ATI Technologies QC-110 Series User manual

Manual, Tool Changer, QC-110
Document #9620-20-B-110 Series Base Tool Changer-26
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
B-1
Table of Contents
B. Base Tool Changer ..................................................................................................................B-3
QC-110 Series—Robotic Tool Changer ......................................................................................B-3
1. Product Overview..................................................................................................................B-3
1.1 Master Plate Assembly ............................................................................................................. B-4
1.2 Tool Plate Assembly.................................................................................................................. B-5
1.3 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 with J16 Pattern Installation.......................................................................B-11
2.8 Optional Module with J16 Pattern Removal...........................................................................B-11
2.9 Pneumatic Connections ......................................................................................................... B-12
2.9.1 Valve Requirements and Connections for the Locking Mechanism ..............................B-12
2.10 Electrical Connections............................................................................................................ B-13
2.10.1 PNP Type Lock and Unlock Sensors (-SD, -SFB, -SG, -SGH, -SM, -SMH, -SM1,
and -ST sensor designation).........................................................................................B-13
2.10.2 NPN Type Lock and Unlock Sensors (-SE, -SF, -SP, -SU sensor designation).............B-13
2.10.3 2-Namur Type Lock and Unlock Sensors (-SV sensor designation) .............................B-14
3. Operation .............................................................................................................................B-15
3.1 Conditions for Coupling......................................................................................................... B-16
3.2 Fail-Safe Operation ................................................................................................................. B-16
3.3 Conditions for Uncoupling..................................................................................................... B-17
3.4 ToolIdentication.................................................................................................................... B-17
3.5 Tool Storage Considerations ................................................................................................. B-18
4. Maintenance.........................................................................................................................B-19
4.1 Preventive Maintenance ......................................................................................................... B-19
4.2 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins....................... B-20
4.3 Pin Block Inspection and Cleaning ....................................................................................... B-22
5. Troubleshooting and Service Procedures........................................................................B-23
5.1 Troubleshooting Procedures ................................................................................................. B-23

Manual, Tool Changer, QC-110
Document #9620-20-B-110 Series Base Tool Changer-26
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
B-2
5.2 Service Procedures................................................................................................................. B-24
5.2.1 V-ring Seal Replacement...............................................................................................B-24
5.2.2 Alignment Pin Replacement..........................................................................................B-25
5.2.3 Rubber Bushing Replacement ......................................................................................B-26
5.2.4 Lock and Unlock Sensor Replacement Procedures......................................................B-27
5.2.4.1 Lock and Unlock Sensor Assembly Replacement
(with Sensor Assemblies) ..............................................................................B-27
5.2.5 RTL Sensor Replacement Procedures..........................................................................B-29
5.2.5.1 RTL Flat Pack Style Sensor Replacement (Y-Style and Lead Cable)............B-29
5.2.5.2 RTL Flat Pack Style Sensor Replacement (with Potted Assembly)...............B-31
6. Serviceable Parts ................................................................................................................B-33
6.1 Common Parts (Alignment Pins, Rubber Bushings and Master plates)............................ B-33
6.2 Current Model 9120-110xM-000-000-S0................................................................................. B-33
6.3 Current Models with PNP Sensors 9120-110xM-000-000-(SM, ST)-(RD, RD1) ................... B-34
6.4 Current Models with NPN Sensors 9120-110xM-000-000-(SP, SU)-(RD1) .......................... B-35
6.5 Current Model with NAMUR Sensors 9120-110xM-000-000-SV .......................................... B-36
6.6 Current Models 9120-110xM-000-000-SM1 ........................................................................... B-37
6.7 Discontinued Models 9120-110xM-000-000-(SD, SG, SE, SF)-(RD) .................................... B-38
6.8 Discontinued Models 9120-110xM-000-000-(SGH, SEH)...................................................... B-39
6.9 Discontinued Models 9120-110xM-000-000-SMH.................................................................. B-40
6.10 Discontinued Model 9120-110xM-000-000-SFB .................................................................... B-41
6.11 Current Models 9120-110xT-000-000...................................................................................... B-42
7. Specications ......................................................................................................................B-43
8. Drawings ..............................................................................................................................B-44
8.1 QC-110 Tool Changer, 3/8 NPT............................................................................................... B-44
8.2 QC-110 Tool Changer, G 3/8 BSPP......................................................................................... B-47
8.3 QC-110 Tool Changer, Rc 1/4 BSPT Ports............................................................................. B-50
8.4 QC-110 Tool Changer, G 1/4 BSPP Ports............................................................................... B-53

