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Document #: 9610-20-2255
June 2015
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
Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
Foreword
This manual contains basic information applicable to all ATI Quick-Change robotic Tool Changers. Certain QuickChange 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.
Please contact ATI Industrial Automation with any questions concerning your particular model.
CAUTION: This manual describes the function, application, and safety considerations of this
product. This manual must be read and understood before any attempt is made to install or
operate the product, otherwise damage to the product or unsafe conditions may occur.
Information contained in this document is the property of ATI Industrial Automation, Inc. (ATI) and shall not be
reproduced in whole or in part without prior written approval of ATI. The information herein is subject 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 the customers and authorized agents of ATI
Industrial Automation and may not be divulged to any third party without prior written consent from ATI. No warranty
including implied warranties is made with regard to accuracy of this document or fitness of this device for a particular
application. ATI Industrial Automation shall not be liable for any errors contained in this document or for any incidental
or consequential damages caused thereby. ATI Industrial Automation also reserves the right to make changes to this
manual at any time without prior notice.
ATI assumes no responsibility for any errors or omissions in this document. Users critical evaluation of this document is
welcomed.
Copyright by ATI Industrial Automation. All rights reserved.
How to Reach Us
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
Table of Contents
1. Safety.......................................................................................................................................... 6
1.1
Explanation of Notifications.......................................................................................................... 6
1.2
1.3
Safety Precautions......................................................................................................................... 7
2. Product Overview...................................................................................................................... 8
2.1
2.2
2.3
2.4
2.5
Optional Modules......................................................................................................................... 12
3. Installation............................................................................................................................... 13
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.7.1
3.7.2
3.7.3
3.7.4
3.7.5
3.7.6
Air Requirements............................................................................................................... 22
3.8.2
Electrical Connections................................................................................................................. 24
3.9.1
3.9.2
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
4. Operation................................................................................................................................. 25
4.1
Coupling Sequence...................................................................................................................... 26
4.2
Fail-Safe Operation...................................................................................................................... 26
4.3
Uncoupling Sequence.................................................................................................................. 26
4.4
Tool Identification......................................................................................................................... 27
4.5
5. Maintenance............................................................................................................................. 28
5.1
Preventive Maintenance.............................................................................................................. 28
5.2
5.3
Service Procedures...................................................................................................................... 33
6.2.1 1/8 and 1/4 Rubber Bushing Inspection & Replacement............................................... 33
6.2.2 3/8 Rubber Bushing Replacement................................................................................... 33
6.2.3
6.2.4
6.2.5
7. Serviceable Parts.................................................................................................................... 37
7.1
Models QC-40............................................................................................................................... 37
7.2
Models QC-41............................................................................................................................... 38
7.3
Models QC-43............................................................................................................................... 39
7.4
Models QC-60............................................................................................................................... 40
7.5
Models QC-71............................................................................................................................... 41
7.6
Models QC-100............................................................................................................................. 42
8. Drawings.................................................................................................................................. 43
8.1
8.2
8.3
8.4
8.5
8.6
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
Glossary of Terms
Term
Definition
Master Plate
The half of the Tool Changer that is mounted to a robot. The Master Plate contains the
locking mechanism.
Tool Plate
The half of the Tool Changer to which various tools or end-effectors are mounted.
Cover Plate
Simple, blank closure plate on standard Quick-Change Master Plates that closes the
pneumatic chamber.
Piston
Piston located in the Master Plate that actuates the locking mechanism.
Cam
Circular cam attached to the piston that forces the locking balls outward during the
locking process.
Bearing Race
Hardened steel ring in the Tool Plate that is engaged by the locking balls during the
locking process.
End-Effector
Tool Stand
Stand that holds Tools not being used by the robot. This is usually supplied by the
customer and is specific to the application.
RIP
Robot Interface Plate interface plate between the robot flange and Master Plate.
Electrical Module
Any of a wide variety of modules that pass electrical power through the Master Plate to
the Tool Plate and to the end-effector.
Pneumatic Module
Any of a wide variety of modules that pass pneumatic power through the Master Plate to
the Tool Plate and to the end-effector.
Detection Shaft
Threaded stem inserted into the back side (top) of the Piston, functions as a target to
actuate the Lock/Unlock switches.
Sensor Plate
Cover plate for the back side of the Master plate, seals the pneumatic chamber and
provides mounting points for the Lock/Unlock switches.
Lock Port
Pneumatic port on the Master Plate to which air is supplied to Lock the Master Plate to
the Tool Plate.
Unlock Port
Pneumatic port on the Master Plate to which air is supplied to Unlock the Master Plate
from the Tool Plate.
No-Touch
Design feature of all ATI Quick-Change products that allows coupling the Master Plate
and Tool Plate without physical contact prior to locking.
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
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 were they apply.
The notifications included here are specific to the product(s) covered by this manual. It is expected that the
user heed all notifications from the robot manufacturer and/or the manufacturers of other components used
in the installation.
DANGER: Notification of information or instructions that if not followed will result in
death or serious injury. The notification provides information about the nature of the
hazardous situation, the consequences of not avoiding the hazard, and the method for
avoiding the situation.
WARNING: Notification of information or instructions that if not followed could result
in death or serious injury. The notification provides information about the nature of the
hazardous situation, the consequences of not avoiding the hazard, and the method for
avoiding the situation.
