ATI Technologies AOV User manual

Engineered Products for Robotic Productivity
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati‑ia.com
AOV Media Changer System
Product Manual
Document #: 9610-50-1046

Manual, AOV Media Changer System
Document #9610-50-1046-02
Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com
2
Table of Contents
1. Product Overview..................................................................................................................... 3
1.1 Media Feeder .................................................................................................................................3
1.2 Media Remover..............................................................................................................................4
1.3 Media Checker...............................................................................................................................4
2. Installation of Components..................................................................................................... 5
2.1 Media Feeder Installation .............................................................................................................6
2.2 Media Remover Installation..........................................................................................................7
2.3 Media Checker Installation...........................................................................................................8
2.4 Pneumatics....................................................................................................................................9
2.5 Electrical Connections..................................................................................................................9
2.5.1 PNP Type Sensor...............................................................................................................9
2.5.2 NPN Type Sensor...............................................................................................................9
3. Operation ................................................................................................................................ 10
3.1 Recommended Sequence of Operations for AMC ................................................................... 11
3.1.1 Recommendations ........................................................................................................... 11
3.1.2 Fetch Media...................................................................................................................... 11
3.1.3 Check Media ....................................................................................................................15
3.1.4 Sand.................................................................................................................................17
3.1.5 Remove Media.................................................................................................................17
3.2 Normal Operation........................................................................................................................19
4. Troubleshooting and Service Procedures ........................................................................... 20
4.1 Troubleshooting..........................................................................................................................20
4.2 Service Intervals..........................................................................................................................21
4.3 Service Procedures.....................................................................................................................22
4.3.1 Replacement of Retaining Gasket, Constant Force Springs, and Media Support Glides in
Media Feeder...................................................................................................................22
4.3.2 Replacement of Hook Disc on Media Checker.................................................................27
4.3.3 Replacement of Needles in Media Remover....................................................................27
5. Serviceable Parts ................................................................................................................... 28

Manual, AOV Media Changer System
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1. Product Overview
The AOV Media Changer (AMC) is an accessory to the AOV tools. TheAMC works with standard industrial
sanding disc and allow for adaptation to changing assembly lines and part requirements.
The AMC system allows the checking and changing of media without human interaction, once a
program is in place.
For drawings and further details, refer to https://www.ati‑ia.com/Products/deburr/deburring_home.aspx.
1.1 Media Feeder
The media feeder provides a storage location and dispenser for 5 inch or 6 inch sanding discs.
Figure 1.1—Media Feeder (6” Version Shown)
Alignment Rail
Media Storage
Media Retaining Gasket
(4) Mounting Hole

Manual, AOV Media Changer System
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1.2 Media Remover
CAUTION: Needles can pinch or puncture clothing and skin avoid contact during
setup, service, and operation of needle grippers causing injury to personnel and
damage to equipment.
The media remover uses pneumatically actuated needles to remove media from AOV.
Figure 1.2—Media Remover (Not a Recommended Mounting Orientation)
Mounting Bracket
(7) Mounting Holes Provided
Needle Gripper
4 mm Push Tube Fitting (Extend)
4 mm Push Tube Fitting (Retract)
Needle Height Adjustment
1.3 Media Checker
The media checker detects the presence or absence of sanding media.
Figure 1.3—Media Checker
Sensor cable with 3-pin M8 connector
Media Detection Piston
(4) Mounting Hole
(connector not shown)

Manual, AOV Media Changer System
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2. Installation of Components
Required Equipment:
The items listed in this section are the minimum requirements to operate the AMC.
1. (2) 4 mm air lines in for media remover. Each air line will supply air to the Media Remover and operate the
needle drive mechanism.
• One line is for needle extension.
• One line is for needle retracting.
• The lines will need to purge when switching over from extend to retract or vice versa. See following section
for recommended equipment.
2. (1) 3‑pin M8 connector for media detection. This cable will be used to connect the Media Checker to I/O on the
robot.
Recommended Optional Equipment:
The items listed in the following section are only recommended equipment that can help refine the media change
out process. These are not necessary to operate theAMC.
1. (2) Programmable regulator
• One will be used to adjust the compliance pressure during the operation. Not necessary, but it makes fetching
new media a little easier.
• The other will be used in conjunction with a solenoid valve to control the needle gripper.
2. (1) 4 or 5 position solenoid valve
• This solenoid is used to switch and purge the air between the extend and retract air ports in
the Media Remover.

