ATI Technologies SR-61 User manual

Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
Protector™
Robotic Collision Sensor
SR-61 Manual
U.S. Patent Nos. 6069415 and 6690208
Document #: 9610-60-1006-13

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
2
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 by ATI Industrial Automation. All rights reserved.
How to Reach Us
Sale, Service and Information about ATI products:
ATI IndustrialAutomation
1031 Goodworth Drive
Apex, NC 27539 USA
www.ati-ia.com
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Technical support and questions:
Application Engineering
Tel: [phone], Option 2, Option 2
Fax: [phone]
E-mail: [email protected]

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
3
Table of Contents
1. Safety......................................................................................................................................... 6
1.1 ExplanationofNotications.........................................................................................................6
1.2 General Safety Guidelines............................................................................................................6
1.3 Safety Precautions........................................................................................................................7
2. Product Overview..................................................................................................................... 8
2.1 Product Description......................................................................................................................8
3. Installation ................................................................................................................................ 9
3.1 Mechanical Installation.................................................................................................................9
3.1.1 FastenerTorqueSpecications ..........................................................................................9
3.2 Electrical Connection..................................................................................................................10
3.2.1 Test Switch Functionality.................................................................................................. 11
3.3 Pneumatic Connection ............................................................................................................... 11
3.3.1 Operating Requirements.................................................................................................. 11
3.3.2 Calculating Estimated Pressure Setting........................................................................... 11
3.3.2.1 Calculate Applied Loads ................................................................................... 11
3.3.2.2 Obtain Required Pressure Setting....................................................................13
3.3.3 Determining Exact Pressure Required.............................................................................14
4. Operation ................................................................................................................................ 15
5. Maintenance............................................................................................................................ 16
5.1 Periodic Lubrication Instructions..............................................................................................16
5.1.1 Cover Plate and Stem Disassembly.................................................................................16
5.1.2 Cover Plate and Stem Cleaning and Lubrication .............................................................17
5.1.3 Cover Plate and Stem Re-assembly................................................................................18
6. Troubleshooting ..................................................................................................................... 19
6.1 Cable Replacement.....................................................................................................................20
6.2 Replacement of Switch/Connector Block Assembly ...............................................................20
6.2.1 Replacement of Original Style Switch/Connector Block Assembly ..................................21
6.2.2 Replacement of Current Style Switch/Connector Block Assembly...................................22
6.3 Switch Adjustment......................................................................................................................23
6.3.1 Original Style Switch Adjustment......................................................................................23
6.3.2 Current Style Switch Adjustment......................................................................................24
6.4 Spring Conversion......................................................................................................................26
6.5 Seal Replacement........................................................................................................................27
6.6 IP65 Boot Replacement ..............................................................................................................28
6.7 Weld Splatter Shield Replacement............................................................................................29
6.8 Flexible Boot Replacement ........................................................................................................30

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
4
7. Specications ......................................................................................................................... 31
8. Serviceable Parts ................................................................................................................... 31
8.1 SR-61 with C5 Boot.....................................................................................................................31
9. Drawings ................................................................................................................................. 32
9.1 SR-61 Collision Sensor with Original Style Switch..................................................................32
9.2 SR-61 Collision Sensor with Current Style Switch ..................................................................33
10. Terms and Conditions of Sale............................................................................................... 35

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
5
Glossary of Terms
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 The accidental impact between the end of arm tooling and some obstruction in its path.
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.
Cover Plate Disk-shaped aluminum cover for Protector Body.
Crash The result of a disturbance that displaces the Protector components from their standard,
working position.
Interface Plate Optional component used to adapt the Protector 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 Protector 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, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
6
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 Protector is not designed for, nor should it be used in, situations involving the safety of humans or
animals. The Protector 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
Protector 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 Protector system. Failure to do so may result in damage to
equipment or injury to personnel.

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
7
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
Protector’s signal circuit, and that the robot is in a safe, locked-out condition consistent
with local and national safety standards before performing maintance 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 either of the two (2) set screws installed in the
wall of the Body. Doing so may result in damage to the unit or failure of the switch to
operate. See Figure 5.5.

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
8
2. Product Overview
The Protector is a pneumatically-pressurized device offering protection to industrial robots and tooling in the event
of accidental impacts and unanticipated loads. The Protector 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 Protector
cannot respond to pure axial tension, which is an unlikely mode of loading. Removal of the upsetting force or
moment allows the Protector to return to its normal working position.
As a collision occurs, internal motion of the Protector 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 Protector breaks away is adjustable by controlling the air pressure supplied
to the unit.
All Protector devices provide axial (compression only), torsional, and moment compliance.
2.1 Product Description
The Protector 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 8mm connector is mounted on the side of the Protector body. The user connects to the switch using the
8mm connector for which a variety of cables are available. The user must also supply the Protector with dry,
regulated, compressed air through a port on the side of the Protector body. The size and location of these
connections are shown in the drawing provided at the end of this manual.
Figure 2.1—Protector Collision Sensor
Pneumatic Port
Body
8mm Connector
Switch/Connector
Block Assembly
Cover Plate
Stem

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
9
3. Installation
The Protector 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
The Protector can be mounted directly to the robot or to the user tooling using the dowel pin holes and
the clearance / tapped holes in the Protector body. Should this not be possible, an interface plate must be
fabricated.
A second interface plate is often required for mounting to the Protector 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Protector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 Protector using hardware
appropriately sized for the application. Connect an appropriately sized air line and tting to the Protector.
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.
Figure 3.1—Installation
Switch Connector
SR-61 Collision Sensor
Optional Interface Plate (Body)
Custom Interface plates available from ATI
Optional Interface Plate (Stem)
Custom Interface plates available from ATI
Mounting Fasteners
Customer Supplied
M4 Mounting Fasteners (Customer Supplied)
(ATI Supplied with custom Interface Plates)
M4 Mounting Fasteners (Customer Supplied)
(ATI Supplied with custom Interface Plates)
(2) Dowel Pins (Customer Supplied)
(ATI Supplied with custom Interface Plates)
Dowel Pin (Customer Supplied)
(ATI Supplied with custom Interface Plates)
Pneumatic Port
3.1.1 FastenerTorqueSpecications
Table 3.1—Recommended torques for ATI supplied fasteners
Fastener Size Torque Recommended Thread Locker
M3-0.5 Cap Screw 19 in-lbs Loctite 222 or equivilantM4-0.7 Cap Screw 41 in-lbs
M5-0.8 Cap Screw 85 in-lbs.

Manual, Collision Sensor, Protector™,SR-61
Document #9610-60-1006-13
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 USA• Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
10
3.2 Electrical Connection
The Protector is connected to the user’s control wiring as a normally-open PNP or NPN proximity 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 (see Table 6.1), 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 10–30 VDC.
Figure 3.2—Switch Wiring