Engineered Products for Robotic Productivity
Pinnacle Park • 1041 Goodworth Drive • Apex, NC 27539 USA • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com
Robotic Tool Changers
QC-5 through QC-27
Manual
Document #: 9610-20-2254
Page 1: ...ed Products for Robotic Productivity Pinnacle Park 1041 Goodworth Drive Apex NC 27539 USA Tel 919 772 0115 Fax 919 772 8259 www ati ia com Robotic Tool Changers QC 5 through QC 27 Manual Document 9610...
Page 2: ...ject to change without notice This manual is periodically revised to reflect and incorporate changes made to the product The information contained herein is confidential and reserved exclusively for t...
Page 3: ...Installation 21 3 7 1 QC 5 and QC 11 Simple Electrical Module Installation 21 3 7 2 QC 5 and QC 11 Simple Electrical Module Removal 21 3 7 3 QC 5 and QC 11 Master Electrical Module Installation 22 3...
Page 4: ...stment Test or Replacement 46 6 2 2 QC 20 and QC 21 Proximity Sensor Adjustment Test or Replacement 49 6 2 3 Rubber Bushing Inspection and Replacement 52 6 2 4 QC 27M Alignment Pin Replacement 53 6 2...
Page 5: ...to the Master plate locking mechanism to force the cam to press the locking balls against the bearing race and lock the Master and Tool plates together Lock Port A pneumatic port on the Master plate t...
Page 6: ...f the Master plate Tool plate The half of the Tool Changer to which various tools or end effectors are mounted Tool Stand A stand that holds the Tools not being used by the robot Trip Dog A physical d...
Page 7: ...ation can emphasize but is not limited to specific grease types best operating practices and maintenance tips 1 2 General Safety Guidelines Prior to purchase and installation the customer should verif...
Page 8: ...can occur with the Tool not placed and energized circuits on Place the Tool in the tool stand turn off and discharge all energized circuits purge all pressurized connections and verify all circuits a...
Page 9: ...er Models and Features Model Payload Flats Plate Pneumatic Ports Part No QC 5 18 lbs 1 Flat Master 6 M5 X 0 8 Pass through ports 2 M5 X 0 8 Lock Unlock air ports 9120 005M 000 0001 Tool 6 M5 X 0 8 Pas...
Page 10: ...8 BSPT Pass through ports 9120 021T 000 000 R2 QC 27 83 lbs 1 Flat for K series modules Master 8 1 8 NPT Pass through ports 2 M5 X 0 8 Lock Unlock air ports 9120 027M 000 000 SQx yyyy2 5 6 Master 8 G...
Page 11: ...th bushings to ensure repeatable alignment during the coupling process An extreme pressure grease is applied to the cam male coupling ball bearings and pins to enhance performance and maximize the lif...
Page 12: ...ace Plate SIP The sensor interface plate SIP system provides locking mechanism position signals to the customer process controller These signals indicate 2 possible conditions for the Tool Changer Mas...
Page 13: ...vailable from ATI upon request Refer to Section 3 4 Tool Interface Plate for more information All fasteners used to mount the Tool Changer to the robot and to customer s tooling should have pre applie...
Page 14: ...Do not use fasteners that exceed the thread depth in the Tool Changer s robot or tool side Refer to Section 9 Drawings for details on the mounting hole thread depth Secure the Tool Changer with the p...
Page 15: ...erface plate and boss in the Master plate A boss and 2 dowel pins can be difficult to align and cause damage to the Master Plate Incorrect Mounting of the Master Plate equipment Correct size dowel pin...
Page 16: ...sm during shipment Depending on the Master and interface plate configuration remove the cover plate or install an interface plate to the cover plate Refer to Figure 3 2 Tools required 2 mm 2 5 mm and...
Page 17: ...plate in place must be removed before installation 5 If equipped connect the Lock and Unlock sensor cables 6 Position and install the Master plate to the interface plate Refer to Figure 3 2 Refer to T...
Page 18: ...ol plates 3 Turn off and de energize all energized circuits e g electrical air water etc 4 Disconnect all utilities e g electrical air water etc 5 Disconnect the Lock and Unlock sensor cables 6 Remove...
Page 19: ...ate and Tool Boss and two dowel pins as alignment features can be difficult to align and can damage equipment Gap Incorrect Mounting of Tool Plate single dowel pin along with a If the customer chooses...
