ATI Technologies QC-18 User manual

Manual, Robotic Electric Tool Changer, QC‑18
Document #9620‑20‑B‑18 Electric Tool Changer‑06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-1
US Patent No.: 8,132,816 B2
Table of Contents
B. Base Tool Changer ..................................................................................................................B-3
QC-18—Electric Tool Changer ....................................................................................................B-3
1. Product Overview..................................................................................................................B-3
1.1 Master Plate Assembly ............................................................................................................. B-3
1.2 Tool Plate Assembly.................................................................................................................. B-4
1.3 Servo Motor Module.................................................................................................................. B-5
1.4 Optional Modules...................................................................................................................... B-5
2. Installation .............................................................................................................................B-6
2.1 Master Interface......................................................................................................................... B-7
2.2 Master Plate Installation........................................................................................................... B-8
2.3 Master Plate Removal............................................................................................................... B-8
2.4 Tool Interface............................................................................................................................. B-9
2.5 Tool Plate Installation ............................................................................................................. B-10
2.6 Tool Plate Removal ................................................................................................................. B-10
2.7 Optional Module Installation...................................................................................................B-11
2.7.1 K Series Module Installation..........................................................................................B-11
2.7.2 K Series Module Removal.............................................................................................B-11
2.7.3 J16 Series Module Installation ......................................................................................B-12
2.7.4 J16 Series Module Removal .........................................................................................B-12
2.8 Electrical Connections............................................................................................................ B-13
3. Operation .............................................................................................................................B-14
3.1 Power Loss During Operation................................................................................................ B-15
3.2 Procedure for Tool Pickup...................................................................................................... B-15
3.3 Fail-Safe Condition.................................................................................................................. B-16
3.4 Procedure for Tool Drop Off................................................................................................... B-16
3.5 Tool Storage Considerations ................................................................................................. B-17
4. Maintenance.........................................................................................................................B-18
4.1 Preventive Maintenance ......................................................................................................... B-18
4.2 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins....................... B-19
4.3 Pin Block Inspection and Cleaning ....................................................................................... B-21

Manual, Robotic Electric Tool Changer, QC‑18
Document #9620‑20‑B‑18 Electric Tool Changer‑06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-2
US Patent No.: 8,132,816 B2
5. Troubleshooting and Service Procedures........................................................................B-22
5.1 Troubleshooting Procedures ................................................................................................. B-22
5.2 Manual Actuaion...................................................................................................................... B-23
5.3 Service Procedures................................................................................................................. B-24
5.3.1 V-ring Seal Replacement...............................................................................................B-24
5.3.2 Alignment Pin Replacement..........................................................................................B-25
5.3.3 Servo Motor Module Replacement................................................................................B-26
6. Serviceable Parts ................................................................................................................B-28
6.1 Master Plate - Model 9120-018M-2387-0-0-0-SG2 Serviceable Parts.................................. B-28
6.2 Tool Plate Serviceable Parts .................................................................................................. B-28
6.3 Accessories............................................................................................................................. B-28
7. Specifications......................................................................................................................B-29
8. Drawings ..............................................................................................................................B-30
8.1 QC-18 Tool Changer................................................................................................................ B-30

Manual, Robotic Electric Tool Changer, QC‑18
Document #9620‑20‑B‑18 Electric Tool Changer‑06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-3
US Patent No.: 8,132,816 B2
B. Base Tool Changer
QC-18—Electric Tool Changer
1. Product Overview
The QC‑18 Electric Tool Changer consists of a Master plate assembly and a Tool plate assembly.
CAUTION: Do not use the QC-18 Tool Changer in an application where water is present
or other fluids are being passed. Using the QC-18 Tool Changer in an application where
water is present or other fluids are being passed, can cause injury to personnel and
damage to equipment.
1.1 Master Plate Assembly
The Master plate assembly includes an anodized aluminum body, a hardened stainless steel locking
mechanism, and hardened steel alignment pins. The Master has (4) Flats, FlatA is specifically for mounting
the servo motor module. Flat C supports both K series modules and optional modules with J16 mounting
patterns. Flats B and D support optional modules with J16 mounting patterns.
The servo motor module has an integrated controller and high torque motor (refer to Section 1.3—Servo
Motor Module for more details).
A PNP DC proximity sensor is designed into the body of the Master plate to verify Tool plate presence when
coupled. The sensors provide a ready to lock (RTL) signal through the control module.
Figure 1.1—Master Plate Assembly with Servo Motor Module
12-Pin Motor Control
and Power Connector
Servo Motor Module
Mounted to Flat A
Flat D for Optional Modules
with J16 Mounting Pattern
Flat B for Optional Modules
with J16 Mounting Pattern
Flat C for K Series Modules or
Optional Modules with
J16 Mounting Pattern
Anodized Aluminum Body
QC-18 Master Base Assembly
(9120-018M-0-0-0-0-SG)
Manual Override for
Locking Mechanism
Alignment Pins
Hardened Stainless Steel
Locking Mechanism
RTL Proximity Sensor
The Master provides a mounting pattern with (2) dowel pins for locating the Master and includes (4)
mounting fasteners (M4 socket head cap screws) (refer to Section 8—Drawings for mounting details).
PNP DC Proximity sensors are designed into the body of the Master plate to verify the lock/unlock position
of the locking cam. The sensors provide the Lock and Unlock (L/U) signals through the motor controller
(refer to Figure 1.2).

