ATI Technologies SR 48 User manual

Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
Robotic Collision Sensor
SR‑48 Manual
U.S. Patent Nos. 6069415 and 6690208
Document #: 9610‑60‑1012

Manual, Collision Sensor,SR‑48
Document #9610‑60‑1012‑06
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
2
Forward
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. Failure to read and understand the information in this manual may result in
damage to equipment or injury to personnel.
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 reect and incorporate changes made to the product.
The information contained herein is condential 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 tness 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 2022 by ATI Industrial Automation. All rights reserved.
How to Reach Us
Sale, Service and Information about ATI products:
ATI Industrial Automation
1031 Goodworth Drive
Apex, NC 27539 USA
www.ati‑ia.com
Tel: [phone]
Fax: [phone]
Application Engineering
Tel: [phone]
Fax: [phone]
E‑mail: applicationsengineers@ati‑ia.com

Manual, Collision Sensor, SR‑48
Document #9610‑60‑1012‑06
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
3
Table of Contents
Forward ............................................................................................................................................ 2
Glossary ........................................................................................................................................... 4
1. Safety......................................................................................................................................... 5
1.1 ExplanationofNotications......................................................................................................... 5
1.2 General Safety Guidelines............................................................................................................ 5
1.3 Safety Precautions ........................................................................................................................ 6
2. Product Overview..................................................................................................................... 7
2.1 Product Description ...................................................................................................................... 7
3. Installation ................................................................................................................................ 8
3.1 Mechanical Installation ................................................................................................................. 8
3.1.1 FastenerTorqueSpecications .......................................................................................... 8
3.2 Electrical Connection.................................................................................................................... 9
3.2.1 Test Switch Functionality .................................................................................................... 9
3.3 Pneumatic Connection ............................................................................................................... 10
3.3.1 Calculating Estimated Pressure Setting ........................................................................... 10
3.3.1.1 Calculate Applied Loads ................................................................................... 10
3.3.1.2 Obtain Required Pressure Setting .................................................................... 12
3.3.2 Determining Exact Pressure Required ............................................................................. 13
4. Operation ................................................................................................................................ 13
5. Maintenance............................................................................................................................ 13
5.1 Periodic Lubrication Instructions .............................................................................................. 14
5.1.1 Cover Plate and Stem Disassembly................................................................................. 14
5.1.2 Cover Plate and Stem Cleaning and Lubrication ............................................................. 15
5.1.3 Cover Plate and Stem Re‑assembly ................................................................................ 16
6. Troubleshooting ..................................................................................................................... 17
6.1 Cable Replacement ..................................................................................................................... 18
6.2 Spring Conversion ...................................................................................................................... 19
6.3 Seal Replacement........................................................................................................................ 20
6.4 Weld Splatter Shield Replacement ............................................................................................ 21
7. Specications ......................................................................................................................... 21
8. Drawings ................................................................................................................................. 22
8.1 SR‑48 Collision Sensor Assembly Drawing.............................................................................. 22
8.2 SR‑48 Collision Sensor Assembly Replacement Parts............................................................ 23
9. Terms and Conditions of Sale............................................................................................... 25

Manual, Collision Sensor,SR‑48
Document #9610‑60‑1012‑06
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
4
Glossary
Term Denition
Body Cylindrical aluminum housing and air pressure chamber. An interface plate to the
user’s robot is usually attached here.
Cam A hardened steel ring mounted inside the cover on which the hardened steel ball
segments mounted to the stem are nested.
Collision Sensing Switch
A switch that changes state to an open circuit when a crash is detected. It is
mounted in a threaded hole in the side of the body under the connector block.
It is a normally open, PNP or NPN metal sensing proximity switch. It appears
closed in the working (reset) position since it is sensing a steel target. The steel
target moves out of range in the event of a crash.
Collision The accidental impact between the end of arm tooling and some
obstruction in its path.
Cover Plate Disk‑shaped aluminum cover for Collision Sensor body.
Crash The result of a disturbance that displaces the Collision Sensor components from
their standard, working position.
Interface Plate Optional component used to adapt the Collision Sensor body or stem to the
user’s robot or tooling.
Piston The component which, together with the Body, creates a pressure chamber.
Varying the pressure in this chamber varies the load required to move the piston.
Reset The ability of the Collision Sensor to return to its working position when a
disturbing force or displacement is removed.
Stem Round tapered post containing tapped holes and a dowel pin hole. An interface
plate to the user’s tooling is usually attached here.
Switch Target A steel block mounted on top of the piston, the position of which is sensed by the
Collision Sensing switch.

