ATI Technologies QC‑1210 Series Manual
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ATI Technologies QC‑1210 Series Manual

Tool changer
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Manual, Tool Changer, QC-1210
Document #9620-20-B-1210 Series Base Tool Changer-11
B. Base Tool Changer ................................................................................................................B-3
QC-1210 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
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-15
3.3
Conditions for Uncoupling ..................................................................................................... B-16
3.4
3.5
Tool Storage Considerations ................................................................................................. B-17
4.
Maintenance .........................................................................................................................B-18
4.1
Preventive Maintenance ......................................................................................................... B-18
4.2
4.3
Pin Block Inspection and Cleaning ....................................................................................... B-21
5.
Troubleshooting and Service Procedures ........................................................................B-22
5.1
Troubleshooting Procedures ................................................................................................. B-22
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 •

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  • Page 1: Table Of Contents

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 Table of Contents B. Base Tool Changer ........................B-3 QC-1210 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 Interface .........................
  • Page 2 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 Service Procedures ......................... B-23 5.2.1 Lock and Unlock Sensor and Sensor Cable Replacement ...........B-23 5.2.2 Ready-to-Lock Sensor and Cable Replacement ............B-34 5.2.3 Seal Inspection and Replacement .................B-44 Serviceable Parts ........................B-45 Common Master Parts ......................

  • Page 3: Base Tool Changer

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 B. Base Tool Changer QC-1210 Series—Robotic Tool Changer 1. Product Overview The QC 1210 Robotic Tool Changer enhances the flexibility and reliability of a robotic cell by enabling a robot to change tooling automatically.

  • Page 4: Master Plate Assembly

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 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). The Master plate has (9) flat sides for mounting optional modules.

  • Page 5: Tool Plate Assembly

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 1.2 Tool Plate Assembly The Tool plate assembly includes an anodized aluminum body and hardened stainless steel bearing races. Flat A of the Tool plate is reserved for the tool‑side Control/Signal module and a valve spacer. The Tool plate has (6) flat sides for mounting additional modules (optional).

  • Page 6: Installation

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 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 3.1. Furthermore, removable (blue) Loctite 242 must be used on these fasteners.

  • Page 7: Master Interface

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 2.1 Master Interface The Master plate is typically attached to the robot arm. An interface plate can adapt the Master plate to a specific robot arm. Alignment features (dowel holes and bosses) accurately position and bolt holes secure the Master plate to the robot arm or an interface plate.

  • Page 8: Master Plate Installation

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 2.2 Master Plate Installation Tools required: 8 mm hex key Supplies required: Clean rag, Loctite ® 1. Make sure mounting surface of the Master plate and robot arm or interface plate are clean and free of debris.

  • Page 9: Tool Interface

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 2.4 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 10: Tool Plate Installation

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 2.5 Tool Plate Installation Tools required: 8 mm hex key Supplies required: Clean rag, Loctite 242 1. Make sure mounting surface of the Master plate and robot arm or interface plate are clean and free of debris.

  • Page 11: Pneumatic Connections

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 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‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 2.8 Electrical Connections A 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‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 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 air/valve adapter module to provide lock and unlock pressure to the locking mechanism.

  • Page 14: Conditions For Coupling

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 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.

  • Page 15: Fail-Safe Operation

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 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”...

  • Page 16: Conditions For Uncoupling

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 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 17: Tool Storage Considerations

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 3.5 Tool Storage Considerations NOTICE: Tool stand design is critical to the operation of the Tool Changer. Improperly designed tool stands can cause jamming and excessive wear of the Tool Changer components. Tool plates with customer tooling attached may be stored in a tool stand.

  • Page 18: Maintenance

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 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 (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 19: Cleaning And Lubrication Of The Locking Mechanism And Alignment Pins

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 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 20 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 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 5.3—Check Ball Bearing Movement 7.

