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ATI Technologies QC‑300 Manual

Robotic tool changer
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QC‑300 Robotic Tool Changer
Manual
Document #: 9610‑20‑2363
Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati‑ia.com • Email: info@ati‑ia.com
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Summary of Contents for ATI Technologies QC‑300

  • Page 1 QC‑300 Robotic Tool Changer Manual Document #: 9610‑20‑2363 Engineered Products for Robotic Productivity Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati‑ia.com • Email: info@ati‑ia.com...

  • Page 2: Foreword

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 Foreword This manual contains basic information applicable to all ATI Tool Changer robotic Tool Changers. Certain Tool Changer models have their own manuals that contain more detailed information. Also, additional information about electrical, pneumatic, fluid, high‑power and high‑current modules and other options is available in other manuals and documents.

  • Page 3: Table Of Contents

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 Table of Contents Foreword ............................2 Glossary ............................5 Safety ............................6 1.1 Explanation of Notifications ......................6 General Safety Guidelines ......................6 Safety Precautions ........................7 Product Overview ........................8 Master Plate Assembly ......................... 9 Tool Plate Assembly ........................
  • Page 4 Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 Maintenance ..........................28 Preventive Maintenance ......................28 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins ......29 Optional Electrical Module Pin Block Inspection and Cleaning ..........31 Troubleshooting and Service Procedures ................32 Troubleshooting Procedures .....................

  • Page 5: Glossary

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 Glossary Definition Term The half of the Tool Changer that mounts to a robot. The Master plate contains Master plate the locking mechanism. The half of the Tool Changer to which various tools or end‑effectors are Tool plate mounted.

  • Page 6: Safety

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 1. Safety The safety section describes general safety guidelines to be followed with this product, explanation of the notification found in this manual, and safety precaution that apply to the product. More specific notification are imbedded within the sections of the manual where they apply.

  • Page 7: Safety Precautions

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 1.3 Safety Precautions WARNING: Remove all temporary protective materials (caps, plugs, tape, etc.) on locking face of Tool Changer and modules prior to operation. Failure to do so will result in damage to Tool Changers, modules, and end‑of‑arm tooling and could cause injury to personnel.

  • Page 8: Product Overview

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 2. 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. The Tool Changer consists of a Master plate, which is attached to the robot arm, and a Tool plate, which is attached to customer tooling.

  • Page 9: Master Plate Assembly

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 2.1 Master Plate Assembly The Master plate assembly includes an anodized aluminum body, a hardened stainless‑steel locking mechanism, and hardened steel alignment pins. The locking mechanism consists of a cam, a male coupling, and chrome‑steel ball bearings.

  • Page 10: Master Plate/Tool Plate Locking Mechanism

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 2.3 Master Plate/Tool Plate Locking Mechanism The coupling of the Master plate and the Tool plate is achieved through a patented, high‑strength, high‑repeatability, and stainless steel mechanism. During locking, steel balls in the Master plate are driven outward by a circular cam attached to a pneumatically actuated piston.

  • Page 11: Optional Sensor Interface Plate (Sip)

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 2.4 Optional Sensor Interface Plate (SIP) The sensor interface plate (SIP) system provides locking mechanism position signals to the customer’s process controller. These signals indicate (2) possible conditions for the Tool Changer Master plate: unlocked or locked.

  • Page 12: Installation

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 3. 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’s safety practices and policies.
  • Page 13 Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 The Master plate of the Tool Changer mounts to the robot arm using an interface plate or a SIP. Custom interface plates are available from ATI. Refer to Section 3.1—Master Interface Plate Section 2.4—Optional Sensor Interface Plate (SIP) for more information.

  • Page 14: Master Interface Plate

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 3.1 Master Interface Plate 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 15: Master Plate Installation

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 Figure 3.1—Interface Plate and SIP with Master Plate Configurations Dowel Pin Sensor Plate (Cover Plate Removed) O-ring Sensor Interface plate (SIP) Mounting Fastener (Supplied by Customer) Master Plate Boss Detection shaft Master Plate Body O-ring Cover Plate Removed Dowel Pin Cover Plate Left in Place Dowel Pin Boss...