Manual, Robotic Electric Tool Changer, QC‑18
Document #9620‑20‑B‑18 Electric Tool Changer‑06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-4
US Patent No.: 8,132,816 B2
The locking mechanism consists of a male coupling with holes that retain hardened chrome steel ball
bearings. Ahardened stainless steel cam is gear driven by a 24V brushless DC servo motor. Tapered pins
located on the Master body mate with holes in the Tool body 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 assembly.
Figure 1.2—Locking Mechanism
2 Amp 24 V Brushless
DC Motor
Gear Driven
Locking Mechanism Lock and Unlock Proximity Sensors
RTL Proximity Sensor
Hardened Stainless Steel Cam
Hardened Chrome Steel
Ball Bearings
1.2 Tool Plate Assembly
The Tool plate assembly includes an anodized aluminum body, a hardened stainless steel bearing race, and
hardened steel alignment bushings. Asensor target is built into the Tool body so the RTL proximity sensor in
the Master body can sense the Tool presence.
The Tool has (4) flats, Flat Ais not used for mounting modules because the servo motor module on the
Master requires the space a module would occupy. The Flat C supports both K series modules and optional
modules with J16 mounting patterns. Flats B and D support optional modules with J16 mounting patterns.
Figure 1.3—Tool Plate Assembly
Alignment Bushings
Hardened Stainless Steel
Bearing Race
RTL Sensor Target
Flat D for Optional Module
with J16 Mounting Pattern
Flat C for K Series Modules or
Modules with J16 Mounting Pattern
Flat B for Optional Module
with J16 Mounting Pattern

Manual, Robotic Electric Tool Changer, QC‑18
Document #9620‑20‑B‑18 Electric Tool Changer‑06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-5
US Patent No.: 8,132,816 B2
1.3 Servo Motor Module
The 9005‑20‑2387 servo motor module has an integrated motor controller and a 24VDC brushless
servo motor with sensor feedback. The module is equipped with a 12‑pin connector to interface with a
customer cable.
Figure 1.4—Servo Motor Module
QC- 18 Master Base Assembly
(9120-018M-0-0-0-0-SG2)
9005-20-2387 - 24 VDC Series
Servo Motor with Integrated Controller
Mounted on Flat A
12-Pin Motor Control
and Power Connector
1.4 Optional Modules
There are (3) Flats available for mounting of the optional modules for support of various utility pass
through, such as signal and power.
For assistance in choosing the right modules for your particular application, contact an ATI
Sales Representative.
Figure 1.5—Optional Modules
QC-18 Master Assembly
(9120-018M-2387 Shown)
QC-18 Tool Assembly
(9120-018T Shown)
Optional Module
(9120-R19-M Shown)
Optional Module
(9120-R19-T Shown)
(4) M4 Socket Flat Head Cap Screws
(4) M4 Socket Flat
Head Cap Screws

