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Manual, Tool Changer, QC‑50
Document #9620‑20‑B‑50 Tool Changer‑04

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 •

www.ati‑ia.com

• Email:

info@ati‑ia.com

B-1

Table of Contents

B. Base Tool Changer ..................................................................................................................B-3

QC-50 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-8

2.3

Master Plate Removal ............................................................................................................... B-8

2.4

Tool Interface ............................................................................................................................. B-9

2.5

Tool Plate Installation ............................................................................................................. B-10

2.6

Tool Plate Removal ................................................................................................................. B-10

2.7

Optional Module with J16 Pattern Installation .......................................................................B-11

2.8

Optional Module with J16 Pattern Removal ...........................................................................B-11

2.9

Optional K Series Module Installation ................................................................................... B-12

2.10 Optional K Series Module Removal ....................................................................................... B-12

2.11 Pneumatic Connections and Valve Requirements ............................................................... B-13

2.11.1 Valve Requirements and Connections for the Locking Mechanism ..............................B-13

2.12 Electrical Connections ............................................................................................................ B-14

2.12.1 PNP Type Lock and Unlock Sensors .............................................................................B-14

2.12.2 NPN Type Lock and Unlock Sensors ............................................................................B-14

3. Operation .............................................................................................................................B-15

3.1

Conditions for Coupling ......................................................................................................... B-16

3.2

Fail-Safe Operation ................................................................................................................. B-17

3.3

Conditions for Uncoupling ..................................................................................................... B-18

3.4 Tool Identification

.................................................................................................................... B-18

3.5

Tool Storage Considerations ................................................................................................. B-19

4. Maintenance .........................................................................................................................B-20

4.1

Preventive Maintenance ......................................................................................................... B-20

4.2

Cleaning and Lubrication of the Locking Mechanism and Alignment Pins ....................... B-21

4.3

Pin Block Inspection and Cleaning ....................................................................................... B-23

Summary of Contents for QC-50 Series

Page 1: ...dule with J16 Pattern Installation B 11 2 8 Optional Module with J16 Pattern Removal B 11 2 9 Optional K Series Module Installation B 12 2 10 Optional K Series Module Removal B 12 2 11 Pneumatic Connections and Valve Requirements B 13 2 11 1 Valve Requirements and Connections for the Locking Mechanism B 13 2 12 Electrical Connections B 14 2 12 1 PNP Type Lock and Unlock Sensors B 14 2 12 2 NPN Typ...

Page 2: ...ce Procedures B 24 5 1 Troubleshooting Procedures B 24 5 2 Service Procedures B 25 5 2 1 Lock and Unlock Sensor Replacement B 25 5 2 2 Rubber Bushing Replacement B 26 5 2 3 Seal Inspection and Replacement B 27 5 2 4 Alignment Pin Replacement B 28 6 Serviceable Parts B 30 6 1 QC 50 Master Plates B 30 6 2 QC 50 Tool Plate B 31 7 Specifications B 32 8 Drawings B 33 8 1 QC 50 Tool Changer with Standar...

Page 3: ...p the customer tooling a pneumatically driven locking mechanism couples the 2 plates The patented fail safe locking mechanism utilizes a multi tapered cam with ball locking technology to ensure the Tool Changer does not uncouple if air pressure falls below 60 psi 4 1 bar during operation The robot can be programmed to select the desired customer tooling by coupling the Master plate to the Tool pla...

Page 4: ...y air pressure for coupling and uncoupling the Tool Changer The Master plate assembly is equipped with 16 M5 pass through air ports and 4 G 1 8 BSPP pass through air ports Figure 1 1 Master Plate Assembly 9120 050AM 0 0 0 0 SB E Shown 6 Ball Bearing Cam Male Coupling 2 Alignment Pin Lock Unlock 90 Elbows with Push Tube Fittings Internal Proximity Sensor Unlock Internal Proximity Sensor Lock 16 M5 ...

