ATI Technologies QC-201 User manual

Manual, Tool Changer, QC-201
Document #9620-20-B-201 Base Tool Changer-12
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 ...................................................................................................... 2
QC-201—Robotic Tool Changer ...................................................................................... 2
1.Product Overview .......................................................................................................... 2
1.1Master Plate Assembly ......................................................................................... 2
1.2Tool Plate Assembly ............................................................................................. 3
2.Installation ..................................................................................................................... 3
2.1Master Interface .................................................................................................... 3
2.2Tool Interface ........................................................................................................ 4
2.3Tool Stand Design ................................................................................................ 5
2.3.1Tool Locating Features ............................................................................. 6
2.3.2Tool Stand Sensors .................................................................................. 7
2.4Pneumatic and Electrical Connections ................................................................. 7
3.Operation ....................................................................................................................... 8
3.1Coupling Sequence .............................................................................................. 8
3.2Fail-Safe Operation .............................................................................................. 9
3.3Uncoupling ............................................................................................................ 9
4.Maintenance ................................................................................................................ 10
4.1Preventive Maintenance ..................................................................................... 10
4.2Cleaning, Lubrication, Adjustment and Replacement ......................................... 12
4.2.1Cleaning and Lubrication of the Locking Mechanism and Alignment
Pins (Master Plate). ................................................................................ 12
4.2.2Cleaning the Locking Mechanism and Alignment Pin Bushings
(Tool Plate). ............................................................................................ 13
5.Troubleshooting .......................................................................................................... 14
6.Recommended Spare Parts ....................................................................................... 14
7.Specifications .............................................................................................................. 15
8.Drawings ...................................................................................................................... 16
8.1QC-201 Master Plate Assembly ......................................................................... 16
8.2QC-201 Tool Plate Assembly ............................................................................. 17

Manual, Tool Changer, QC-201
Document #9620-20-B-201 Base Tool Changer-12
Pinnacle Park  1031 Goodworth Drive  Apex, NC 27539  Tel: [phone]  Fax: [phone]  www.ati-ia.com  Email: [email protected]
B - 2
B. Base Tool Changer
QC-201—Robotic Tool Changer
1. Product Overview
1.1 Master Plate Assembly
The Master Plate includes an anodized aluminum body, a hardened stainless-steel locking
mechanism, hardened steel alignment pins and self-sealing ports. (See Figure 1.1)
The body of the Master Plate has (4) flat sides for mounting of optional modules.
The locking mechanism consists of a cylindrical housing with holes that retain hardened
chrome-steel balls. Tapered pins located on the Master Plate mate with holes in the bearing race
on the Tool Plate to ensure repeatable alignment during the coupling process. A thin film of
grease is applied to the ball bearings and pins to enhance performance and maximize life of the
components.
On the QC-201, one G3/8 connection is available to supply pneumatic pressure to the Tool
Plate through a self-sealing port. This port is internally configured to supply pneumatic pressure
for coupling and uncoupling the tool changer. This port has limited operating capabilities when
used for a secondary application. (Please refer to Section 7—Specifications and Section 8—
Drawings). This port will seal when the Master is uncoupled from the Tool, thus eliminating the
need to turn off the supply pressure to the port.
A proximity sensor is designed into the body of the Master Plate to verify Tool Plate presence
when coupled. The sensor provides a ready-to-lock (RTL) signal.
Figure 1.1—Master Plate

Manual, Tool Changer, QC-201
Document #9620-20-B-201 Base Tool Changer-12
Pinnacle Park  1031 Goodworth Drive  Apex, NC 27539  Tel: [phone]  Fax: [phone]  www.ati-ia.com  Email: [email protected]
B - 3
1.2 Tool Plate Assembly
The Tool Plate includes an anodized aluminum body and a hardened stainless steel bearing race.
(See Figure 1.2) The Tool Plate has (4) flat sides for mounting of optional modules.
Pass-through ports supply pneumatics to the customer by way of one G3/8 connection. The
pass-through port that is in line with the lock/unlock port on the master assembly is supplied
with a plug.
Figure 1.2—Tool Plate Assembly
2. Installation
2.1 Master Interface
The Master Plate 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. Most often a robot interface plate (RIP) or sensor
interface plate (SIP) is utilized to adapt the Master Plate to a specific robot flange that is not
compatible with the Master Plate mounting features. Custom RIPs and SIPs are available upon
request. (Refer to application drawing).
All fasteners used to mount the tool changer to the robot and to user tools should be tightened to
a torque specification of 680 in-lbs. Loctite 242 must be used on these fasteners. Fasteners
should have an engagement length at least 2X fastener diameter.
A SIP is specified when tool changer Lock and Unlock (L/U) sensing is required. The SIP is a
special interface plate that contains two (2) sensors for detecting the state of the locking
mechanism. (See Figure 2.1 for a typical installation arrangement.)