Manual, AOV Media Changer System
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2.1 Media Feeder Installation
The media feeder can be installed at any an angle and in any orientation that allows the AOV sanding pad to
contact the media in the feeder completely. To install the media feeder, complete the following procedure:
Tools required: Hex keys
Supplies required: (4) Customer supplied socket head cap screws
1. Mount the media feeder to a rigid surface using the (4) mounting holes in the bottom plate with customer
supplied socket head cap screws.
2. Load the feeder by inserting small stacks (15‑25 discs) of media into the storage opening with the hook
and loop side facing outward.
Figure 2.1—Media Feeder
Alignment Rail
Media Storage
Media Retaining Gasket
(4) Mounting Hole

Manual, AOV Media Changer System
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2.2 Media Remover Installation
The media remover can be installed at any an angle and in any orientation that allow the media to fall away
from the media remover. Figure 2.2 is shown only for information purpose and is not a recommended
mounting orientation. Customer supplied waste receptacle is advised for removed media. The media
remover can be installed by performing the following procedure:
CAUTION: Needles can pinch or puncture clothing and skin avoid contact during
setup, service, and operation of needle grippers causing injury to personnel and
damage to equipment.
Tools required: Hex keys
Supplies required: (3 or 4) Customer supplied fasteners
1. Mount the media remover to a rigid surface using either of the mounting patterns on the bracket with
customer supplied fasteners.
2. Connect air supply to the (2) push tube fittings.
Figure 2.2—Media Remover (Not a Recommended Mounting Orientation)
Mounting Bracket
(7) Mounting Holes Provided
Needle Gripper
4 mm Push Tube Fitting (Extend)
4 mm Push Tube Fitting (Retract)
Needle Height Adjustment

Manual, AOV Media Changer System
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Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com
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2.3 Media Checker Installation
The media checker can be installed at any an angle and in any orientation that allow the sanding pad of the
AOV to contact the piston in the checker completely. The media checker can be installed by performing the
following procedure:
Tools required: Hex keys
Supplies required: (4) Customer supplied socket head cap screws
1. Mount the media checker to a rigid surface using the (4) mounting holes with customer supplied socket
head cap screws. Tighten hand tight.
2. Attach the 3‑pin M8 connector on the sensor cable to the customer supplied connection.
Figure 2.3—Media Checker
Sensor cable with 3-pin M8 connector
Media Detection Piston
(4) Mounting Hole
(connector not shown)

Manual, AOV Media Changer System
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Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com
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2.4 Pneumatics
The air supply should be dry, filtered, and free of oil. A coalescing filter (ATI Part # 9005‑50‑6160 or
equivalent) with elements rated for 5 micron or better is required.
Customer supplied solenoid valves are actuated from the robot or program logic controller by means of a
digital output signal. The extend/retract for the media remover must supply a regulated air supply pressure
of 4.1 bar [60 psi].
2.5 Electrical Connections
The media checker has an integrated sensor.
2.5.1 PNP Type Sensor Table 2.1—PNP (Current Sourcing)
Description Value
Voltage Supply Range 10‑30VDC
Output Circuit PNP make function (NO)
Figure 2.4—PNP Type Lock, Unlock and RTL Sensors
(3) Blue Brown (1)
(4) Black
Brown (1)
Black (4)
Blue (3)
+Vs
Output
0 V
PNP
Z
Connector
PNP (Current Sourcing)
2.5.2 NPN Type Sensor Table 2.2—NPN (Current Sinking)
Description Value
Voltage Supply Range 10‑30VDC
Output Circuit NPN make function (NO)
Figure 2.5—NPN Type Lock, Unlock and RTL Sensors
(3) Blue Brown (1)
(4) Black
Brown (1)
Black (4)
Blue (3)
+Vs
Output
0 V
NPN
Z
Connector
NPN (Current Sinking)

Manual, AOV Media Changer System
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3. Operation
The media changer system uses (3) different components. The robot program must accommodate for any clearance
needed. Refer to Section 3.1—Recommended Sequence of Operations for AMC for more details.
CAUTION: Do not use spare parts other than original ATI spare parts. Use of spare parts
not supplied by ATI can damage equipment and void the warranty. Always use original
ATI spare parts.
CAUTION: Never be present near the tool while it is in operation. Flying debris can cause
injury. If it is necessary to approach the tool while in motion, stand behind appropriate
Plexiglas windows. Provide a barrier to prohibit people from approaching the tool.
CAUTION: Needles can pinch or puncture clothing and skin avoid contact during
setup, service, and operation of needle grippers causing injury to personnel and
damage to equipment.
Figure 3.1—System
Media Remover
Media Feeder
Media Checker

Manual, AOV Media Changer System
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3.1 Recommended Sequence of Operations for AMC
3.1.1 Recommendations
1. When teaching the motions, be sure that the AOV is positioned perpendicular to the working
surfaces for each media change module.
2. Consider a method of discarding used discs removed by the Media Remover. A recommended
option is to mount the Remover in a way so that the used discs will drop into a collection bin
after the removal process.
3. Setting a common home position for each individual process is recommended to make
transitioning between each process easier.
4. Prior to operating the Media Feeder, it is important to load new media in such a way to
reduce the natural curl inherent in some media. When loading the Media Feeder, please
consider the following:
a. Feed several small stacks of media (15‑25 discs) at a time instead of all at once.
b. If there is significant curl in a disc, offset the rotation of each new stack about 10 to 20
degrees so that the curls on the discs do not stack on top of each other.
c. Gently bend the stack of discs by hand to reduce the intensity of the curl.
3.1.2 Fetch Media
1. (Optional) Set compliance pressure to 60 PSI.
a. Increasing the compliance pressure during the fetch process can improve the likelihood of
a fetch success.
b. Increasing the compliance pressure will reduce compliance travel. This will reduce the risk
of the sander crashing into the feeder.
2. (Optional) Removing the debris shield prior to programming can aid in teaching the fetching
program by providing a visual on the stack of discs (Refer to Section 4.3.1—Replacement of
Retaining Gasket, Constant Force Springs, and Media Support Glides in Media Feeder) for
debris shield removal and installation.
3. HOME: It is recommended setting a common home position for each individual process to
make transitioning between each process easier.
4. AWAY: Move sander so the backing pad is in the position as shown in Figure 3.2
and Figure 3.3.
a. The backing pad’s hook surface should be approximately ¼” away from the top surface of
the Media Feeder (roughly half way up the alignment rail).
Figure 3.2—Away 1