CAUTION: Notification of information or instructions that if not followed could result
in moderate injury or will cause damage to equipment. The notification provides
information about the nature of the hazardous situation, the consequences of not
avoiding the hazard, and the method for avoiding the situation.
NOTICE: Notification of specific information or instructions about maintaining, operating,
installation, or setup of the product that if not followed could result in damage to equipment. The
notification can emphasize but is not limited to specific grease types, good operating practices,
or maintenance tips.
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
All pneumatic fittings and tubing must be capable of withstanding the repetitive motions of the application
without failing. The routing of electrical and pneumatic lines must minimize the possibility of stress/strain,
kinking, rupture, etc. Failure of critical electrical or pneumatic lines to function properly may result in injury
to personnel and equipment.
All electrical power, pneumatic and fluid circuits should be disconnected during servicing.
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
2. Product Overview
QC models are available with different anodizing, pneumatic port sizes and quantities, refer to Table 2.1 for specific
part numbers.
The Quick-Change Tool Changer provides flexibility to robot applications by allowing the robot to change endeffectors (e.g., grippers, vacuum cup tooling, pneumatic and electric motors, weld guns, etc.) automatically. The
Quick-Change consists of a Master plate and a Tool plate.
The Master plate is installed on the robot arm and locks to the Tool plate with a pneumatically-driven locking
mechanism. This locking mechanism uses a patented, multi-tapered cam with ball locking technology and a
patented fail-safe mechanism. The Master allows for the passage of pneumatic and electrical connections to the
Tool plate. End-effectors such as grippers, material handlers, etc. are attached to one or more Tool Plates.
In operation, the robot can be programmed to select the desired end-effector by coupling the Master Plate to the
Tool Plate. Electrical signals, pneumatic power, and fluids can be transferred to the end-effector(s) through the
Master Plate and Tool Plate by optional modules and ports. See the respective manuals for these options for more
details on their operation.
A Tool Changer enhances the flexibility and reliability of a robotic cell. Robotic Tool Changers are used in
automated Tool-change applications, as well as manual Tool-change operations. Robotic Tool Changers also
provide a method for quick Tool change for maintenance purposes.
Model
Payload
QC-40
110 lbs
QC-41
110 lbs
QC-43
110 lbs
Notes
1. QC Tool Changer Master and Tool Plate Assemblies with (-B and -E) part numbers have black anodized bodies
2. Additional options are available upon request.
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
Table 2.1Standard QC Tool Changer Models and Features
Model Payload
Flats
Plate
Pneumatic Ports
Part No.
(8) 1/8 NPT Pass-through ports
9120-060M-000-000
Master
(2) 1/8 NPT Lock/Unlock air ports
9120-060M-000-000-B
(8) 1/8 NPT Pass-through ports
9120-060T-000-000
Tool
9120-060T-000-000-B
(2) Flat
(8) 1/8-28 BSPP Pass-through ports 9120-060M-000-000-E
(1) J16 pattern
Master
QC-60 160 lbs
(2) 1/8-28 BSPP Lock/Unlock air ports
and
(1) K series
Tool
(8) 1/8-28 BSPP Pass-through ports 9120-060T-000-000-E
(8) 1/8 BSPT Pass-through ports
9120-060M-000-000-R
Master
(2) 1/8 BSPT Lock/Unlock air ports
Tool
(8) 1/8 BSPT Pass-through ports
9120-060T-000-000-R
(8) 1/4 NPT Pass-through ports
9120-071M-000-000
Master
(2) 1/8 NPT Lock/Unlock air ports
9120-071M-000-000-B
(8) 1/4 NPT Pass-through ports
9120-071T-000-000
Tool
9120-071T-000-000-B
(8) 1/4 BSPP Pass-through ports
9120-071M-000-000-E
Master
QC-71 180 lbs
(2) Flats
(2) 1/8 BSPP Lock/Unlock air ports
(8) 1/4 BSPP Pass-through ports
9120-071T-000-000-E
Tool
(8) 1/4 BSPT(R) Pass-through ports 9120-071M-000-000-R
Master
(2) 1/8 BSPT Lock/Unlock air ports
Tool
(8) 1/4 BSPT(R) Pass-through ports
9120-071T-000-000-R
(8) 3/8 NPT Pass-through ports
9120-100M-000-000
Master
(2) 1/8 NPT Lock/Unlock air ports
Tool
(8) 3/8 NPT Pass-through ports
9120-100T-000-000
QC-100 330 lbs
(2) Flats
(8) G 3/8 BSPP Pass-through ports
9120-100M-000-000-E
Master
(2) G 1/8 BSPP Lock/Unlock air ports
Tool
(8) G 3/8 BSPP Pass-through ports
9120-100T-000-000-E
Notes
1. QC Tool Changer Master and Tool Plate Assemblies with (-B and -E) part numbers have black anodized bodies
2. Additional options are available upon request.
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
Cover Plate
Cover Plate
Optional Module
Flat B
Optional Module
Flat A
1/8"NPT Lock,
Unlock Air Ports
Ball Bearings
1/8"NPT Lock,
Unlock Air Ports
Optional Module Flat B
Ball Bearings
Male Coupling
Male Coupling
(2) Alignment Bushings
Optional Module
Flat A
(2) Alignment
Bushings
Pass-Through
Air Ports
The air port provides Lock and Unlock air for the locking mechanism and pass through air for the end of
arm tooling. An Adapter Plate Assembly provides a standoff for the air ports and a mounting pattern to
attach to the robot arm.