Manual, Tool Changer, QC-201
Document #9620-20-B-201 Base Tool Changer-12
Pinnacle Park  1031 Goodworth Drive  Apex, NC 27539  Tel: [phone]  Fax: [phone]  www.ati-ia.com  Email: [email protected]
B - 4
Robot Arm
S.I.P.
QC-151 Master Assembly
with PV1 and DE45
Modules
QC-151 Tool Assembly
with PV1 and DE45
Modules
E.I.P.
(Customer Supplied)
Mounting Bolts
(Customer Supplied)
Dowel Locating Pin
(Customer Supplied)
Mounting Bolts
Dowel Locating
Pin
Boss
Boss
Figure 2.1—Typical Installation
If the customer chooses to design and build a robot interface plate, the following should be
considered:
The interface plate should be designed to include bolt holes for mounting, dowel pins and a
boss for accurate positioning on the robot and Master Plate.
The interface plate must be properly designed to provide rigid mounting to the Master plate
boss area and to maintain a gap between the interface plate and the body outside of the boss.
The plate design should take into account clearances required for tool changer module
attachments and accessories.
2.2 Tool Interface
The Tool Plate is attached to customer-supplied tooling. The Tool Plate is designed with
mounting features such as a recess and/or bolt and dowel holes. These features are used to
accurately position and secure the end-effector. Most often an End-effector Interface Plate (EIP)
is utilized to adapt the Tool Plate to an end-effector that is not compatible with the Tool Plate
mounting features. Custom EIPs can be supplied by ATI to meet customer requirements. (See
Figure 2.1) (Refer to the application drawing).
When the customer chooses to design and build an EIP, the following should be considered:
The interface plate should be designed to include bolt holes for mounting, dowel pins and a
boss that mates with tool body recess for accurate positioning.
The plate design should take into account clearances required for tool changer module
attachments and accessories.
QC-201 Master Assembly
with PV1 and DE45
Modules
Modules
QC-201 Tool Assembly
with PV1 and DE45
Modules

Manual, Tool Changer, QC-201
Document #9620-20-B-201 Base Tool Changer-12
Pinnacle Park  1031 Goodworth Drive  Apex, NC 27539  Tel: [phone]  Fax: [phone]  www.ati-ia.com  Email: [email protected]
B - 5
2.3 Tool Stand Design
In most cases, the tools are stored in a tool stand when not being used by the robot. During
coupling and lock-up the tool stand must allow for movement (float) in a plane parallel with the
mating surfaces of the Master Plate and Tool Plates (X and Y). Even slight misalignment
between the Master Plate and Tool Plate can generate high forces during lock-up if the Tool
Plate is not allowed to float into place during lock-up. These high forces can cause excessive
wear and even jamming of the end effector and robot. The degree of float required depends on
the accuracy of the robot’s positioning and the repeatability of the tool location in the tool stand
during lock-up. See Figure 2.2 and Table 2.1 for recommended maximum allowable float
(offsets) prior to coupling. The tool stand should be designed to minimize misalignment during
coupling and uncoupling. In some cases greater offsets than shown in Table 2.1 can be
accommodated by the Master and Tool Plates, but will increase wear.
Ideally, the tool should be hanging vertically in the tool stand so that gravity acts 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.
Lock-up should occur with the Master Plate in the No-Touch™ Locking zone (see Table 2.1)
but not touching the Tool Plate. As locking occurs, the Master Plate should draw the Tool Plate
into the locked position.
Tool stands may also need to incorporate means for covering tools and electrical modules to
protect them in dirty environments such as grinding or welding. Alternatively, locating tool
stands in areas shielded from weld spatter, fluids, adhesives or other debris would eliminate the
need for tool covers.
CAUTION: During coupling and lock-up, the tool stand must allow for
movement (float) in a plane parallel to the mating surfaces of the Master
plate and Tool plate(s), and in a direction to this plane towards the Master
plate.
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.