Manual, Robotic Electric Tool Changer, QC‑18
Document #9620‑20‑B‑18 Electric Tool Changer‑06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-6
US Patent No.: 8,132,816 B2
2. Installation
The Master plate assembly is attached to the robot arm and may require an interface plate to match mounting
patterns or create space to accommodate hollow wrist utilities. The Tool plate assembly is attached to the tooling
and may require an interface plate to match mounting patterns (refer to Section 8—Drawings for specific mounting
pattern details).
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.
Head of Mounting Fastener Must Be Flush or
Below Mating Surface. (Do Not Use Lock
Washer under Head of Mounting Fastener).
Mating Surface
WARNING: Do not perform maintenance or repair(s) on the Tool Changer or modules unless
the Tool is safely supported or placed in the tool stand, all energized circuits (for example:
electrical, air, water, etc.) are turned off, pressurized connections are purged and power
is discharged from circuits in accordance with the customer specific safety practices and
policies. Injury or equipment damage can occur with the Tool not placed and energized
circuits on. Place the Tool in the tool stand, turn off and discharge all energized circuits,
purge all pressurized connections, and verify all circuits are de-energized before performing
maintenance or repair(s) on the Tool Changer or modules.
WARNING: Mounting fasteners must have a thread locker such as Loctite 242 or equivalent
applied to the threads unless they have a pre-applied thread locker. Fasteners may come
loose resulting in injury to personnel or damage to equipment. Use fasteners with pre-applied
thread locker or apply thread locker to all mounting fasteners.
CAUTION: Do not use fasteners that exceed the thread depth in the Tool Changer (refer to
Section 8—Drawings 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.
Table 2.1—Optional Module Fastener Size, Class, and Torque Specications
Mounting conditions Fastener Size &
Property Class Recommended Torque Thread Locker
Optional Module or adapter plate to Master or
Tool plate, Supplied Fasteners
M3 x 0.5 Class 12.9
Pre-applied Adhesive or
Loctite 222
Socket head cap 10 in-lbs (1.13 Nm)
Socket at head cap 8 in-lbs (0.9 Nm)
M4 x 0.7 Class 12.9
Socket head cap 15 in-lbs (1.69 Nm)
Socket at head cap 10 in-lbs (1.13 Nm)

Manual, Robotic Electric Tool Changer, QC‑18
Document #9620‑20‑B‑18 Electric Tool Changer‑06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-7
US Patent No.: 8,132,816 B2
2.1 Master Interface
The Master assembly is attached to the robot arm. The Master plate is designed with mounting features
such as a boss and/or bolt and dowel holes. These features are used to accurately position and secure the
Master to the robot.
An interface plate is utilized to adapt the Master plate to a specific robot flange that is not compatible with
the Master plate mounting features. Custom interface plates are available upon request (refer to Section 8—
Drawings of this manual for technical information on mounting features).
If the customer chooses to design and build an interface plate, the following should be considered:
CAUTION: Do not use more than two alignment features when securing a Master plate
to an interface plate. Using more than two alignment features can cause damage to
equipment. Use either two dowel pins or a single dowel pin along with a boss/recess
feature to align the Master plate with the interface plate.
CAUTION: Do not use dowel pins that are too long that will not allow the interface plate
and Master body to mate flush with each other. Using dowel pins that are too long will
cause a gap between the interface plate and the Master body causing damage to the
equipment. Use the proper size dowel pins that will not extend further than allowed by
the Master body.
Master Plate
Interface Plate
Dowel pins which are
proper size allowing
interface plate and Master
Plate to mount flush.
Two dowel pins
(or a single dowel
pin along
with a boss/recess) being
used as alignment features.
Flush
Correct Mounting of Master Plate
Master Plate
Interface Plate
Dowel pins which are
too long can cause a
plate and Master Plate.
gap between interface
Optional Boss
GapGap
A boss and two dowel pins
as alignment features can
as difficult to align and can
cause damage to equipment.
Incorrect Mounting of Master Plate
• The interface plate should be designed to include bolt holes for mounting and either two dowel pins
or a dowel pin and a boss for accurate positioning on the robot and Master plate. The dowel and boss
features are important to prevent rotation (refer to robot manual for robot mounting features).
• The thickness of the interface plate must be great enough to provide the necessary thread engagement
for the mounting bolts.
• Dowel pins must not extend out from the surface of the interface plate farther than the depth of the
dowel holes in the Master plate.
• If a boss is used on the Master plate, a recess of proper depth and diameter must be machined into the
interface plate to correspond with the boss on the Master plate.
• Mounting bolts should not be too long, such that a gap is formed at the interface.
• The interface plate must be properly designed to provide rigid mounting to the Master plate.
• The interface plate design should take into account clearances required for Tool Changer module
attachments and accessories.

Manual, Robotic Electric Tool Changer, QC‑18
Document #9620‑20‑B‑18 Electric Tool Changer‑06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-8
US Patent No.: 8,132,816 B2
2.2 Master Plate Installation
Tools required: 4 mm hex key, torque wrench
Supplies required: Clean rag
1. Make sure mounting surface of the Master plate and robot arm or interface plate are clean and
free of debris.
2. If an interface plate is required, attach the plate to the robot using appropriate mounting fasteners
and torque values.
3. Attach the Master plate assembly to the interface plate using the (4) M4 socket head cap screws
provided. Tighten to 15 in‑lbs (1.7 Nm).
4. Connect and route the cable and secure per customer cable routing requirements.
5. Connect controller to customer interface cable to the 12‑pin connector on the QC‑18 servo motor module
and connect cable to customer interface as prescribed in Section 2.8—Electrical Connections.
6. Connect any electrical connection to optional modules.
7. If installation is complete, the Master plate may be put into normal operations.
Figure 2.1—Typical Master Plate Installation
Robot
ATI or Customer Supplied
Interface Plate (If Required)
Customer Supplied
Mounting Fasteners
Customer Supplied
Controller Cable
Availabe from ATI
(4) M4 Socket
Head Cap Screws
Electrical
Connection
QC-18 Master Assembly
(9120-018M-2387 Shown)
12-Pin Connector
Customer Supplied
4 mm Dowel Pins
2.3 Master Plate Removal
Tools required: 4 mm hex key
1. Place the Tool in a secure location.
2. Uncouple the Master and Tool plates.
3. Turn off and de‑energize all energized circuits (for example: electrical, pneumatic, and hydraulic).
4. If needed, disconnect all utilities (for example: electrical, pneumatic, and hydraulic).
5. Note: support the Master plate while removing the fasteners. Remove the (4) M4 socket head cap screws
connecting the Master plate to the robot arm or interface plate.