Alignment pins mate with 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 life of the Master Plate assembly. In some models the Master plate is equipped with tapered
alignment pins, other models such as the QC-43 Mater Plate have hardened stainless steel alignment
bushings.
A cover plate is attached to the master to protect the internal locking mechanism during shipment. This
cover plate can be removed during installation if replaced by a robot interface plate or Sensor interface plate.
Refer to Section3Installation for details.
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
Piston
Ball Bearings
Bearing Race
Circular Cam
Ball Cage
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
Detection Shaft
(Sensor Target)
Lock Sensor
Unlock Sensor
Sensor Plate
O-ring
Model
QC-40
QC-41
QC-43
QC-60
QC-71
QC-100
Note: The ATI website provides information on the Standard compatible modules additional custom
modules are available, contact an ATI Sales Representative directly
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
3. Installation
The Master Plate of the Tool Changer mounts to the robot arm using a robot Interface Plate (RIP) or a Sensor
Interface Plate (SIP). Custom interface plates are available from ATI upon request. Refer to Section3.1Robot
Interface Plates (RIP) or Section2.4Optional Sensor Interface Plate (SIP) for more information.
The end-effector is typically attached to the Tool Plate with a tool interface plate, standard and custom tool interface
plates are available from ATI upon request. Refer to Section3.4Tool Interface Plate for more information.
All fasteners used to mount the Tool Changer to the robot and to customers tooling should be tightened to a torque
value as indicated. Refer to Table 3.1. Furthermore, fasteners should have pre-applied adhesive or be applied
with removable (blue) Loctite 222. Table 3.1 contains recommended values based on engineering standards.
Pneumatic lines and electrical cables are attached, bundled, and must be strain-relieved in a manner that allows for
freedom of movement during operation.
WARNING: All pneumatic fittings and tubing must be capable of withstanding the repetitive
motions of the application without failing. The routing of electrical and pneumatic lines must
minimize the possibility of over stressing, pullout, or kinking the lines. Failure to do so can
cause some critical electrical and/or pneumatic lines not to function properly and may result in
injury to personnel or damage to equipment.
WARNING: Do not use lock washer under the head of the mounting fasteners or allow the
mounting fasteners to protrude above the mating surfaces of the Master and Tool Plates.
Allowing fasteners to protrude above the mating surface will create a gap between the Master
and Tool Plates and not allow the locking mechanism to fully engage, this can cause damage
to equipment or personal injury. Make sure the mounting fasteners are flush or below the
mating surfaces of the Master and Tool Plates.
Mating Surface
CAUTION: Do not apply Lock or Unlock air pressure to the Tool Changer prior to installing a
robot interface plate (RIP) or sensor interface plate (SIP). Applying air pressure can damage
the cover plate, O-ring or may cause injury to personnel from flying debris. Always install an
appropriate RIP or SIP and have the Tool Changer mounted securely to the robot before
applying air pressure. Refer to Section3.1Robot Interface Plates (RIP) and Section3.2
Master Plate Installation for more information.
CAUTION: Do not use fasteners that exceed the thread depth in the Tool Changer. Refer to
Section8Drawings for details on mounting hole thread depth. Secure the Tool Changer with
the proper length fasteners. This is true for both robot and tool interfaces.
CAUTION: Failure to follow the Robot Interface Plate or tool interface plate design
consideration in Section3.1Robot Interface Plates (RIP) and Section3.4Tool Interface
Plate may result in cover plate O-ring damage or loosening of the interface during operation.
Follow the guidelines provided when designing a RIP, TIP for the Tool Changer.
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
Table 3.1Fastener Size, Class, and Torque Specifications
Mounting Conditions
Recommended
Torque
Thread
Locker
Pre-applied
Adhesive or
Loctite 222
Pre-applied
Adhesive or
Loctite 242
Pre-applied
Adhesive or
Loctite 222
The interface plate should be designed to include bolt holes for mounting, dowel pins, and a boss
for accurate positioning on the robot and Master Plate. (Refer to robot manual) (The dowel and boss
features are important to prevent anti-rotation)
A piston cover plate is provided with each Quick-Change Master Plate. If the robot interface plate
provides sealing for the piston cylinder, then the cover plate can be removed. Refer to Figure3.1
The robot interface plate must be properly designed to provide rigid mounting on the boss surfaces.
The interface plate should not contact the Master body outside of the boss. The recommended
dimensions for the interface plate bore, with and without the cover plate, are provided in Section8
Drawings. The mating diameters must provide sufficient clearance so that mating corner radii do not
interfere.
The thickness of the interface plate must be great enough to provide the necessary thread engagement
for the mounting bolts.
Mounting bolts should not be too long, such that a gap is formed at the interface.