Manual, Collision Sensor, SR‑48
Document #9610‑60‑1012‑06
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
5
1. Safety
The safety section describes general safety guidelines to be followed with this product, explanation of the
notications found in this manual, and safety precautions that apply to the product. More specic notications are
imbedded within the sections of the manual were they apply.
1.1 ExplanationofNotications
The notications included here are specic to the product(s) covered by this manual. It is expected that the
user heed all notications from the robot manufacturer and/or the manufacturers of other components used
in the installation.
DANGER: Noticationofinformationorinstructionsthatifnotfollowedwillresultin
deathorseriousinjury.Thenoticationprovidesinformationaboutthenatureofthe
hazardous situation, the consequences of not avoiding the hazard, and the method for
avoiding the situation.
WARNING: Noticationofinformationorinstructionsthatifnotfollowedcouldresult
indeathorseriousinjury.Thenoticationprovidesinformationaboutthenatureofthe
hazardous situation, the consequences of not avoiding the hazard, and the method for
avoiding the situation.
CAUTION: Noticationofinformationorinstructionsthatifnotfollowedcouldresult
inmoderateinjuryorwillcausedamagetoequipment.Thenoticationprovides
information about the nature of the hazardous situation, the consequences of not
avoiding the hazard, and the method for avoiding the situation.
NOTICE: Noticationofspecicinformationorinstructionsaboutmaintenance,operation,
installation, or setup of the product that if not followed could result in damage to equipment. The
noticationcanemphasizespecicgreasetypes,goodoperatingpractices,ormaintenancetips.
1.2 General Safety Guidelines
The Collision Sensor is not designed for, nor should it be used in, situations involving the safety of humans
or animals. The Collision Sensor is designed as a safety device to protect industrial components and
machinery from damage resulting from collisions and impacts. In all situations the user is responsible for
insuring that applicable safety practices are followed as outlined by the manufacturer of the equipment on
which the Collision Sensor is used.
The routing of electrical and pneumatic lines must minimize the possibility of stress, pullout, kinking,
rupture, etc. Failure of critical electrical and/or pneumatic lines to function properly may result in injury to
personnel and damage to equipment.
CAUTION: The customer should lock out and discharge all energy to the work cell prior
to working on any Collision Sensor system. Failure to do so may result in damage to
equipment or injury to personnel.

Manual, Collision Sensor,SR‑48
Document #9610‑60‑1012‑06
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
6
1.3 Safety Precautions
WARNING: Do not perform maintenance or repair on the Collision Sensor with air
pressure applied, current supplied to the sensor, or the robot not in a safe condition.
Injury or equipment damage can occur if this is not observed. Always ensure that air
pressure has been vented from the unit, that electrical current is not supplied to the
Collision Sensor’s signal circuit, and that the robot is in a safe, locked‑out condition
consistent with local and national safety standards before performing maintenance or
repair on the Collision Sensor.
WARNING: The Collision Sensor is only to be used for intended applications and
applications approved by the manufacturer. Using the Collision Sensor in applications
other than intended will result in damage to Collision Sensor or end‑of‑arm tooling and
could cause injury to personnel.
CAUTION: Do not adjust or remove the set screw installed in the wall of the body.
Doing so may result in damage to the unit or failure of the switch to operate.
Refer to Figure 5.4.

Manual, Collision Sensor, SR‑48
Document #9610‑60‑1012‑06
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
7
2. Product Overview
The Collision Sensor is a pneumatically‑pressurized device offering protection to industrial robots and tooling in
the event of accidental impacts and unanticipated loads. The Collision Sensor works by “breaking away” from its
working geometry in the event of excessive torsional, moment, or compressive axial forces, or any combination of
these. The Collision Sensor cannot respond to pure axial tension, which is an unlikely mode of loading. Removal of
the upsetting force or moment allows the Collision Sensor to return to its normal working position.
As a collision occurs, internal motion of the Collision Sensor components cause a switch to change state to an open
circuit. The switch circuit may be monitored by robotic controllers to stop operations before damage to the robot
or tooling occurs. The load threshold at which the Collision Sensor breaks away is adjustable by controlling the air
pressure supplied to the unit.
All Collision Sensor devices provide axial (compression only), torsional, and moment compliance.
2.1 Product Description
The Collision Sensor consists of a piston housing (body) closed with a cover plate assembly. A stem
assembly protrudes through the cover plate assembly. The cover plate assembly incorporates a cam to
accurately and repeatably position the stem assembly. The stem assembly is forced into position against the
cam by a piston. The piston is supported by user supplied compressed air and an optional assist spring. The
stem provides a mounting surface for customized interface plates. Tapped and through holes on the back
surface of the body allow direct bolting of the body to the robot. All load‑bearing components and those
with wear surfaces are made of hard‑coat anodized aluminum, hardened bearing steel, or hardened tool steel.
A collision sensing switch is positioned in the side of the body. A connector block assembly containing a M8
connector is mounted on the side of the Collision Sensor body. The user connects to the switch using the M8
connector for which a variety of cables are available. The user must also supply the Collision Sensor with
dry, regulated, compressed air through a port on the side of the Collision Sensor body. The size and location
of these connections are shown in the drawing provided at the end of this manual.
Figure 2.1—Collision Sensor Collision Sensor