Manual, Robotic Electric Tool Changer, QC‑18
Document #9620‑20‑B‑18 Electric Tool Changer‑06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-9
US Patent No.: 8,132,816 B2
2.4 Tool Interface
The Tool plate is attached to the customer’s tooling. It may be necessary for an interface plate to be utilized
to adapt the Tool plate to customer’s tooling. The Tool plate is designed with alignment features (dowel
holes and a recess) to accurately position and bolt holes to secure the Tool plate to customer’s tooling.
Custom tool interface plates can be supplied by ATI to meet customer’s requirements (see Figure 2.2).
If the customer chooses to design and build a tool interface plate, the following should be considered:
CAUTION: Do not use more than two alignment features when securing a Tool plate
to an interface plate. Using more than two alignment features can cause damage to
equipment. Use either two dowel pins or a single dowel pin along with a boss/recess
feature to align the Tool plate with the interface plate.
CAUTION: Do not use dowel pins that are too long that will not allow the interface
plate and Tool body to mate flush with each other. Using dowel pins that are too long
will cause a gap between the interface plate and the Tool body causing damage to the
equipment. Use the proper size dowel pins that will not extend further than allowed
by the Tool body.
Tool Plate
Interface Plate
Dowel pins which are
proper size allowing
interface plate and Tool
Plate to mount flush.
Two dowel pins (or a
boss/recess) being used as
alignment features.
Correct Mounting of Tool Plate
Tool Plate
Interface Plate
Dowel pins which
are too long and
cause a gap between
interface plate and Tool.
Boss and two dowel pins
as alignment features can be
difficult to align and can
cause damage to equipment.
Gap
Incorrect Mounting of Tool Plate
single dowel pin along with a
• The interface plate should be designed to include bolt holes for mounting and either two dowel pins or
a dowel pin and a boss for accurate positioning on the customer tooling and Tool plate. The dowel and
boss features are important to prevent rotation.
• Dowel pins must not extend out from the surface of the interface plate farther than the depth of the
dowel holes in the Tool plate.
• 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.
• If a boss is to be used on the interface plate, a boss of proper height and diameter must be machined
into the interface plate to correspond with the recess in the Tool plate.
• 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. Even greater protection will result if the standard race cover with removable
access plug is used. [Note: Through hole diameter in plate: .563” (14.3 mm). Grommet outside
diameter: .88” (22.5 mm)].

Manual, Robotic Electric Tool Changer, QC‑18
Document #9620‑20‑B‑18 Electric Tool Changer‑06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-10
US Patent No.: 8,132,816 B2
2.5 Tool Plate Installation
Tools required: 4 mm hex key, torque wrench
Supplies required: Clean rag
1. Make sure the mounting surface of the Tool plate and tool interface plate is clean and free of debris.
2. Attach tool or interface plate to the Tool plate assembly using the customer supplied M6 mounting
fasteners. Tighten to appropriate torque.
3. If required attach tool hanger, refer to the tool stand installation and operation manual.
4. After Tool base is secured, connect any electrical connection to optional modules.
5. If installation is complete, the Tool plate may be put into normal operations.
Figure 2.2—Typical Tool Installation
Electrical Connection
Tool Base Assembly
Tool or Interface Plate
Supplied by Customer
Mounting fasteners
Supplied by Customer
2.6 Tool Plate Removal
Tools required: 4 mm hex key
1. Place the Tool in a secure location.
2. Uncouple the Master and Tool plates.
3. Turn off and de‑energize all energized circuits (for example: electrical, pneumatic, and hydraulic).
4. If needed, disconnect all utilities (for example: electrical, pneumatic, and hydraulic).
5. Remove the fasteners connecting the Tool plate to the tooling or tool interface plate.