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
Figure3.1RIP and SIP with Master Plate Configurations
Sensor Plate
O-ring
Sensor Plate (Cover Plate Removed)
Mounting Fasteners
(Supplied by Customer)
Detection shaft
O-ring
Dowel Pin
Sensor Interface plate (SIP)
Master Plate Boss
Master Plate Body
O-ring
Cover Plate Left in Place
Maintain a Gap
RIP Boss
Mounting Fasteners
Dowel Pin (Supplied by Customer)
Robot Interface Plate
(RIP)
Master Plate Boss
Maintain a Gap
Dowel Pin
O-ring
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
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Robot Arm
Dowel Pins
(Customer Supplied)
Robot Arm
Dowel Pins
(Customer Supplied)
Sensor Plate
(Replaces Cover Plate)
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
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The tool interface plate should be designed to include bolt holes for mounting, dowel pins, and a boss
that mates with Tool Plate recess for accurate positioning. (The dowel and boss features are important
to prevent anti-rotation).
The locating boss height should not exceed the customer interface depth specified on the drawing.
The thickness of the interface plate must be great enough to provide the necessary thread engagement
for the mounting bolts. Fasteners should be chosen to meet minimum recommended engagement
lengths while not exceeding the maximum available thread depth. Use of bolts that are too long can
cause damage to the tool side changer.
The plate design should take into account clearances required for Tool Changer module attachments
and accessories.
The tool interface plate should be designed with a hole in its center to allow for manually returning
the locking mechanism to the unlocked position under adverse conditions (i.e. unintended loss of
power and/or air pressure). The center access hole should be kept small [minimum recommended hole
diameter: 1 (25.4 mm)] to prevent debris from contaminating the locking mechanism while operating
in dirty environments.
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
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Dowel Pin
(Customer Supplied)
Dowel Pin
(Customer Supplied)
Interface Plate
(Customer Supplied)
Interface Plate
(Customer Supplied)
(6) M8 Socket Head Cap Screws
(Customer Supplied)
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
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Fluid/Air Module
(9120-FR2-M Shown)
(4) M4 Socket Head
Cap Screws
Fluid/Air Module
(9120-FR2-T Shown)
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
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5. Remove the module from the Adapter Plate.
6. Remove the two M4 socket head cap screws securing the adapter plate to the Master or Tool
Plate.
7. Remove the adapter plate.
3.7.5 QC-40. QC-41, QC-43, QC-71, and QC-100 Optional Module Installation
1. If the Tool Changer is in service, dock the Tool safely in the tool stand and uncouple the Tool
Changer to allow clear access to the Master and Tool plates. Leave the locking mechanism in
the unlocked.
2. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).
3. Align optional module on the Master or Tool Plate as shown in Figure3.6.
4. If not using fasteners with pre-applied adhesive, apply Loctite 222 to four M4 socket head
cap screws.
5. Secure module with four M4 mounting fasteners. Refer to Table 3.1 for proper torque for your
specific mounting fasteners.
6. Remove all protective caps, plugs, tape, etc from the module prior to operation.
7. If installation is complete, return circuits to normal operation.
Figure3.6Optional Module Installation
Fluid/Air Module
(9120-FR2-T Shown)
3.7.6 QC-40, QC-41, QC-43, QC-71, and QC-100 Optional Module Removal
1. Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to
the Master or Tool plate.
2. Turn off all energized circuits (e.g. electrical, air, water, etc.).
3. Disconnect any cables, air line, etc. if required.
4. Supporting the module, remove the four M4 socket head cap screws.
5. Remove the module from the Master or Tool Plate.
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
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Figure3.7QC-40, QC-43 and QC-71 Lock and Unlock Pneumatic Connections
4 or 5 -way Valve
Lock Port
Unlock Port
Exhaust
Open to Atmosphere
Lock Port
Unlock Port
Exhaust
Open to Atmosphere
Unlock Port
Lock Port
Exhaust
Open to Atmosphere
Lock Port
Unlock Port
Exhaust
Open to Atmosphere
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
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Value
10-30 VDC
Output Current
< 100 mA
0.8 mm
Output Circuit
PNP
Connector
(4) Black
+Vs
Black (4)
Output
Z
Blue (3)
(3) Blue
Brown (1)
0V
Value
10-30 VDC
Output Current
< 100 mA
0.8 mm
Output Circuit
NPN
Black (4)
Blue (3)
Connector
(4) Black
+Vs
Z
Output
Brown (1)
0V
(3) Blue
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
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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 65 to 100 psi. Robot motion should be halted if the air
supply pressure drops below 60 psi for any reason.
NOTICE: All Tool Changers are initially lubricated using MobilGrease XHP222 Special grease. The
end user must apply additional lubricant to the locking mechanism components and alignment pins
prior to start of service (See Section5.2Cleaning and Lubrication of the Locking Mechanism and
Alignment Pins). Tubes of lubricant for this purpose are shipped with every tool changer. Note:
MobilGrease XHP222 Special is a NLGI #2 lithium complex grease with molybdenum disulfide.
The robot should be programmed to minimize misalignment during coupling and uncoupling. Additionally, the Tool
Stand should be durable and not allow deflection, under uncoupled Tool weight that will take alignment of the Tool
Changer plates outside of accepted offsets. See Figure4.1 and Table 4.1 for recommended maximum allowable
offsets prior to coupling. In some cases, greater offsets than shown in Table 4.1 can be accommodated by the
Master and Tool Plates, but will increase wear.
Lock-up should occur with the Master Plate in the No-Touch Locking zone (see Table 4.1) but not touching the
Tool Plate. As locking occurs, the Master Plate should draw the Tool Plate into the locked position.