Page 20: ...rs with pre applied adhesive refer to Table 3 1 for proper thread engagement torque and thread locker Note Mounting fasteners are supplied with ATI custom tool interface plates 3 Connect utilities to...
Page 21: ...odule as desired 5 Clean the mounting surfaces 6 Align the module to the flat of the Master or Tool plate assembly 7 Apply Loctite 222 to M3 socket head cap screws 8 Secure the module with 2 M3 socket...
Page 22: ...10 Attach the module to the cover using the 2 long and 2 short M3 socket flat head cap screws using a 2 5 mm hex key Tighten to 48 in oz 0 34 Nm 11 Remove all protective caps plugs tape etc from the m...
Page 23: ...24 in oz 0 17 Nm 10 Apply Loctite 222 to the 2 screw locks 11 Attach the connector to the module using the 2 screw locks using a 3 16 wrench Tighten to 24 in oz 0 17 Nm 12 Remove all protective caps p...
Page 24: ...2 to the M3 socket head cap screws 7 Secure the module with 2 M3 socket head cap screws using a 2 5 mm hex key Tighten to 10 in lbs 1 13 Nm 8 Remove all protective caps plugs tape etc from the module...
Page 25: ...adapter plate to flat B of the QC 21 Master or Tool plate 6 Apply Loctite 222 to the 2 M4 socket flat head cap screws 7 Secure adapter plate to the Tool Changer with 2 M4 socket flat head cap screws...
Page 26: ...ing interface plate For interface plate installation refer to Section 3 2 Master Plate Installation The SIP assembly comes partially assembled the Lock and Unlock sensors are assembled to the proper p...
Page 27: ...make sure it is present as shown in Figure 3 10 Figure 3 10 QC 11 Sensor Plate Assembly with Lock Unlock Sensors and O ring O ring Sensor Plate Assembly 7 Press the detection shaft into the sensor pla...
Page 28: ...bs 1 36 Nm Figure 3 12 QC 11 Sensor Plate Assembly Installation Tool Changer Master Plate 3 mm Hex Key 2 5 mm Hex Key 12 Look straight into the sensor plate assembly and verify the detection shaft doe...
Page 29: ...hen the Tool Changer is in the Locked position c Verify that the Unlocked signal turns ON and the sensor LED is illuminated when the Tool Changer is in the Unlocked position d If not adjust and test t...
Page 30: ...the Master plate is present and in good condition lubricate with Magnalube if needed Figure 3 14 QC 20 and QC 21 Cover Plate Removal Cover Plate O ring Tool Changer Master Plate M3 Socket Flat Head Sc...
Page 31: ...the M3 socket head cap screw with O ring through the detection shaft Thread the M3 socket head cap screw into the piston 12 Place the sensor plate assembly into the appropriate location on the Tool C...
Page 32: ...nel from flying debris Always install an interface plate and have the Tool Changer mounted securely to the robot before applying air pressure Refer to Section 3 1 Robot Interface Plates and Section 3...
Page 33: ...ated air with the following conditions Pressure range 60 100 psi 4 1 6 9 Bar Filter minimum 40 microns Flow maximum 1 3 CFM at 70 psi 4 8 Bar when cycled continuously 3 9 2 Valve Requirements and Conn...
Page 34: ...Supply Clean Dry Non lubricatedAir 60 100 psi 4 1 6 9 Bar Exhaust Open to Atmosphere LockPort UnlockPort 3 10 Electrical Connections The optional Lock and Unlock sensors are available in PNP and NPN t...
Page 35: ...ock Sensors The NPN Lock and Unlock sensors are 4 mm cylindrical inductive proximity sensor Table 3 3 NPN Current Sinking Description Value Voltage Supply Range 10 30 VDC Output Current 100 mA Nominal...
Page 36: ...epresentative for specific requirements for custom applications The robot should be programmed to minimize misalignment during coupling and uncoupling Additionally the tool stand should be durable and...
Page 37: ...ess is complete before moving the robot CAUTION If air pressure is lost during operation ATI s patented fail safe design prevents the Tool plate from being released Do not use the Tool Changer in a fa...
Page 38: ...sition only 3 A sufficient delay must be programmed between unlocking valve actuation and robot motion so that the unlocking process is complete and the Tool plate is fully released before moving the...