Page 5: ...ounting details Contact ATI for specification The Tool plate assembly is equipped with 16 M5 pass through air ports and 4 G 1 8 BSPP pass through air ports Figure 1 2 Tool Plate Assembly 2 Alignment Pin Bushing Bearing Race 4 G 1 8 BSPP Pass Through Air Port 16 M5 Pass Through Air Port 1 3 Optional Modules There are 4 flats available on both the Master and Tool for mounting optional modules with a...

Page 6: ...m circuits in accordance with the customer specific safety practices and policies Injury or equipment damage 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 are de energized before performing maintenance or repair s on the Tool Changer or modules CAU...

Page 7: ... plate to mount flush Two dowel pins or a single dowel pin along with a boss recess used as alignment features Flush Correct Mounting of Master Plate Master Plate Interface Plate Dowel pins that are too long can cause a plate and Master Plate gap between interface Optional Boss Gap Gap A boss and two dowel pins can be difficult to align and can cause damage to equipment Incorrect Mounting of Maste...

Page 8: ...rque NOTICE If an ATI interface plate is used fasteners to mount the Master plate are supplied with the interface plate 3 Connect utilities to the appropriate module and Master plate connections 4 Safely resume normal operation Figure 2 1 Master Plate Installation Robot Arm Master Plate Dowel Pin Customer Supplied M8 Socket Head Cap Screw Customer Supplied See Table 2 1 2 3 Master Plate Removal To...

Page 9: ...late 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 to design and build a tool interface plate consider the following points The interface plate should include bolt holes for mounting and either 2 dowel pins or a dowel pin and a boss for accurate pos...

Page 10: ...an ATI Interface Plate is used fasteners to mount the Tool plate are supplied with the Interface Plate 3 Connect utilities to the appropriate module and Tool plate connections 4 Safely resume normal operation Figure 2 2 Tool Plate Installation Tool Plate Dowel Pins Customer Supplied Hardware 6 M8 Socket Head Cap Screw See Table 2 1 for Torque Values Customer Supplied Hardware Tooling Interface Pla...

Page 11: ...ve apply Loctite 222 to 4 M4 socket head cap screws 7 Secure the module with 4 M4 mounting fasteners using a 3 mm hex key Refer to Table 3 1 for proper torque for your specific mounting fasteners 8 Remove all protective caps plugs tape etc from the module prior to operation 9 Safely resume normal operation Figure 2 3 Optional Module Installation Master Plate Assembly Tool Plate Assembly Fluid Air ...

Page 12: ...x key Refer to Table 2 1 for proper torque for your specific mounting fasteners Note To install the module on the Master the Master plate might have to be removed Refer to Section 2 3 Master Plate Removal 7 Remove all protective caps plugs tape etc from the module prior to operation 8 Safely resume normal operation Figure 2 4 Optional Module Installation Master Plate Tool Plate Electrical Module 9...

Page 13: ...and only requires the customer to supply a single air source to the valve adapter A customer supplied 2 position 4 way or 5 way valve with either 4 port or 5 port configuration must be used to actuate the locking mechanism in the Master plate It is imperative that when air is supplied to the Lock or Unlock Port on the Master plate that the opposite port be vented to atmosphere i e when air is supp...

Page 14: ... used on 9120 050AM 0 0 0 0 SB E and 9120 050AM 0 0 0 0 SB1 Table 2 2 PNP Current Sourcing Description Value Voltage Supply Range 10 30 VDC Output Circuit PNP make function NO Figure 2 6 PNP Type Lock Unlock and RTL Sensors 3 Blue Brown 1 4 Black Brown 1 Black 4 Blue 3 Vs Output 0 V PNP Z Connector PNP Current Sourcing 2 12 2 NPN Type Lock and Unlock Sensors Table 2 3 NPN Current Sinking Descripti...

Page 15: ...specialized lubricants might be required Coupling should occur with the Master plate in the No Touch locking zone As coupling occurs the Master plate should pull the Tool plate into the locked position Program the robot to minimize misalignment during coupling and uncoupling Greater offsets can be accommodated by the Master and Tool plates but will increase wear Misalignments can be caused by impr...