Figure4.1 Offset Definitions
Master Plate
Tool Plate
Z
Cocking Offset
(About X and Y)
Y
Twisting Offset
(About Z)
X
X, Y, and Z Offset
No-Touch Zone Z
Offset (Max)*
(mm)
Cocking Offset
(Max)
(degrees)
Twisting Offset
(Max)
(degrees)
QC-40
QC-41
QC-43
+3
1.0
QC-60
QC-71
+3
0.6
QC-100
+3
0.7
Notes: *Maximum values shown. Decreasing actual values will minimize wear during coupling/uncoupling.
Actual allowable values may be higher in some cases but higher offsets will increase wear during coupling.
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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 robot.
4. In automated Tool change applications, it is recommended that a Tool presence sensor(s) be used in
the Tool Stand to verify that the Tool is present and to verify that the Tool remains in place as the robot
moves away after the unlocking process.
When using multiple Tools, it is good practice to implement a Tool-ID system that identifies each Tool
with a unique code. This can be used to verify that the robot has picked up the proper Tool. This may be
accomplished by using an optional electrical module (for power and signal pass-through) and uniquely
jumpering pins on the Tool-side of the module. See electrical module documentation for more information.
DeviceNet Tool-ID modules are also available.
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
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5. Maintenance
WARNING: Do not perform maintenance or repair on Tool Changer or modules unless the
Tool is safely supported or docked in the Tool Stand and all energized circuits (e.g., electrical,
air, water, etc.) have been turned off. Injury or equipment damage can occur with Tool not
docked and energized circuits on. Dock the Tool safely in the Tool Stand and turn off all
energized circuits before performing maintenance or repair on Tool Changer or modules.
NOTICE: The cleanliness of the work environment strongly influences the trouble free operation of
the Tool Changer. The dirtier the environment, the greater the need for protection against debris.
Protection of the entire EOAT, the Master, the Tool and all of the modules may be necessary. Protective
measures include the following: 1) Placement of Tools Stands away from debris generators. 2) Covers
incorporated into the Tool Stands. 3) Guards, deflectors, air curtains, and similar devices built into the
EAOT and the Tool Stand.
Inspection Schedule
Weekly
Monthly
All
Weekly
Mounting Fasteners
Inspect fasteners for proper torque, interference or wear. Tighten and correct as required. Refer to Section3
Installation.
Balls/Alignment Pins/Holes/Bearing Race
Inspect for lubrication and wear. MobilGrease XHP222 Special a NLGI #2 lithium complex grease with
molybdenum disulfide additive is suggested for locking mechanism and alignment pin lubrication. Over time,
lubricants can become contaminated with process debris. Therefore, it is recommended to thoroughly clean
the existing grease and replace with new as needed. See Section5.2Cleaning and Lubrication of the
Locking Mechanism and Alignment Pins.
Inspect for excessive alignment pin/bushing wear may be an indication of poor robot position during pickup/
drop-off. Adjust robot position as needed. Check tool stand for wear and alignment problems. The QC-100
model has replaceable alignment pins, refer to Section6.2.4QC-100 Alignment Pin Replacement
Inspect for wear on the balls/bearing race could be an indication of excessive loading.
Inspect sensor cables for any damage, cuts, and abrasion. Replace as necessary.
Hoses
Inspect hose connection for tightness and leaks. If leaking or loose secure hose connection.
Inspect hoses for interferences, abrasions, cuts, and leaks. Replace as required.
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5.2 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins
1. Dock the Tool safely in the tool stand and uncouple the Tool Changer to allow clear access to the
Master and Tool plates. Leave the locking mechanism in the unlocked.
1. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).
2. The locking mechanism must be in the unlock state before cleaning.
3. Use a clean rag to thoroughly remove the existing lubricant and debris from the ball bearings, the male
coupling, the cam and the alignment pins.
Figure5.1 Cleaning Ball Bearings and Outer Surfaces of Male Coupling
4. Use a clean rag to thoroughly remove the existing lubricant and debris from the inner surface of the
male coupling and the cam.
Figure5.2 Cleaning Ball Bearings, Cam and Inner Surfaces of Male Coupling
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
5. 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.
Figure5.3 Check Ball Bearing Movement
6. Apply a liberal coating of MobilGrease XHP222 Special grease to the ball bearings, the male
coupling (inside and out), and the alignment pins.
Figure5.4 Apply Lubricant to Locking Mechanism
7. Use a clean rag to thoroughly remove the any lubricant and debris from the bearing race and the
bushings from the Tool Plate.
Figure5.5 Clean Tool Plate Surfaces of Locking Mechanism
Clean Bushing Surfaces
Clean Bearing
Race Surfaces
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Weld Debris
Master Module Pin Block
4. If debris or darkened pins exist, remove debris using a vacuum, 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 erosion to the contact surface or pins to stick.
Clean contact surfaces with a vacuum and non-abrasive media such as a nylon brush (ATI part
number 3690-0000064-60)
Figure5.7Clean Pin Blocks with a Nylon Brush
5. Inspect the Master and Tool pin blocks for stuck pins or severe pin block damage.
Figure5.8Stuck Pin and Pin Block Damage
Note: Pin blocks shown are for
illustration purposes only.
Stuck Pins
6. If stuck pins or severe pin block damage exists, contact ATI for possible pin replacement procedures or
module replacement.