Manual, Tool Changer, QC-110
Document #9620-20-B-110 Series Base Tool Changer-26
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
B-3
B. Base Tool Changer
QC-110 Series—Robotic Tool Changer
1. Product Overview
ATI Tool Changers enhance the versatility of a robot by enabling the use of multiple customer tools, such as:
grippers, vacuum cup tooling, pneumatic and electric motors, weld guns, and more.
The Tool Changer consists of a Master plate, which is attached to the robot arm, and a Tool plate, which is attached
to customer tooling. When the robot picks up the customer tooling, a pneumatically-driven locking mechanism
couples the two plates. The patented, fail-safe locking mechanism utilizes a multi-tapered cam with ball locking
technology to ensure the Tool Changer does not uncouple if air pressure falls below 60 psi (4.1 bar) during
operation.
The robot can be programmed to select the desired customer tooling by coupling the Master plate to the Tool plate.
Electricity, uid, and other forces of energy transfer to the customer tooling through optional modules that are
attached to the Master and Tool plates. Refer to the ATI website for compatible modules or contact an ATI sales
representative for more details.
For the most current product information and specications on the QC-110 Series of Tool Changers, please click
the following link: QC-110 Series

Manual, Tool Changer, QC-110
Document #9620-20-B-110 Series Base Tool Changer-26
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
B-4
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 plate has (2) at sides for mounting of optional modules.
The locking mechanism consists of a cam, a male coupling, and chrome steel ball bearings.
Tapered pins are located on the Master plate mate with bushings in the Tool plate 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.
1/8 NPT, G 1/8 BSPP, or Rc 1/8 BSPT port connections are available to supply air pressure for coupling and
uncoupling the Tool Changer.
There are (8) 3/8 NPT, G 3/8 BSPP, Rc 1/4 BSPT, or G 1/4 PSPP port connections available for pass through
air for supplying air to tools.
Proximity sensors detect the Lock and Unlock positions of the locking mechanism and are designed into the
body of the Master plate. The sensors provide “lock” and “unlock” signals.A proximity sensor is installed
into the body of the Master plate to verify Tool plate presence when coupled, the sensor provides a ready-to-
lock (RTL) signal. The optional RTL sensor can be ordered separately.
A mounting pattern is machined into the Master plate for mounting to a robot arm or a robot interface plate.
Figure 1.1—Master Plate Assembly
Cam
(2) Alignment Pins
Male Coupling
(6) Ball Bearing
Proximity Sensor
Assembly Location
(RTL Signal)
1/8" NPT, G 1/8 BSPP, or Rc 1/8 BSPT
Lock and Unlock Port Connection
(8) 3/8" NPT, G 3/8 BSPP, or Rc 3/8 BSPT
Pass-through Air Ports Connection
Proximity Sensor
Assembly Location
(Lock/Unlock Signal)
Flat B
Flat A

Manual, Tool Changer, QC-110
Document #9620-20-B-110 Series Base Tool Changer-26
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
B-5
1.2 Tool Plate Assembly
The Tool plate assembly includes an anodized aluminum body and a hardened stainless-steel bearing race.
The Tool plate has (2) at sides for mounting of optional modules. The Tool plate body also includes a
125 mm BC machined mounting pattern for mounting to customer tooling or a tooling interface plate.
There are (8) 3/8 NPT, G 3/8 BSPP, Rc 1/4 BSPT, or G 1/4 PSPP port connections available for pass through
air for supplying air to tools.
Figure 1.2—Tool Plate Assembly
3/8” NPT or BSPP
Air Ports (8)
Alignment Pin Bushing (2)
Proximity Sensor Target
(RTL)
Bearing Race
Flat A
Flat B
1.3 Optional Modules
There are (2) ats available for mounting of the optional modules for support of various utility pass through,
such as signal, uid/air, vacuum, and electric.
For assistance in choosing the right modules for your particular application, visit our website
(QC-110 Series) and click on the Compatible Modules tab to see what is available or contact an ATI Sales
Representative.