Manual, Robotic Electric Tool Changer, QC‑18
Document #9620‑20‑B‑18 Electric Tool Changer‑06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-11
US Patent No.: 8,132,816 B2
2.7 Optional Module Installation
The optional modules are typically installed on Tool Changers by ATI prior to shipment. Installation
and removal are outlined in the following section: Tool Changers are compatible with many different
types of modules.
2.7.1 K Series Module Installation
Tools required: 2 mm or 2.5 mm hex key, torque wrench
Supplies required: Clean rag, Loctite 222
1. If the Tool Changer is in service, place the Tool safely in the tool stand and uncouple the Tool
Changer to allow clear access to the Master and Tool plates.
2. Turn off and de‑energize all energized circuits (for example: electrical, pneumatic, and
hydraulic circuits).
3. Make sure mounting surfaces of the Tool plate, Master plate, and modules are clean and free of
debris. Align optional module on flatA of Master or Tool plate assembly.
4. If not using fasteners with pre‑applied adhesive, apply Loctite 222 to M3 mounting fasteners.
Secure module with (2) M3 mounting fasteners using a 2 mm or 2.5 mm hex key (refer to Table
2.1 for proper torque for your specific mounting fasteners).
5. Remove all protective caps, plugs, tape, etc from the module prior to operation.
6. Safely resume normal operation.
Figure 2.3—K Series Module Installation
QC-18 Master Assembly
(9120-018M-2387 Shown)
QC-18 Tool Assembly
(9120-018T Shown)
Optional Module
(9120-K19-M Shown)
Optional Module
(9120-K19-T Shown)
(2) M3 Socket Head Cap Screws
(2) M3 Socket Head Cap Screws
2.7.2 K Series Module Removal
Tools required: 2 mm or 2.5 mm hex key
1. Place the Tool in a secure location.
2. Uncouple the Master and Tool plates.
3. Turn off and de‑energize all energized circuits (for example: electrical, pneumatic,
and hydraulic).
4. Disconnect any cables, air line, etc. if required.
5. Remove the (2) M3 socket head cap screws using a 2 mm or 2.5 mm hex key. Note: For the
module on the master, the Master plate may have to be removed (refer to Section 2.3—Master
Plate Removal).
6. Remove the module from the Master or Tool plate.

Manual, Robotic Electric Tool Changer, QC‑18
Document #9620‑20‑B‑18 Electric Tool Changer‑06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-12
US Patent No.: 8,132,816 B2
2.7.3 J16 Series Module Installation
Tools required: 2.5 mm or 3 mm hex key, torque wrench
Supplies required: Clean rag, Loctite 222
1. If the Tool Changer is in service, place the Tool safely in the tool stand and uncouple the Tool
Changer to allow clear access to the Master and Tool plates.
2. Turn off and de‑energize all energized circuits (for example: electrical, pneumatic, and
hydraulic circuits).
3. Make sure mounting surfaces of the Tool plate, Master plate, and modules are clean and free of
debris. Align optional module on the Master or Tool plate as shown in Figure 2.4.
4. If not using fasteners with pre‑applied adhesive, apply Loctite 222 to (4) M4 socket head cap
screws or (4) M4 socket flat head cap screws. Secure module with (4) M4 mounting fasteners
using a 2.5 mm or 3 mm hex key (refer to Table 2.1 for proper torque for your specific
mounting fasteners).
5. Remove all protective caps, plugs, tape, etc from the module prior to operation.
6. Safely resume normal operation.
Figure 2.4—J16 Series Module Installation
QC-18 Master Assembly
(9120-018M-2387 Shown)
QC-18 Tool Assembly
(9120-018T Shown)
Optional Module
(9120-R19-M Shown)
Optional Module
(9120-R19-T Shown)
(4) M4 Socket Flat Head Cap Screws
(4) M4 Socket Flat
Head Cap Screws
2.7.4 J16 Series Module Removal
Tools required: 2.5 mm or 3 mm hex key
1. Place the Tool in a secure location.
2. Uncouple the Master and Tool plates.
3. Turn off and de‑energize all energized circuits (for example: electrical, pneumatic,
and hydraulic).
4. Disconnect any cables, air line, etc. if required.
5. Remove the (4) M4 socket head cap screws or (4) M4 socket flat head cap screws using a
2.5 mm or 3 mm hex key, and lift the module from the Master or Tool plate.