7. After maintenance is complete, return all circuits to normal operation (e.g. electrical, air, water, etc.).
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
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6.1 Troubleshooting
The troubleshooting table is provided to assist in diagnosing issues that may cause the Tool Changer not to
function properly.
Table 6.1Troubleshooting
Symptom
Cause
Resolution
Insufficient or no air pressure Verify proper air pressure and pneumatic valve is
supplied. Refer to Section3.8Lock/Unlock Pneumatic
supply to the lock or unlock
ports.
Connections and Valving.
Tool Changer
will not lock and/
or unlock (or
Lock sensor
does not indicate
Tool Changer is
Locked)
Pneumatic connections
loose or damaged.
The ball bearings and/or cam Clean and lubricate as needed to restore smooth
are not moving freely in the
operation (see Section5.2Cleaning and Lubrication of
male coupling.
the Locking Mechanism and Alignment Pins).
Loss of
Communication
Debris in and around contact Inspect V-ring seal for damage, replace damaged seal.
pins. Contact Pin worn or
Refer to Section6.2.3Optional Electrical Module Seal
damaged.
Inspection and Replacement
Cable connections loose or
cables damaged
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
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Rubber Bushing
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4. If the collar remains in the Master body, remove it.
5. Lightly lubricate the new rubber bushing and push into the Master body (refer to Figure6.2).
6. Insert the new collar into the rubber bushing, make sure the bushing is pressed all the way in.
7. After maintenance is complete, return all circuits to normal operation (e.g. electrical, air,
water, etc.).
Figure6.2 3/8 Rubber Bushing Replacement (QC-41 Shown)
Collar
Rubber Bushing
V-ring Seal
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7. Disconnect the sensor cable.
8. Loosen the hex nut and unscrew the proximity sensor from the Master Plate Assembly. Retain
the washer from the sensor.
9. To test the suspect sensor, connect the sensor cable and place a ferrous target in front of the
Proximity Sensor to confirm that the sensor is functional. The sensor lock or unlock signal
should read on(true) and the sensor LED should illuminate.
10. If the proximity sensor is not functioning properly replace. Disconnect the sensor cable and
discard.
11. Back the sensor hex nut to the connector end of the new sensor.
12. Thread the proximity sensor into the Master Plate Assembly until it touches the Detection
Shaft, then back the sensor off 1/2 turn.
CAUTION: Do not operate locking mechanism with sensor touching the
detection shaft. Operating the locking mechanism with the sensor touching the
detection shaft will damage the sensor. Back off the sensor turn and secure
with the set screw before operating the locking mechanism.
13. Connect the sensor cable. The Proximity Sensor LED should be illuminated.
14. 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 and torque to 20 in-lbs.
15. Attach the Master Plate to the sensor interface plate using the mounting fasteners. Refer to
Table 3.1 for torque and thread locker specifications.
16. If required, connect other utilities to the optional modules on the Master Plate.
17. Confirm the operation of the replaced sensor by issuing the Lock command to lock a Tool to
the Master and then checking to see that the LED in the replaced Sensor body is on.
Figure6.5Replace Proximity Sensor
Detection Shaft
Master Plate
(QC-41 Shown)
Washer
Lock Sensor
Sensor LED
Sensor Cable
Unlock Sensor
Mounting Fasteners
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
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7. Serviceable Parts
The following items are commonly used as spare parts for the QC-40 through QC-100 Tool Changers.
QTY
PART NUMBER
DESCRIPTION
9120-040M-000-000
3500-1064035-12
SHCS, M5x35, ZN
9120-040T-000-000
4010-0000013-01
8590-9909999-04
8590-9909999-08
6*
8590-9909999-07
8590-9909999-02
8590-9909999-14
6*
8590-9909999-07
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
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7
8
1
5
2
3
QTY
PART NUMBER
DESCRIPTION
9120-041M-000-000
4010-0000010-01
3700-20-2000
4010-0000013-01
3500-1064035-12
9120-041T-000-000
8*
8590-9909999-08
8590-9909999-12
8590-9909999-14
8*
8590-9909999-12
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38
Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
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QTY
PART NUMBER
DESCRIPTION
9120-043M-000-000
3500-1064035-15
9120-043T-000-000
4010-0000013-01
8590-9909999-04
8590-9909999-08
6*
8590-9909999-07
8590-9909999-02
8590-9909999-14
6*
8590-9909999-07
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Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
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QTY
PART NUMBER
DESCRIPTION
9120-060M-000-000
3500-1266040-15
9120-060T-000-000
4010-0000013-01
8590-9909999-08
6*
8590-9909999-07
8590-9909999-02
8590-9909999-14
6*
8590-9909999-07
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40
Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
2
1
3
4
QTY
PART NUMBER
DESCRIPTION
9120-071M-000-000
4010-0000021-01
3500-1066040-12
9120-071T-000-000
8590-9909999-08
6*
8590-9909999-07
8590-9909999-14
8590-9909999-09
6*
8590-9909999-07
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7
8
3
6
5
QTY
PART NUMBER
DESCRIPTION
9120-100M-000-000
3700-20-1373
3500-1068055-15
9120-100T-000-000
4010-0000010-01
3700-20-2000
8590-9909999-04
8590-9909999-08
8*
8590-9909999-07
8590-9909999-23
8590-9909999-14
8*
8590-9909999-07
42
43
80
5
7
54.1
J16
Modules
Tool Side
(projection only)
49
(Typ.)
30
(Typ.)