Manual, Collision Sensor,SR‑48
Document #9610‑60‑1012‑06
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
8
3. Installation
The Collision Sensor is commonly mounted with its body toward the robot and its stem toward the user tooling,
however, this is strictly up to the user.
3.1 Mechanical Installation
Refer to Figure 2.1
The Collision Sensor can be mounted directly to the robot or to the user tooling using the dowel pin holes
and the clearance / tapped holes in the Collision Sensor body. Should this not be possible, an interface plate
must be fabricated.
A second interface plate is often required for mounting to the Collision Sensor stem. Such interface plates
may be ordered from ATI as blank plates or machined as necessary for specic applications. Another option
is for the user to fabricate their own interface plates.
NOTICE: ThesurfacetowhichtheCollisionSensorbodyismountedmustbeatandsmooth
and provide support for the entire surface of the body.
Once any required machining of the interface plates is complete, mount the Collision Sensor using
hardware appropriately sized for the application. Connect an appropriately sized air line and tting to the
Collision Sensor.
NOTICE: Do not supply air pressure at this time.
All mounting hardware should be tightened. The use of an industrial thread‑locking compound is
recommended for all fasteners, refer to Section 3.1.1—Fastener Torque Specications.
3.1.1 FastenerTorqueSpecications
Table 3.1—Recommended Torques for ATI Supplied Fasteners
Fastener Size Torque Recommended Threadlocker
M3‑0.5 Cap Screw 19 in‑lbs (2.1 Nm)
Loctite 222 or equivalent
M4‑0.7 Cap Screw 41 in‑lbs (4.6 Nm)
M5‑0.8 Cap Screw 85 in‑lbs (9.6 Nm)
M6‑1.0 Flat Head Cap Screw 85 in‑lbs (9.6 Nm)

Manual, Collision Sensor, SR‑48
Document #9610‑60‑1012‑06
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
9
3.2 Electrical Connection
The Collision Sensor is connected to the user’s control wiring as a normally‑closed, dry‑contact switch. The
following sketch details the connections between the internal switch and the pins in the connector block
assembly. Optional mating cables, available from ATI (refer to Table 6.2), utilize the brown‑black‑blue color
code indicated.
CAUTION: The user is responsible for connecting the collision sensor to their controls
and providing an “electrical load” in series with the collision sensing switch. The switch
is rated for instrument level signals of 100mA (max.) at 10–30VDC.
Figure 3.1—Switch Wiring
3.2.1 Test Switch Functionality
Once the Collision Sensor has been installed and connected as described in the preceding
paragraphs, proper electrical operation of the unit may be conrmed.
Supply the Collision Sensor with approximately 15 psi (1 bar) and ensure that the unit is
electrically connected to the user’s control circuit or to a test box per Figure 3.1. The switch
should appear closed.
Manually push the Collision Sensor to simulate a collision while observing the switch output.
When the collision occurs the switch will open and the test light will turn off.
Release the Collision Sensor and it will return to its working position. The test light will illuminate.

Manual, Collision Sensor,SR‑48
Document #9610‑60‑1012‑06
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
10
3.3 Pneumatic Connection
Compressed air is to be supplied to the port marked “P” in the range of 20 psi to 90 psi. This port accepts
#10‑32 or M5 pneumatic ttings. The pressure setting required for a particular application can be estimated
using the procedure outlined in Section 3.3.1—Calculating Estimated Pressure Setting The exact pressure
required must be determined through testing using the procedure outlined in Section 3.3.2—Determining
Exact Pressure Required.
3.3.1 Calculating Estimated Pressure Setting
In order to determine the proper pressure setting for the collision sensor one must consider all
static and dynamic loads to which it is subjected. These include the loads produced due to the
static weight of the tooling, the inertial loads imposed by robot motion and the loads produced by
the end‑effector when performing its intended tasks. Once these loads are calculated, the nominal
pressure setting for the break‑away point can be determined. The calculation proceeds as follows:
3.3.1.1 Calculate Applied Loads
Figure 3.2 can be used to convert the forces acting on the end‑effector tooling into
the resulting moment, torque, and axial loads applied to the Collision Sensor. Use
the diagram shown in Figure 3.2 and the formulas below to calculate the worst‑case
applied loads for your application. All (3) load cases—axial, torque, and moment—
should be assessed for their static, dynamic, and working force components.
NOTICE: Not all of the component forces (static, dynamic, and working) are
present during all phases of the robot program. As a result, the worst case
conditions for axial, torque, and moment loads may occur at different times
in the program.