  • Page 21: Pin Block Inspection And Cleaning

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 4.3 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 22: Troubleshooting And Service Procedures

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 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 (e.g.

  • Page 23: Service Procedures

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 5.2 Service Procedures Component replacement procedures are provided in the following section. 5.2.1 Lock and Unlock Sensor and Sensor Cable Replacement The proximity sensors are designed for reliability and therefore, should not require frequent replacement.
  • Page 24 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 5.2.1.1 Control Module to Junction Module Cable Replacement Refer to Figure 6.2 Parts required: Section 6—Serviceable Parts Tools required: 2 mm and 5 mm hex key, electrical tester Supplies required: Clean rag, Loctite 242 1.
  • Page 25 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 14. Secure the cables to Flat F using the (2) M3 socket flat head cap screws and (2) cable retaining tabs. Tighten to contact using a 2 mm hex key. 15.
  • Page 26 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 5.2.1.2 Lock\Unlock Sensor Assemblies (L1/U1) and Extension Cable Replacement Refer to Figure 6.5 Parts required: Section 6—Serviceable Parts Tools required: 2 mm, 2.5 mm, and 5 mm hex key, electrical tester Supplies required: Clean rag, Loctite 242 1.
  • Page 27 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 12. Install the new lock and/or unlock sensor assembly, routing the cable into the cable channel of the Tool Changer body. 13. Connect the lock and/or unlock sensor cable connectors to the proper extension cable on Flat C.
  • Page 28 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 25. Safely resume normal operation. 26. Confirm the operation of the unlock sensor by unlocking the Tool Changer and then checking to see if the unlock sensor cable LED is on. Figure 6.7—Unlock Sensor Cable LEDs Unlock (U) Green LED (Power)
  • Page 29 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 5.2.1.3 Lock and Unlock Sensor Assemblies (L2/U2) and Extension Cable Replacement Refer to Figure 6.9 Parts required: Section 6—Serviceable Parts Tools required: 2 mm, 2.5 mm and 5 mm hex key, electrical tester Supplies required: Clean rag, Loctite 242 1.
  • Page 30 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 14. Insert the lock and/or unlock sensor assembly into the Tool Changer body as shown Ensure that new O‑ring is in place before inserting sensor. Figure 6.9. 15. Secure the sensor assembly with the (2) M3 socket head cap screws using a 2.5 mm hex key.
  • Page 31 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 5.2.1.4 Lock and Unlock Sensor Assemblies (L3/U3) and Extension Cable Replacement Refer to Figure 6.12 Parts required: Section 6—Serviceable Parts Tools required: 2 mm, 2.5 mm and 5 mm hex key, electrical tester Supplies required: Clean rag, Loctite 242 1.
  • Page 32 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 11. Pull the sensor assembly straight out from the Tool Changer body. 12. 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 33 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 24. Safely resume normal operation. 25. Confirm the operation of the unlock sensor by unlocking the Tool Changer and then checking to see if the unlock sensor cable LED is on. Figure 6.13—Unlock Sensor Cable LEDs Unlock (U) Green LED (Power)