20
(Typ.)
Notes:
1. Master mounting hardware provided.
2. Cover plate is not necessary if robot interface 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 with optional J16 Electrical Modules. For other modules
see the Modules and Options section of the catalog.
Flat A
50 H7, 6 Dp.
Customer Interface
B.C.
Pneumatic
Port I.D.
115
15
(Typ.)
33
J16-T
(B)
Amphenol Connector
PT02A-14-19S
60
J16
Modules
Flat B
27
Tool
Plate
54.2
Coupled
(A)
10.1
15.1
115
80 h7, Boss
Customer
Interface
1/8 NPT
Unlock Port
Flat B
Warning:
Do not apply lock/unlock air pressure without master cover plate
properly attached. If cover plate is not used, master should be
properly attached to interface. Failure to do so could result in
damage to cover plate and o-ring.
42.5
J16-M
10.3 M5 SHCS
Provided
27
Master
Plate
Amphenol Connector
PT02A-14-19P
15.1
18.1
Male
Coupling
12.5
Master Side
(projection only)
12.5
10
B.C.
Flat A
79
Cover
Plate
65
1/8 NPT
Lock Port
9230-20-1966-03
Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
8. Drawings
8.1 QC-40 Tool Changer with J16 Module
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44
10
55.8
R19
Modules
Tool Side
(projection only)
60.2
R19
Modules
80
25
25
Amphenol Connector
PT02E-14-19S
33.3
R19-T
6.3
(B)
6X 3/8 NPT
Pneumatic
Thru Ports
(14.1 From
Mating Surface)
Pneumatic
Port I.D.
30
30
27.1
Tool Plate
4X 1/8 NPT
Pneumatic
Thru Ports
(15.1 From
Mating Surface)
50 H7 6
Customer Interface
B.C.
Notes:
1. Master mounting hardware provided.
2. Cover plate is not necessary if robot interface plate provides
sealing. The recommended interface plate bore depth with
a cover plate is 2.5mm.
3. Orientation marks are provided to assist in robot teaching.
4. Shown with optional R19 Electrical Modules. For other modules
see the Modules and Options section of the catalog.
57.6
(Typ.)
8 H7 8
Customer Interface
130
Tapped M8 x 1.25 8
Equally Spaced
Customer Interface
15.1
14.1
(A)
15.1
20.1
10
130
12.5
1/8 NPT
Lock Port
14.8
44.9
R19-M
79
Cover Plate
6 H7 20
Customer Interface
6X 3/8 NPT
Pneumatic
Thru Ports
4X 1/8 NPT
Pneumatic
Thru Ports
10.3 M5 SHCS
Provided
30.1
Master
Plate
40.1
R19
Modules
65
6 H7 6
Customer Interface
B.C.
1/8 NPT
Unlock Port
12.5
9230-20-1967-03
Master Side
(projection only)
Warning:
Do not apply lock/unlock air pressure without master cover plate
properly attached. If cover plate is not used, master should be
properly attached to interface. Failure to do so could result in
damage to cover plate and o-ring.
Amphenol Connector
PT02E-14-19P
18
Male
Coupling
57.2
Coupled
Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
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80
45
49
(Typ.)
30
(Typ.)
Tool Side
(projection only)
5
6
7
20
(Typ.)
Notes:
1. Master mounting hardware provided.
2. Cover plate is not necessary if robot interface 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.
Warning:
Do not apply lock/unlock air pressure without master cover plate
properly attached. If cover plate is not used, master should be
properly attached to interface. Failure to do so could result in
damage to cover plate and o-ring.
Flat A
6
50 H7
Customer Interface
B.C.
Pneumatic
Port I.D.
6X Tapped
8
M8 x 1.25
Equally Spaced
Customer Interface
115
8
2X 8 H7
Customer Interface
15
(Typ.)
Flat B
(B)
8X 1/8 NPT
Pneumatic
Thru Ports
3X 15.5
Alignment
Pins
15.1
27
Tool
Plate
10.1
15.1
54.2
Coupled
18.1
Male
Coupling
PROJECT #
CHECKED BY:
DRAWN BY:
DSS 7/9/14
SHEET 1 OF 1
D. Wagner 7/9/14
(A)
Description
115
80 h7, Boss
Customer
Interface
Initial Drawing
Date
1/8 NPT
Lock Port
Flat A
79
Cover
Plate
65
7/9/2014
SIZE
SCALE
1:1.7
9230-20-4583
DRAWING NUMBER
01
REVISION
TITLE
12.5
Master Side
(projection only)
12.5
10
B.C.
6
2X 6 H7
Customer Interface
DAW
Initiator
1/8 NPT
Unlock Port
Flat B
6X Thru Hole
for M5 x 35
SHCS Provided
Equally Spaced
Customer Interface
8X 1/8 NPT
Pneumatic
Thru Ports
(Even #s 10.1 From
Mating Surface)
(Odd #s 15.1
From Mating
Surface)
10.3 M5 SHCS
Provided
27
Master
Plate
01
Rev.
Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
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46
2 0
130
Tool Side
(projection only)
3 9 .8
K1 9
Modules
2 3 .1
T ool
Plate
6 .1
(B)
14. 1
Amphenol Connector
PT02E-14-19S
30. 9
K19-T
Pneumatic
Port I.D.
8 H7, 16 Dp.
Customer Interface
53
(Typ.)