Manual, Tool Changer, QC-110
Document #9620-20-B-110 Series Base Tool Changer-26
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
B-6
2. Installation
All fasteners used to mount the Tool Changer to the robot and customer tooling should be tightened to a torque
value as indicated in Table 2.1. Furthermore, removable (blue) Loctite 242®must be used on these fasteners.
Table 2.1 contains recommended values based on engineering standards.
WARNING: Do not perform maintenance or repair(s) on the Tool Changer or modules unless
the Tool is safely supported or placed in the tool stand, all energized circuits (e.g. electrical,
air, water, etc.) are turned off, pressurized connections are purged and power is discharged
from circuits in accordance with the customer specic 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: Do not use lock washers 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. The mounting fasteners must be ush 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
CAUTION: Thread locker applied to fasteners must not be used more than once. Fasteners
might become loose and cause equipment damage. Always apply new thread locker when
reusing 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—FastenerSize,Class,andTorqueSpecications
Mounting conditions Fastener Size &
Property Class Recommended Torque Thread Locker
Master plate to Robot Interface Plate (6061-T6 aluminum)
Minimum thread engagement of 15 mm (0.59”) [1.5X fastener Ø].
Conrm available engagement with Robot Manufacturer
M10-1.5 Class
12.9 52 N-m (38 ft-lbs.)
Pre-applied
adhesive or
Loctite 242
Master plate to Robot (steel; USS ≥ 90KSI)
Minimum thread engagement of 10 mm (0.39”) [1.0X fastener Ø].
Conrm available engagement with Robot Manufacturer
M10-1.5 Class
12.9 75 N-m (55 ft-lbs.)
Tool Interface Plate (aluminum) to Tool plate
Minimum thread engagement of 15 mm (0.59”) [1.5X fastener Ø]. Do not
exceed maximum available thread depth of 20mm
as shown in Section 8—Drawings
M10-1.5 Class
12.9 52 N-m (38 ft-lbs.)
Optional Module or adapter plate to Master or Tool plate,
Supplied Fasteners
M4 x 0.7
Class 12.9 Pre-applied
Adhesive or
Loctite 222
Socket Head Cap 20 in-lbs
(2.26 Nm)
Socket Flat Head
Cap 15 in-lbs (1.69 Nm)

Manual, Tool Changer, QC-110
Document #9620-20-B-110 Series Base Tool Changer-26
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
B-7
2.1 Master Interface
The Master plate is typically attached to the robot arm. An interface plate can adapt the Master plate to a
specic robot arm. Alignment features (dowel holes and bosses) accurately position and bolt holes secure
the Master plate to the robot arm or an interface plate. Custom interface plates are available from ATI upon
request. (refer to the drawings for technical information on mounting features.)
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 or do not allow the interface plate
and Master body to mate ush. Using dowel pins that are too long will cause a gap
between the interface plate and Master body and damage the equipment. Use dowel
pins that will not extend further than allowed by the Master body.
Master Plate
Interface Plate
Correct size dowel
pins allow the interface
plate and Master
plate to mount flush.
Two dowel pins
(or a single dowel
pin along
with a boss/recess)
used as alignment features.
Flush
Correct Mounting of Master Plate
Master Plate
Interface Plate
Dowel pins that are
too long can cause a
plate and Master Plate.
gap between interface
Optional Boss
GapGap
A boss and two dowel pins can
be difficult to align and can
cause damage to equipment.
Incorrect Mounting of Master Plate
If the customer chooses to design and build an interface plate, consider the following points:
• The interface plate should 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 prevent
unwanted rotation. Refer to the robot manual for robot mounting features.
• The thickness of the interface plate must be sufcient 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 that are too long can create a gap between the interface plate and the Master plate,
which can damage equipment.
• The interface plate must provide rigid mounting to the Master plate.
• The interface plate design must account for clearances required for Tool Changer module attachments
and accessories.