  • Page 34: Ready-To-Lock Sensor And Cable Replacement

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 5.2.2 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.
  • Page 35 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 5.2.2.1 RTL Sensor Replacement (RS1/RS2/RS3) Refer to Figure 6.18 Parts required: Section 6—Serviceable Parts Tools required: 1/2” hex key Supplies required: Clean rag, Loctite 222 1. Inspect the sensor cable for damage, check the cable continuity, check the cable connection.
  • Page 36 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 12. 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 37 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 5.2.2.2 RTL Cable Replacement (R1 to RS1/RS2) Refer to Figure 6.18 Parts required: Section 6—Serviceable Parts Tools required: 2 mm and 5 mm hex key Supplies required: Clean rag, Loctite 242 1.
  • Page 38 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 Figure 6.18—RTL Cable Replacement (R1 to RS1/RS2) Remove Module M6 Socket Head Cap Screws on Flat F M3 Socket Flat Head Screws M6 Socket Head Cap Screws Cable Retaining Tabs Remove Module on Flat E Cable Retaining Tabs...
  • Page 39 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 26. Install the (2) M6 socket head cap screws securing the module to the Tool Changer body using a 5 mm hex key. Tighten to 70 in‑lbs (7.9 Nm). 27. Connect all cable connection to corresponding connectors on the junction module, as previously marked.
  • Page 40 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 5.2.2.3 RTL Cable Replacement (R2 to RS3) Refer to Figure 6.20 Parts required: Section 6—Serviceable Parts Tools required: 2 mm and 5 mm hex key Supplies required: Clean rag, Loctite 242 1.
  • Page 41 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 12. Secure the cables to Flat B using the (2) M3 socket flat head cap screws and (2) cable retaining tabs. Tighten to contact using a 2 mm hex key. 13.
  • Page 42 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 5.2.2.4 Alignment Pin Replacement Refer to Figure 6.22 Figure 6.23 Parts required: Refer to Section 6—Serviceable Parts Tools required: 4 mm and 5 mm hex key, torque wrench Supplies required: Clean rag, MobilGrease XHP222, Loctite 242 1.
  • Page 43 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 4. Another approach would be to use the access hole in the back side of the Master plate. If not already removed, remove the Master plate refer to Section 2.3—Master Removal.

  • Page 44: Seal Inspection And Replacement

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 5.2.3 Seal Inspection and 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.

  • Page 45: Serviceable Parts

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 6. Serviceable Parts 6.1 Common Master Parts Table 6.2— Common Master Parts Item No. Part Number Description QC-1210 Master Base Assembly with No Options and NPN lock/ 9121-1210AM-0-0-0-0-0-0-SE unlock sensors with LED cables 9121-1210AM-0-0-0-0-0-0-SG REPLACED BY 9121-1210AM-0-0-0-0-0-0-SL QC-1210 Master Base Assembly with No Options and PNP lock/...

  • Page 46: Cables For Models 9121-1210Am-0-0-0-0-0-0-Sl And 9121-1210Am-0-0-0-0-0-0-Se

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 6.2 Cables for Models 9121-1210AM-0-0-0-0-0-0-SL and 9121-1210AM-0-0-0-0-0-0-SE Table 6.3—9121-1210AM-0-0-0-0-0-0-SL Item No. Qty Part Number Description Connections Cordset, Pentafast 3-pin Straight Female to Picofast L1 to L1, U1 to U1, 9120-C-3M5F-3PM90-0020 3-pin Male Right Angle Threaded to, 0.2 m L3 to L3, U3 to U3 Cordset, Pentafast 3-pin Straight Female to Picofast...

  • Page 47: Tool Plate

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 6.3 Tool Plate Table 6.5—Tool Plate Item No. Part Number Description 9121-1210AT-0-0-0-0-0-0 QC-1210 Base Tool Assembly, No Options 9005-20-1605 QC-1210 Tool Junction Module Adapter Assembly 3500-1066020-15A M6 x 20 mm socket head cap screws Blue Microspheres Pinnacle Park •...

  • Page 48: Specifications

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 7. Specifications Table 6.6—Master and Tool Plates 2980 lbs. Recommended Max Payload The mass attached to the Tool Changer. (1350kg) -20–150°F Operating Temperature Range Optimal operating temperature. (-30–66°C) Locking mechanism supply pressure 70–100 psi Operating Pressure Range operating range.

  • Page 49: Drawings

    Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 8. Drawings 8.1 QC-1210 Tool Changer Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati‑ia.com B-49...
  • Page 50 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati‑ia.com B-50...
  • Page 51 Manual, Tool Changer, QC‑1210 Document #9620‑20‑B‑1210 Series Base Tool Changer‑11 Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati‑ia.com B-51...

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