Page 16: ...ent pins should be relatively concentric with the alignment bushings with no contact between the two 3 It is recommended that the mating faces of the Master and Tool not be touching but be within the No Touch distance of each other when coupling to minimize stress and wear on the locking mechanism The locking mechanism allows the Master to pull up the Tool with gaps between the 2 sides CAUTION Dir...

Page 17: ...ded loss of lock air pressure to the Master plate When air pressure is lost the Tool Changer relaxes and there may be a slight separation between the Master and Tool plates The lock sensor may indicate that the unit is not locked ATI s patented fail safe feature utilizes a multi tapered cam to trap the ball bearings and prevent an unintended release of the Tool plate Positional accuracy of the too...

Page 18: ...noid valve turn the Unlatch output ON CAUTION This Tool Changer may be equipped with a tool stand Interlock TSI feature that physically breaks the Unlatch solenoid circuit Proper use of the TSI prevents unwanted Unlock software commands from being recognized until the circuit is made Make sure the Tool Changer is positioned properly to trip actuate the TSI switch when the Tool is in the tool stand...

Page 19: ...ed 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 design tool stands that hold tools in the horizontal position but the necessary compliance must be provided during coupling and uncoupling In general horizontal position tool stands cause more wear on the locking mechanism an...

Page 20: ...s Table 4 1 Maintenance Application s Tool Change Frequency Inspection Schedule General Usage Material Handling Docking Station 1 per minute Weekly 1 per minute Monthly Welding Servo Deburring Foundry Operations Dirty Environments All Weekly Checklist Mounting Fasteners г г Inspect fasteners for proper torque interferences and wear Tighten and correct as required Refer to Table 2 1 Fastener Size C...

Page 21: ...e the Tool in a secure location 2 Uncouple 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 male coupling cam and alignment pins Figure 4 1 Cleaning Ball Bearings and Outer Surfaces of Male Coupling 5 Use a clean rag to thoroughly remove any lubricant and ...

Page 22: ... a liberal coating of lubricant to the ball bearings the male coupling inside and out and the alignment pins Figure 4 4 Apply Lubricant to Locking Mechanism Apply lubricant on Alignment Pins and Outer Surface of Male Coupling Apply Lubricant on Inner Surface of Male Coupling 8 Use a clean rag to thoroughly remove any lubricant and debris from the Tool plate bearing race and bushings NOTICE No appl...

Page 23: ...ris Blackened 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 cleaners or solvents to clean the contact pins Using abrasive media cleaners or solvents will cause damage to the contact surface or cause pins to stick Clean contact surfaces with a vacuum or non abrasive me...

Page 24: ...erify proper air pressure and pneumatic valve is supplied Refer to Section 2 11 Pneumatic Connections and Valve Requirements Air pressure trapped in de energized Lock or Unlock ports Air pressure must be vented to the atmosphere properly refer to Section 2 11 Pneumatic Connections and Valve Requirements or refer to the troubleshooting section of the air valve adapter manual for more information Pn...

Page 25: ...he Tool Changer body 6 Discard the removed sensor CAUTION The Lock and Unlock sensor assemblies are precision aligned and permanently assembled at the factory Do not attempt to disassemble and rebuild Figure 5 1 Lock and Unlock Sensor Assembly Replacement Unlock Sensor Assembly Lock Sensor Assembly M3 Socket Head Cap Screw Spacer Assembly If required Module on Flat D M4 Socket Head Cap Screw Maste...

Page 26: ... Tool in a secure location 2 Uncouple the Master and Tool plates 3 Turn off and de energize all energized circuits for example electrical air water etc If required fully disconnect these circuits 4 Using needle nose pliers grasp the rubber bushing and pull it out of the Master body Refer to Figure 5 2 5 Lightly lubricate the new rubber bushing and push into the Master body refer to Figure 5 2 6 Sa...

Page 27: ...ure location 2 Uncouple the Master and Tool plates 3 Turn off and de energize all energized circuits e g electrical air water etc 4 To remove the existing seal pinch the edge of the seal and pull the seal away from the pin block on the Master module 5 To install a new seal stretch the new seal over the shoulder of the pin block 6 Push the seal hub down against the pin block 7 Safely resume normal ...