Page 39: ...n in excess of the offsets Ideally the tool should be hanging vertically in the tool stand so that gravity assists to uncouple the Tool plate from the Master plate during unlocking It is possible to d...
Page 40: ...ced and energized circuits on Place the Tool safely in the tool stand turn off and discharge all energized circuits purge all pressurized connections verify all energized circuits are de energized bef...
Page 41: ...ing and Lubrication of the Locking Mechanism and Alignment Pins Inspect for excessive alignment pin bushing wear that may be an indication of poor robot position during pickup drop off Adjust robot po...
Page 42: ...uple the Master and Tool plates 3 Turn off and de energize all energized circuits e g electrical air water etc 4 Use a clean rag to thoroughly remove any lubricant and debris from the ball bearings ma...
Page 43: ...ral coating of lubricant to the ball bearings the male coupling inside and out and the alignment pins Figure 5 4 Apply Lubricant to Locking Mechanism Apply Lubricant on Inner Surface of Male Coupling...
Page 44: ...ld Debris Darkened Pins 5 If debris or darkened pins are present use a vacuum to remove the debris and clean using a nylon brush ATI Part Number 3690 0000064 60 NOTICE Do not use an abrasive media and...
Page 45: ...perly Refer to Section 3 9 Lock and Unlock Pneumatic and Valve Requirements Pneumatic connections are loose or damaged Refer to the air valve adapter manual for more information Debris is caught betwe...
Page 46: ...a secure location 2 Uncouple the Master and Tool plates 3 Test the sensors a If you are testing the Lock sensor make sure the Tool Changer is in the Locked position If you are testing the Unlock sens...
Page 47: ...rify the detection shaft does not touch the Lock and Unlock sensors If the sensors touch the shaft adjust the sensor position Figure 6 4 Verify Sensor and Detection Shaft Clearance Tool Changer Master...
Page 48: ...e to the interface plate For a QC 11 secure the Master plate to the interface plate using the 4 M3 socket head cap screws using a 2 5 mm hex key Tighten to 10 in lbs 1 13 Nm For a QC 27 secure the Mas...
Page 49: ...2 1 Place the Tool in a secure location 2 Uncouple the Master and Tool plates 3 Confirm operation of the replaced sensor a If you are testing the Lock sensor make sure the Tool Changer is in the Locke...
Page 50: ...6 5 QC 20 and QC 21 Replace Proximity Sensor Proximity Sensor Sensor Interface Plate SIP Hex Nut 4 M4 Socket Flat Head Cap Screws QC 21 Master Plate Shown Detection Shaft 8 On the new sensor back the...
Page 51: ...re operating the locking mechanism 11 Holding the sensor in position apply Loctite 222 to the proximity sensor threads between the hex nut and the Master plate assembly Tighten the hex nut using a 6 m...
Page 52: ...urn off and de energize all energized circuits e g electrical air water etc 4 Remove the damaged rubber bushing by grasping with your fingers and pulling the bushing out of the body 5 Dip the new bush...
Page 53: ...8 6 Models QC 27 Serviceable Parts Supplies required Loctite 242 MobilGrease XHP222 Special is a NLGI 2 lithium complex grease with molybdenum disulfide 1 Place the Tool in a secure location 2 Uncoupl...
Page 54: ...ccess to the Master and Tool plates 2 Turn off and de energize all energized circuits e g electrical air water etc 3 To remove the existing seal pinch edge of seal with fingers and gently pull the sea...
Page 55: ...750 lbf in 84 7 Nm Recommended Max Torque about Z Mz 150 in lbs 16 9 Nm 110 lbf in 12 4 Nm 690 in lbs 78 Nm 690 in lbs 78 Nm 880 in lbs 99 4 Nm Positional Repeatability 0 0004 0 0102 mm 0 0004 0 0102...
Page 56: ...following items are commonly used as spare parts for the QC 5 through QC 27 Tool Changers 8 1 Models QC 5 Serviceable Parts 3 2 1 4 QC 5 Master plate Item No Qty Part Number Description 1 1 9120 005M...
Page 57: ...1 Tool Assembly No Options Orange Anodized 9120 011T 000 000 B QC 11 Tool Assembly No Options Black Anodized SIP Assemblies 5 2 3500 1957030 11 SSCR M3 x 3 NYLON TIP PNP Sensors 9120 011M 000 000 SQ y...