Manual, Robotic Electric Tool Changer, QC‑18
Document #9620‑20‑B‑18 Electric Tool Changer‑06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-13
US Patent No.: 8,132,816 B2
2.8 Electrical Connections
The cable connection from the motor controller to the customer connection is provided through a pigtail
connection (refer to Table 2.2 for specific wire color and signal information). The US1 power and US2
power is required to read the Locked and Unlocked sensors.
CAUTION: Poor cable routing can result in wires and cables being pinched in the joint
between the Tool Changer halves. Failure to observe this point may result in premature
failure of the cable and connection. Properly route and secure all cables, particularly on
the Master side.
Table 2.2—Customer Cable Pigtail Connections
Wire Color Signal Signal description
Violet US1 Sensor power (to read Locked, Unlocked, and RTL Sensors)
Yellow US1 GND Sensor power ground
Red US2 Motor power (powers motor and controller)
Green US2 GND Motor power ground
Black Latch Output supplied to the ATI Master module to couple the
Tool Changer.
Orange Unlatch Output supplied to the ATI Master module to uncouple the
Tool Changer.
White Locked Input signal indicating that the coupling mechanism is in the
Locked position.
Tan Unlocked Input signal indicating that the coupling mechanism is in the
Unlocked position.
Blue RTL Proximity sensor input that senses when the ATI Tool is in
close proximity
Brown No Connect No Connect
Gray No Connect No Connect
Pink No Connect No Connect
Figure 2.5—Electrical Connections
2387
12-Pin Connection
9120-018M-2387-0-0-0-SG2
Turch BKM-12-967

Manual, Robotic Electric Tool Changer, QC‑18
Document #9620‑20‑B‑18 Electric Tool Changer‑06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
B-14
US Patent No.: 8,132,816 B2
3. Operation
The Master locking and drive mechanism is mechanically driven to couple and uncouple with the bearing race on
the Tool plate. The Master plate utilizes drive torque from a motor module to provide lock and unlock forces to the
locking mechanism.
The following procedures provide general guidelines for operational sequence of the QC‑18 Tool Changer. The
motor controller electronics and software provide operational behavior that is intended to ensure proper operation
and prevent damage to the unit.
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 Section 4.2—Cleaning 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 Figure 3.1 and Table 3.1 for recommended maximum allowable
offsets prior to coupling. In some cases, greater offsets than shown in Table 3.1 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 (refer to Table 3.1) but not touching
the Tool plate. As locking occurs, the Master plate should draw the Tool plate into the locked position.
Figure 3.1—O󰀨set Denitions
Cocking Offset
About X and Y
Table 3.1—Maximum Recommended O󰀨sets Prior to Coupling
Model Z O󰀨set
(Max)1X and Y O󰀨set
(Max) 2Cocking O󰀨set (Max) Twisting O󰀨set (Max)
QC-18 0.04”
(1.0 mm) ±0.04” (1.0 mm) ±0.7° ±1°
Notes:
1. Maximum values shown. Decreasing actual values will minimize wear during coupling/uncoupling.
2. Actual allowable values may be higher in some cases but higher offsets will increase wear during coupling.

Manual, Robotic Electric Tool Changer, QC‑18
Document #9620‑20‑B‑18 Electric Tool Changer‑06
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US Patent No.: 8,132,816 B2
3.1 Power Loss During Operation
In the event that the motor and motor controller loses power during operation and if the Tool Changer is
within locked sensing range, immediately stop operation and restore power. The motor controller is designed
to apply a small force with the motor to maintain the Tool Changer in the locked position. When power
is lost, a slight separation between the Master and Tool plates might occur but the Tool Changer will not
uncouple it will remain in a fail‑safe condition but I/O (sensor inputs) will be lost between Master and Tool
(refer to Section 3.3—Fail‑Safe Condition for more information).
3.2 Procedure for Tool Pickup
CAUTION: The locking mechanism must be in the unlock position when attempting to
couple the Tool Changer. Failure to adhere to this condition may result in damage to
the unit and/or the robot
NOTICE: When the unit powers up, the QC will remain in place until a Latch or Unlatch output
signal is received. A +24V signal on the Latch will make the QC lock. A +24V signal on the
Unlatch wire will make the QC Unlock. Once a signal is received, the QC will move to that
location until the cycle is complete. The unit homes itself during the first unlatch after power-up.
Therefore, the first latching and/or unlatching cycles will be slightly slower but still meet the
transition time of within 1 second.
1. Verify the Unlock signal is ON and the Locked signal is OFF. Indicates the Tool Changer is in the
Unlocked position.
2. Position the Master above the Tool and move the Master into position. The mating surfaces of the Master
and Tool should be parallel and within 0.04” (1 mm) of each other before coupling to minimize wear on
the locking mechanism.
CAUTION: Make sure that the tapered alignment pins from the Master enter the alignment holes
on the Tool. The alignment pins should be relatively concentric with the alignment holes such
that they do not rub against the edge.
3. (Optional) Verify that the RTL (Ready to Lock) signal is ON. This ensures that the Master is within
1 mm of the Tool.
4. If the Unlatch command is ON, turn it OFF. Turn the Latch command ON. Within 1 second, the
Master will lock.
CAUTION: If the QC is in the proper position or the same signal is raised a consecutive number
of time, the unit will not respond to the repeated signals. The Unlatch and Latch output signal
must be on for a minimum of 50 ms or the QC will not respond.
5. Verify the Unlocked signal is OFF and the Locked signal is ON. This indicates that the Tool Changer is
in the Locked position.
6. Move the tool away from the tool stand.