Manual, Tool Changer, QC-110
Document #9620-20-B-110 Series Base Tool Changer-26
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
B-8
2.2 Master Plate Installation
Tools required: 8 mm hex key, toque wrench
Supplies required: Clean rag, Loctite 242
1. Clean the mounting surfaces.
2. If required, install the IP to the robot arm, align using the boss or dowel pins and secure with customer
supplied fasteners.
3. Align the dowel pins to the corresponding holes in the Master plate and secure the Master plate to the
robot arm or IP with customer supplied (6) M10 socket head cap screws. Apply Loctite 242 to threads
(see Table 2.1 for proper fasteners and torque).
NOTICE: If an ATI IP is used, fasteners to mount the Master plate to the IP is supplied with the
IP. The fasteners to mount the IP or the Master plate directly to the robot is customer supplied.
4. Connect utilities to the appropriate modules and Master plate connections.
Figure 2.1— Typical Master Plate Installation
Robot Arm
Robot Interface Plate
(Customer Supplied)
(If required)
(6) M10-1.5 Socket Head Cap Screws
(Customer Supplied)
Master Plate
(2) Dowel Pin
(Customer Supplied)
Socket Head Cap Screws
(Customer Supplied)
2.3 Master Plate Removal
Tools required: 8 mm hex key
NOTICE: Depending on maintenance or repair being performed, utilities to modules and Master
plate may need to be disconnected.
1. Place the Tool in a secure location.
2. Uncouple the Master and Tool plates.
3. Turn off and de-energize all energized circuits (e.g. electrical, air, water, etc.).
4. Disconnect the utilities from the Master plate and attached modules.
5. Remove the (6) M10 socket head cap screws connecting the Master plate to the robot arm or IP.

Manual, Tool Changer, QC-110
Document #9620-20-B-110 Series Base Tool Changer-26
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
B-9
2.4 Tool Interface
The Tool plate is attached to the customer’s tooling. An interface plate can adapt the Tool plate to customer
tooling. Alignment features (dowel holes and a recess) accurately position and bolt holes secure the Tool
plate to customer tooling. Custom interface plates can be supplied by ATI (Refer to the application drawing).
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 or do not allow the interface plate
and Tool body to mate ush. Using dowel pins that are too long will cause a gap
between the interface plate and Tool body and damage to the equipment. Use dowel
pins that will not extend further than allowed by the Tool body.
Tool Plate
Interface Plate
Dowel pins are
proper size allowing
interface plate and Tool
Plate to mount flush.
Two dowel pins (or a
boss/recess) used as
alignment features.
Correct Mounting of Tool Plate
Tool Plate
Interface Plate
Dowel pins
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
damage equipment.
Gap
Incorrect Mounting of Tool Plate
single dowel pin along with a
If the customer chooses to design and build a tool interface plate, consider the following points:
• The interface plate should 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 prevent unwanted 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 sufcient to provide the necessary thread engagement for
the mounting bolts. Fasteners should 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 must account for 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 interface plate must have a hole in its center 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 with a minimum diameter of 1” (25.4 mm) prevents debris from contaminating the
locking mechanism. Greater protection is provided by leaving the race cover and grommet in place.

Manual, Tool Changer, QC-110
Document #9620-20-B-110 Series Base Tool Changer-26
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com • Email: [email protected]
B-10
2.5 Tool Plate Installation
Tools required: 8 mm hex key, toque wrench
Supplies required: Clean rag, Loctite 242
1. Clean the mounting surfaces.
2. If required, install the tooling interface plate to the customer tooling, align using the boss or dowel pins
and secure with customer supplied fasteners.
3. Align the dowel pins to the corresponding holes in the Tool plate and secure the Tool plate to the tool
interface plate or customer tooling with customer supplied (6) M10 socket head cap screws. Apply
Loctite 242 to threads (see Table 2.1).
NOTICE: If an ATI tool interface plate is used, fasteners to mount the Tool plate to the tool
interface plate may be supplied with the tool interface plate. The fasteners to mount the tool
interface plate or the Tool plate directly to the customer tooling is customer supplied.
4. Connect utilities to the appropriate module and Tool plate connections.
Figure 2.2—Standard Tool Plate Installation
Tool Plate
Dowel Pins (Customer Supplied)
Tool Interface Plate
(Customer Supplied)
(If required)
M10-1.5 Socket Head Cap Screws
(Customer Supplied)
2.6 Tool Plate Removal
Tools required: 8 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 (e.g. electrical, air, water, etc.).
4. Disconnect the utilities from the Tool plate and attached modules.
5. Remove the fasteners connecting the Tool plate to the tooling or tool interface plate.