Page 28: ...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 air water etc If required fully disconnect these circuits 4 Clean off debris and excess grease from the Alignment pin 5 Unscrew the alignment pin assembly from the Master plate using a 2 5 mm hex key see Figure 5 4 If alignment pin cannot be removed using the...

Page 29: ...de of the Master plate by turning the alignment pin clockwise to drive the pin out the front of the plate Refer to Figure 5 5 Figure 5 5 Alternative Method Master Plate Alignment Pin 3 mm Hex Key Socket Rachet Wrench 7 Verify that the assembly pin and set screw are intact 8 Apply Loctite 242 and install the Alignment Pin Assembly into the Bushing on the Tool Changer Tighten to 60 in lbs 6 8 Nm 9 A...

Page 30: ... 2 Master Plate Item No Qty Part Number Description 1 1 9120 050AM 0 0 0 0 E QC 50 Master Assembly BSPP M5 Ports 2 2 3700 20 1373 Mono Alignment Pin QC 100 A2 3 16 4010 0000009 02 M5 Rubber Bushing Nitrile Light 5 4 4 4010 0000021 01 1 4 NPT Nitrile rubber bushing 9120 050AM 0 0 0 0 SB E 5 2 9005 20 1483 Carrier Assembly PNP 5M Cable 9120 050AM 0 0 0 0 SB1 E 5 2 9005 20 2457 Sensor Carrier PNP 4 m...

Page 31: ...4 Pinnacle Park 1031 Goodworth Drive Apex NC 27539 Tel 919 772 0115 Fax 919 772 8259 www ati ia com Email info ati ia com B 31 6 2 QC 50 Tool Plate 1 Table 5 3 Tool Plate Item No Qty Part Number Description 1 1 9120 050BT 0 0 0 0 E QC 50 Tool Assembly BSPP and M5 ...

Page 32: ...ax Moment X Y Mxy 2 000 in lbs 226 Nm Maximum recommended working load for optimum performance of the Tool Changer Recommended Max Torque about Z Mz 2 000 in lbs 226 Nm Maximum recommended working torque for optimum performance of the Tool Changer Positional Repeatability 0 0006 0 015 mm Repeatability tested at rated load at one million cycles Weight coupled no access 5 09 lb 2 3 kg Master 3 37 lb...

Page 33: ... specific configuration requirements 1 Locking mechanism components are hardened 440C stainless steel 2 Master and tool housings are soft coat black anodized aluminum 3 Elbow fittings are included for lock and unlock air 4 Unit features 16X M5 pass through air ports and 4X 1 8 BSPP pass through air ports 5 Unit features integrated lock and unlock sensing 6 Optional center alignment boss available ...

Page 34: ...EVISION NOTES UNLESS OTHERWISE SPECIFIED DO NOT SCALE DRAWING ALL DIMENSIONS ARE IN MILLIMETERS DRAWN BY CHECKED BY Dan Norton 10 31 14 B Kendrick 10 31 14 TITLE SCALE SIZE DRAWING NUMBER PROJECT SHEET OF 9630 20 050 140812 1 02 PROPERTY OF ATI INDUSTRIAL AUTOMATION INC NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI 1031 Goodworth Drive Apex NC 27539 ...

Page 35: ...SS OTHERWISE SPECIFIED DO NOT SCALE DRAWING ALL DIMENSIONS ARE IN MILLIMETERS DRAWN BY CHECKED BY Dan Norton 10 31 14 B Kendrick 10 31 14 TITLE SCALE SIZE DRAWING NUMBER PROJECT SHEET OF 9630 20 050 140812 1 02 PROPERTY OF ATI INDUSTRIAL AUTOMATION INC NOT TO BE REPRODUCED IN ANY MANNER EXCEPT ON ORDER OR WITH PRIOR WRITTEN AUTHORIZATION OF ATI 1031 Goodworth Drive Apex NC 27539 USA Tel 1 919 772 ...

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