  • Page 16: Master Plate Removal

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 3.3 Master Plate Removal Tools required: 10 mm Allen wrench 1. Place 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.

  • Page 17: Tool Interface Plate

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 3.4 Tool Interface Plate 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 secure the Tool plate to customer tooling.

  • Page 18: Tool Plate Installation

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 3.5 Tool Plate Installation Tools required: 10 mm Allen wrench, torque wrench Supplies required: Clean rag, Loctite 242 The end‑effector is typically attaches to the Tool plate with an interface plate, refer to Section 3.4—Tool for specific requirements for your application.

  • Page 19: Optional Module Installation

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 3.7 Optional Module Installation Tools required: 2.5 mm and 3 mm Allen wrench, torque wrench Supplies required: Clean rag, Loctite 222 The optional modules are typically installed on Tool Changers prior to shipment. The following steps outline installation and removal.

  • Page 20: Installing An Optional (Sip) Sensor Interface Plate Assembly

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 3.9 Installing an Optional (SIP) Sensor Interface Plate Assembly The optional sensor interface plate is typically installed on Tool Changers by ATI prior to shipment. The following steps outline installation. The sensor interface plate assembly includes a custom interface plate. This may replace the existing interface plate.
  • Page 21 Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 8. Apply tape over the threads of the detection shaft to protect the threads from grease contamination during assembly. 9. Lightly lubricate the detection shaft with Magnalube. 10. Carefully insert the taped detection shaft through the sensor plate assembly pushing it through until it stops.
  • Page 22 Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 Figure 3.8—Sensor Interface Plate Installation (Image for Reference Only) 3 mm Allen Wrench Master Plate Unlock Sensor Cable Lock Sensor Cable 5 mm Allen Wrench 17. Look into the sensor plate assembly to verify the detection shaft does not contact the lock and unlock sensors.

  • Page 23: Pneumatic Requirements

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 3.10 Pneumatic Requirements 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 24: Electrical Connections

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 3.11 Electrical Connections The Optional Lock and Unlock sensors are available in PNP and DC type. 3.11.1 PNP Type Lock and Unlock Sensors The PNP lock and unlock sensors are 8 mm cylindrical inductive proximity sensor. Table 3.2—PNP (Current Sourcing) Description Value...

  • Page 25: Operation

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 4. 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 to provide lock and unlock pressure to the locking mechanism. CAUTION: Safe, reliable operation of the Tool Changer is dependent on a continuous supply of compressed air at a pressure of 60 to 100 psi.

  • Page 26: Conditions For Coupling

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 4.1 Conditions for Coupling CAUTION: The locking mechanism must be in the unlock position when attempting to couple the Tool Changer. Failure to adhere to this condition may result in damage to the unit and/or the robot. 1.

  • Page 27: Uncoupling Sequence

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 4.3 Uncoupling Sequence 1. Position the Tool plate in the tool stand such that there is little or no contact force between the Tool plate and tool stand. 2. Release air on the Lock port and apply air to the Unlock Port (if equipped, the Unlock sensor will indicate the Tool Changer is in the Unlocked position).

  • Page 28: Maintenance

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 5. 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’s safety practices and policies.

  • Page 29: Cleaning And Lubrication Of The Locking Mechanism And Alignment Pins

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 5.2 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 30 Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 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 31: Optional Electrical Module Pin Block Inspection And Cleaning

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 5.3 Optional Electrical Module 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 (e.g. electrical, air, water, etc.). 4.

  • Page 32: Troubleshooting And Service Procedures

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 6. 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 33 Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 Table 6.1—Troubleshooting Symptom Cause Resolution Units Equipped with and Sensor Interface Plate Verify cable continuity, replace if necessary Unit is locked but Lock sensor/cable is Replace the lock sensor assembly as necessary. Refer Lock signal does damaged.