Manual, Robotic Electric Tool Changer, QC‑18
Document #9620‑20‑B‑18 Electric Tool Changer‑06
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US Patent No.: 8,132,816 B2
3.3 Fail-Safe Condition
In the event of power loss to the locking mechanism the Tool Changer will not uncouple. A slight
separation between the Master and Tool plates might occur just after power loss but at this point the worm
gear teeth will not back drive without power being applied to the unlatch command. This feature provides
the Tool Changer with a fail‑safe mechanism.
Positional accuracy may not be maintained during power loss but will be regained once power is
re‑established to the motor module.
CAUTION: Do not use the Tool Changer in the fail-safe condition for extended periods
of time. Do not transport the Tool Changer in the fail-safe condition. Possible damage
to the locking mechanism could occur.
3.4 Procedure for Tool Drop Off
1. Place the tool securely in the tool stand.
2. If the Latch command is ON, turn it OFF. Turn the Unlatch command ON. Within 1 second, the
Master will unlock.
NOTICE: If the QC is in the proper position or the same signal is raised a consecutive number of
time, the unit will not respond to the repeated signals. The Unlatch and Latch output signal must
be on for a minimum of 50 ms or the QC will not respond.
3. Verify the Unlocked signal is ON and the Locked signal is OFF, indicating the Tool Changer is in the
Unlocked position.
NOTICE: The Unlocked signal should read “ON” and the Locked signal should read “OFF”. Any
other condition indicates a problem and the robot program should be halted.
4. Move the Master away from the tool.

Manual, Robotic Electric Tool Changer, QC‑18
Document #9620‑20‑B‑18 Electric Tool Changer‑06
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
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US Patent No.: 8,132,816 B2
3.5 Tool Storage Considerations
CAUTION: Tool stand design is critical to proper operation of the Tool Changer.
Improperly designed tool stands can cause misalignments that will cause jamming and/
or excessive wear of Tool Changer components.
The tools may be stored in a tool stand when not being used by the robot. ATI provides compatible tool
stands designed for durability, longevity, and maximum adaptability to fit most customers’ applications.
The ATI TSS (Tool Stand Small) system is compatible with ATI Tool Changer sizes QC‑001 to QC‑41. The
TSS systems can be equipped with horizontal modules, clamp modules, and different types of tool sensing.
Two mounting styles are available: a pin and bushing style and a pin and rack style. Visit the ATI Web Site
http://www.ati‑ia.com/products/toolchanger/toolstand/small/SmallStand.aspx for products available for your
specific application, or contact ATI for recommendations and assistance.
If the customer is supplying the tool stand, it should be designed to provide a fixed, repeatable, level, and
stable positions for tool pick up and drop off. The tool stand must support the weight of the Tool Changer
Tool plate, Tool Interface Plate, optional modules, cables, hoses, and customer tooling without allowing
deflection in excess of the offsets specified in Section 3—Operation.
Ideally, the Tool should be hanging vertically in the tool stand so that gravity assists to uncouple the Tool
plate from the Master plate during unlocking. It is possible to design tool stands that hold tools in the
horizontal position but care must be taken that the necessary compliance is provided during coupling and
uncoupling. In general, “horizontal position” tool stands cause more wear on the locking mechanism and
locating features of the Tool and tool stand.
A variety of methods may be used to position the Tool in the tool stand. A common method is to use tapered
alignment pins and bushings. Robot programming and positional repeatability are vital in tool pick up and
drop off, refer to Section 3—Operation.
It is highly recommended that the customer provide a sensor that detects the presence of a properly seated
Tool in the tool stand. The sensor may be used prior to coupling to ensure there is a Tool properly seated in
the stand. Sensors may also be used as the robot starts to move away after uncoupling. This provides a safety
measure in the event that a Tool should become jammed in the stand or if the Tool should fail to release
properly from the robot.
Proximity sensors should be positioned so that the sensing face is vertical to prevent metal shavings, weld
spatter, or other debris from falling on the sensor and creating false readings.
Tool stands may also need to incorporate means for covering Tools and modules to protect them in dirty
environments, such as grinding or welding. Alternatively, positioning tool stands in areas shielded from weld
spatter, fluids, adhesives, or other debris would eliminate the need for tool covers.