Page 58: ...s Orange Anodized 9120 020T 000 PM5 B QC 20 Tool 12 air ports no options Black Anodized 9120 020T 000 PM5 C QC 20 Tool 12 air ports no options Clear Anodized 4 12 4010 0000014 02 M5 Rubber Bushing Nit...
Page 59: ...o Options Orange Anodized 9120 020T 000 P16 B QC 20 Tool 16 Ports No Options Black Anodized 4 16 4010 0000014 02 M5 Rubber Bushing Nitrile SIP Assemblies PNP Sensors 9120 020M 000 P16 SQ yyyy 9120 020...
Page 60: ...e 4 1 9120 021T 000 000 QC 21 Tool no options Orange Anodized 9120 021T 000 000 B QC 21 Tool no options Black Anodized 9120 021T 000 000 E QC 21 Euro Tool no options Black Anodized 9120 021T 000 000 R...
Page 61: ...1 Socket Set Screw M3 x 3 Nylon Tip QC 27 Tool plate 7 1 9120 027T 000 000 QC 21 Tool no options Orange Anodized 9120 027T 000 000 E QC 21 Euro Tool no options Black Anodized Sensor Options 9120 027M...
Page 62: ...nterface M5 Lock Port M5 Unlock Port Master Side w Cover Plate projection only Part Numbers Shown A Master 9120 005M E2A 000 B Tool 9120 005T E2A 000 Notes 1 Master mounting hardware provided 2 Cover...
Page 63: ...X Thru Hole for M3 x 25 SHCS Provided Equally Spaced Customer Interface M5 Unlock Port M5 Lock Port Master Side projection only Part Numbers Shown A Master 9120 011M A15 000 B Tool 9120 011T A15 000 N...
Page 64: ...erface plate provides sealing The recommended interface plate bore depth without a cover plate is 2 5mm with a cover plate is 5 6mm 3 Orientation marks are provided to assist in robot teaching 4 Shown...
Page 65: ...ster 9120 021M K19 000 B Tool 9120 021T K19 000 Notes 1 Master mounting hardware provided 2 Cover plate is not necessary if robot interface plate provides sealing The recommended interface plate bore...
Page 66: ...e Notes Master side mounting hardware is provided 1 Cover plate is not necessary if robot interface plate provides sealing The 2 recommended interface plate bore depth without a cover plate is 2 5mm w...
Page 67: ...NOTES UNLESS OTHERWISE SPECIFIED DO NOT SCALE DRAWING ALL DIMENSIONS ARE IN MILLIMETERS DRAWN BY CHECKED BY D Swanson 11 02 15 D Wagner 11 5 15 TITLE SCALE SIZE DRAWING NUMBER PROJECT SHEET OF 9630 20...
Page 68: ...ISE SPECIFIED DO NOT SCALE DRAWING ALL DIMENSIONS ARE IN MILLIMETERS DRAWN BY CHECKED BY D Swanson 11 02 15 D Wagner 11 5 15 TITLE SCALE SIZE DRAWING NUMBER PROJECT SHEET OF 9630 20 021 E 02 PROPERTY...
Page 69: ...e Projection Only Revision Table Rev Description Initiator Date 03 Eco 14758 9120 027M 000 000 S0 was 9120 027HM 000 000 E 6160 9120 027T 000 000 was 9120 027T 000 000 E LJH 8 19 2016 ITEM NO QTY PART...
Page 70: ...IFIED DO NOT SCALE DRAWING ALL DIMENSIONS ARE IN MILLIMETERS DRAWN BY CHECKED BY D Bohle 07 28 14 K Zachary 07 31 14 TITLE SCALE SIZE DRAWING NUMBER PROJECT SHEET OF 9630 20 027 140722 1 02 PROPERTY O...
Page 71: ...LE DRAWING ALL DIMENSIONS ARE IN MILLIMETERS DRAWN BY CHECKED BY D Bohle 07 28 14 K Zachary 07 31 14 TITLE SCALE SIZE DRAWING NUMBER PROJECT SHEET OF 9630 20 027 140722 1 02 PROPERTY OF ATI INDUSTRIAL...
Page 72: ...arranty and limitation of remedy provisions contained herein is authorized by ATI and may not be relied upon as having been authorized by ATI unless in writing and signed by an executive officer of AT...