80
50 H7, 6 Dp.
Customer Interface
Flat A
B.C.
Notes:
1. Master mounting hardware provided.
2. Cover plate is not necessary if robot interface 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 with optional K19 Electrical Modules. For other modules
see the M odules and Options section of the catalog.
2 0
20
20
Flat B
16
Male
Coupling
(A)
47.2
Coupled
Amphenol Connector
PT02E-14-19P
30. 6
K19-M
8. 5
55
(Typ.)
13 0
50
K 19
Modules
Flat A
Flat B
1/8 NPT
Unlock Port
15
86
9 9 .1
Cover
Plate
B.C.
9230-20-1968-02
Master Side
(projection only)
13.3 M6 SFHCS
Provided
3 Boss
24. 1
Master
Plate
Warning:
Do not apply lock/unlock air pressure without master cover plate
properly attached. If cover plate is not used, master should be
properly attached to interface. Failure to do so could result in
damage to cover plate and o-ring.
Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
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47
Flat B
80
4
2
5 6 .9
G19-T
Tool Side
(projection only)
60
(Typ.)
30
(Typ.)
20
(Typ.)
10
(Typ.)
1 5 .1
(8) 1/4 NPT
Pneumatic
Thru Ports
1 3 .9
(B)
Amphenol Connector
PT02E-14-19S
6 0 .2
G19
Modules
Flat A
Pneumatic
Port I.D.
Notes:
1. Master mounting hardware provided.
2. Cover plate is not necessary if robot interface 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 with optional G19 Electrical Modules. For other modules
see the Modules and Options section of the catalog.
50 H7, 6 Dp.
Customer Interface
B.C.
150
8 H7, 8 Dp.
Customer Interface
32
To o l
Plate
45. 9
G1 9 - T
(A)
19
Amphenol Connector
PT02E-14-19P
49
G19-M
1/8 NPT
Unlock
Port
57
G19-M
Flat A
3 Boss
16.7
3 0 .2
Master
Plate
Warning:
Do not apply lock/unlock air pressure without master cover plate
properly attached. If cover plate is not used, master should be
properly att ached to interface. Failure to do so could result in
damage to cover plate and o-ring.
20
Male
Coupling
62. 2
Coupled
10
Master Side
(projection only)
10
1/8 NPT
Lock
Port
15
Flat B
B.C.
86
9 9 .1
Cover
Plate
15 0
9230-20-1969-02
Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
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B.C.
48
Flat A
60.2
Interface Advice:
The tool interface plate should be designed to use M10 screws,
10 dowel pin and 80 recess.
35
41
27
1/8 NPT
Lock Port
Master
Plate
45.5
Notes:
1. Optional electrical module shown; consult catalog for other options.
2. Mounting hardware is provided; cover plate, o-ring and master plate screws.
3. Cover plate is not necessary if robot interface plate provides sealing.
The recommended interface plate bore depth without the cover plate is 2.5mm,
with the cover plate is 5.6mm.
4. Orientation marks are provided to assist in robot teaching.
5. Misalignments allowed when coupling; consult specifications.
6. See sheet 2 of 2 for Flat B bolt hole patterns.
7. DXF and DWG images available upon request.
41
54.2
41.5
3.2
12.7
1/8 NPT
Unlock Port
Side View
60.2
2/11/03
5/8/02
JHS
JHS
APPROVAL
INITIATOR
75
75
150
100
+0.015
10
H7
-0
10 deep
Customer Interface
(2)
40
B.C.
77 Cylinder Bore
PD
1:2
SCALE
TITLE
B-11X17
SIZE
DRAWING NUMBER
SHEET
9230-20-1201-04
OF
Interface Advice:
The robot interface plate should be designed to use M8 screws,
10 dowel pin and 115 boss. Reference Note 3.
Flat A
Flat B
60
170
20
20
J.SNAPE 3/19/99
MFG. APPR:
ASSEMBLY REF.
ENG. APPR.
CK'D. BY:
DR. BY:
114
177
DESCRIPTION
Added sheet 2 of 2
04
03
REVISION
Cover O-ring
AS568-042
Plate
provided provided
+0
115
h7
- 0.035
Customer
Interface
19
27
79.5 Coupled
+0.015
H7
-0
20 deep
Customer
Interface
11
10
30
20
20
+0.030
H7, 10 deep
-0
Customer Interface
Tool
Plate
3
80
125
Warning:
Do not apply lock air pressure without master interface plate
properly attached; otherwise, damage may occur to cover plate and o-ring.
150
75
75
177.01
Flat B
60
Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
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
18
13.500.05
13.50.05
18
49
(2)
+0.01
0
55
500.05
500.05
(4)
DRAWN BY:
ASSEMBLY REF:
WEIGHT LBS:
CHECKED BY:
16.99
20
J.Snape 3/19/99
10
17
10
+0.10
0
100.10
(8) M4-0.7
(8) M4-0.7,
83.60.05
85.60
50
50
85.60
REVISION
SIZE
DATE:
SHEET
OF
9230-20-1201-04
DRAWING NUMBER
PRODUCT RELEASE #
1:2
SCALE
TITLE
INITIATOR
DESCRIPTION
DATE
Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
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
Quick-Change Tool Changer QC-40 through QC-100 Installation and Operation Manual
Document #9610-20-2255-02
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
50