  • Page 34: Service Procedures

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 6.2 Service Procedures The following service procedures provide instructions for component replacement. 6.2.1 Proximity Sensor Adjustment, Test, or Replacement Parts required: Refer to Section 7—Serviceable Parts Tools required: 10 mm Allen wrench, 13 mm wrench Supplies required: Loctite 222 The proximity sensors are very reliable and normally do not need to be replaced.
  • Page 35 Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 Figure 6.1—Replace Proximity Sensor Sensor Interface Plate Lock Sensor Detection Shaft with LED Washer Unlock Sensor with LED Sensor Cable Master Plate (6) M12 Socket Head Cap Screw Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati‑ia.com • Email: info@ati‑ia.com...

  • Page 36: Optional Electrical Module Seal Inspection And Replacement

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 6.2.2 Optional Electrical Module Seal Inspection and Replacement Parts required: Refer to Section 7—Serviceable Parts The seal protects the electrical connection between the Master and Tool module. If the seal becomes worn or damaged, it must be replaced. 1.

  • Page 37: 3/8" Rubber Bushing Replacement

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 6.2.3 3/8” Rubber Bushing Replacement Parts required: Refer to Section 7—Serviceable Parts Tools required: Needle‑nose pliers Supplies required: P80 lubricant Rubber bushings seal the ports in the Master and Tool plates. If the bushings are damaged, replace them.

  • Page 38: Self-Sealing Valve Replacement

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 6.2.4 Self‑Sealing Valve Replacement Parts required: Refer to Section 7—Serviceable Parts Tools required: Flat head screwdriver, torque wrench Supplies required: Clean rag, Magnalube G lubricant 1. Place the Tool in a secure location. 2.
  • Page 39 Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 11. Lubricate the bore in the module housing with Magnalube G (Teflon/Petroleum based grease). NOTICE: Do not lubricate the O‑ring face seal until after installation. Lubricating the O‑ring before installation can cause the O‑ring to blow out during coupling and uncoupling.

  • Page 40: Serviceable Parts

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 7. Serviceable Parts The following items are commonly used as spare parts for the QC‑300 Tool Changer. 7.1 QC‑300 Master Plate Serviceable Parts Table 7.1— QC‑300 Master Plate Serviceable Parts Item No. Qty Part Number Description 9120‑300M‑000‑000‑000‑000...

  • Page 41: Qc-300 Tool Plate Serviceable Parts

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 7.2 QC‑300 Tool Plate Serviceable Parts Table 7.2— QC‑300 Tool Plate Serviceable Parts Item No. Part Number Description QC‑300 Tool with built‑in 5 pin electrical module and RTL 9120‑300T‑000‑000‑000‑000 sensor QC‑300 Tool with no options and no electrical or ready‑to‑lock 9120‑300T‑000‑000‑000‑000‑E0 sensor peg 9120‑300M‑000‑000‑000‑000‑B...

  • Page 42: Specifications

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 8. Specifications Table 8.1—Master and Standard Tool Plates 1000 lbs. Recommended Max Payload The mass attached to the Tool Changer. (450 kg) ‑20–150°F Operating Temperature Range Optimal operating temperature range. (‑30–66°C) Locking mechanism supply pressure operating range. 60–100 psi Supply to be clean, dry, and filtered to 40 micron or Operating Pressure Range...

  • Page 43: Drawings

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 9. Drawings 9.1 QC‑300 Tool Changer with G19 and FN2 Modules Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati‑ia.com • Email: info@ati‑ia.com...

  • Page 44: Terms And Conditions Of Sale

    Manual, Robotic Tool Changer, QC‑300 Document #9610‑20‑2363‑02 10. Terms and Conditions of Sale The following Terms and Conditions are a supplement to and include a portion of ATI’s Standard Terms and Conditions, which are on file at ATI and available upon request. ATI warrants to Purchaser that robotic Tool Changer products purchased hereunder will be free from defects in material and workmanship under normal use for a period of three (3) years from the date of shipment.

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