Manual, Robotic Electric Tool Changer, QC‑18
Document #9620‑20‑B‑18 Electric Tool Changer‑06
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US Patent No.: 8,132,816 B2
4. Maintenance
WARNING: Do not perform maintenance or repair(s) on the Tool Changer or modules unless
the Tool is safely supported or placed in the tool stand, all energized circuits (for example:
electrical, air, water, etc.) are turned off, pressurized connections are purged and power
is discharged from circuits in accordance with the customer specific safety practices and
policies. Injury or equipment damage can occur with the Tool not placed and energized
circuits on. Place the Tool in the tool stand, turn off and discharge all energized circuits,
purge all pressurized connections, and verify all circuits are de-energized before performing
maintenance or repair(s) on the 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 tool stands away from debris generators.
2) Covers incorporated into the tool stands.
3) Guards, deflectors, air curtains, and similar devices built into the EOAT and the tool stand.
4.1 Preventive Maintenance
The Tool Changer and optional modules are designed to provide a long life with regular maintenance. A
visual inspection and preventive maintenance schedule is provided in the following table depending upon
the application. Detailed assembly drawings are provided in Section 8—Drawings (refer to module sections
for detailed preventive maintenance steps for all utility modules).
Table 4.1—Maintenance
Application(s) Tool Change Frequency Inspection Schedule
General Usage Material Handling Docking Station > 1 per minute Weekly
< 1 per minute Monthly
Welding/Servo/Deburring, Foundry Operations (Dirty
Environments) All Weekly
Checklist
Mounting Fasteners
гInspect fasteners for proper torque, interferences, and wear. Tighten and correct as required.
Ball Bearings/Alignment Pins/Bushings/Bearing Race
гInspect for wear and proper lubrication. MobilGrease XHP222 Special is 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 debris. Therefore, it is recommended to thoroughly clean the
existing grease and replace with new as needed (refer to Section 4.2—Cleaning and Lubrication of the Locking
Mechanism and Alignment Pins).
гInspect 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. To replace worn
alignment pins (refer to Section 5.3.2—Alignment Pin Replacement).
гInspect for wear on the ball bearings/bearing race, may be an indication of excessive loading.
Sensors and Cables
гInspect sensor cable connectors for tightness, if loose tighten connections.
Electrical Contacts/Pin Block (Modules)
гInspect for damage, debris, and stuck/burnt pins. Clean pin blocks as required (refer to Section 4.3—Pin Block
Inspection and Cleaning).
Seals (Modules)
гInspect for wear, abrasion, and cuts (refer to Section 5.3.1—V‑ring Seal Replacement)

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Document #9620‑20‑B‑18 Electric Tool Changer‑06
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US Patent No.: 8,132,816 B2
4.2 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins
Supplies required: Clean rag, cotton swabs, NLGI #2 lithium complex grease
1. Place the Tool in a secure location.
2. Turn off and de‑energize all energized circuits (for example: electrical, pneumatic, and
hydraulic circuits).
3. The locking mechanism must be in the unlock state before cleaning.
4. 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.
Figure 4.1—Cleaning Ball Bearings and Outer Surfaces of Male Coupling
5. Use a clean cotton swab to thoroughly remove the existing lubricant and debris from the balls, rotate the
balls to clean the in and around the balls.
Figure 4.2—Cleaning Ball Bearings of Locking Mechanism
In and Around Ball Bearing
Surface of Male Coupling

Manual, Robotic Electric Tool Changer, QC‑18
Document #9620‑20‑B‑18 Electric Tool Changer‑06
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US Patent No.: 8,132,816 B2
6. Check each ball bearing to make sure it moves freely in the male coupling. Additional cleaning may be
necessary to free up any ball bearings that are sticking in place.
7. Apply a liberal coating of lubricant to the ball bearings, male coupling, and alignment pins.
Figure 4.3—Apply Lubricant to Locking Mechanism
Apply Lubricant in and Around Ball Bearings
Apply Lubricant on Alignment Pins,
Outer Surface of Male Coupling
Apply Lubricant on Alignment Pins,
Outer Surface of Male Coupling
Apply Lubricant on Alignment Pins,
Outer Surface of Male Coupling
8. Use a clean rag to thoroughly remove the any lubricant and debris from the bearing race and the
bushings from the Tool plate.
Figure 4.4—Clean Tool Plate Surfaces of Locking Mechanism
Clean Bushing SurfacesClean Bushing Surfaces
Clean Bearing Race Surfaces
9. No application of lubrication is necessary on the Tool plate components.
10. Safely resume normal operation.