8. Drawings Drawings are available on the ATI website or by contacting an ATI representative. Drawing for tool changer QC‑835 is 9630‑20‑835. Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati‑ia.com B-47...

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