Manual, AOV Media Changer System
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b. The closest edge of the backing pad should be ½” to 1” away from the alignment rail.
Figure 3.3—Away 2
5. TOUCH: Move diagonally (from the “AWAY” position in step 4) so that the backing pad is
lightly pressed against the rail, pushing the sander’s orbital position away from the rail.
a. Doing this movement diagonally is important to avoid crashing. The sander’s orbit should
rotate into position.
b. A good test is to rotating the sanding pad by hand and there should be slight resistance felt
due to the rubbing of the pad against the rail.
Figure 3.4—Touch
6. ROLL: Move linearly along the rail until aligned with the opening.
a. This process reliably forces the sander’s orbit to the 6 o’clock position.
b. Having a known orbit position makes it possible to consistently align the sanding pad for
media fetching.
Figure 3.5—Roll

Manual, AOV Media Changer System
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7. ALIGN: Align the sander with respect to the hole with the sanding discs.
a. Confirm that the orbit is set fully back (6 o’clock position) before saving this point.
b. Reliability can be improved for fetching by tilting the sander slightly (20 degrees) toward
the alignment rail (refer to Figure 3.7).
Figure 3.6—Align
8. DROP: Move the sander into the feeder (approximate speed of 200 mm/s) until the backing pad
clears the rubber gasket.
a. During this motion flatten the tilt of the sanding pad so that in the end position, the sanding
pad is parallel with the stack of discs.
b. Pause shortly (<500ms) before moving moving to the next step.
Figure 3.7—Drop

Manual, AOV Media Changer System
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9. ALIGN and DROP: Pull the pad out of the feeder and return to the “ALIGN” position from step
6. Tilt the sanding pad and repeat step 7.
a. This step helps to ensure the disc is properly attached as well as keep the stack of new
media held down for the next fetch command.
Figure 3.8—Align and Drop
10. LIFT: Lift the sanding pad away from the feeder.
a. If the compliance pressure was adjusted in step 1, return it to the original setting.
Figure 3.9—Lift
11. Return HOME.

Manual, AOV Media Changer System
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3.1.3 Check Media
Teaching this process should be done without a sanding disc on the pad to test the hook and loop
1. Start at the HOME position.
2. ABOVE: Align the sanding pad above the Media Checker’s loop pad.
Figure 3.10—Above 1
Figure 3.11—Above 2

Manual, AOV Media Changer System
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3. TOUCH: Lower the sander until the backing pad makes full contact with the hook and loop.
Figure 3.12—Touch
4. UP: Raise the sander until the Checker has reached its furthest extension.
a. An audible cue (sound of the hook and loop separating) can be used to determine the
furthest extension.
b. The audible cue can be confirmed by ensuring that the illumination of the sensor
connector’s status LED connector is ON.
Figure 3.13—Up
c. Wait up to one second so that the checker can register the signal.
5. Lift up separate the pad from the checker and return HOME.

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3.1.4 Sand
• It is important to test the removal of a freshly used disc. The friction generated from
normal sanding operation can cause the hook and loop to bind stronger than a manually
applied sanding disc.
• It is recommended to perform sanding for at least 15 seconds.
3.1.5 Remove Media
CAUTION: Needles can pinch or puncture clothing and skin avoid contact
during setup, service, and operation of needle grippers causing injury to
personnel and damage to equipment.
Prior to teaching media removal, set the needle depth to 5 mm. This setting is a recommended
starting point and should be adjusted if the following procedure are not working
1. Set the compliance pressure to 10 PSI.
a. Reducing the compliance pressure should lower the risk of breaking needles; especially
during the teaching process.
b. In the vertical orientation, compliance pressure may not be needed. The weight of the motor
may be sufficient.
2. HOME
3. ABOVE: Align the sander so that the side of the pad opposite to the side that was used for the
Checker is slightly above the needle gripper contact point.
a. It is best practice to linearly align the center of the pad to the center of the needles. This
reduces the chance that the pad will roll during media removal.
Figure 3.14—Above 1
Figure 3.15—Above 2

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4. TOUCH: Move the sander to make firm contact with the top plate and extend the
needles (90 PSI).
a. It is recommended to wait up to one second before the next motion command.
Figure 3.16—Touch
5. (Recommended, but optional) LIFT: Lift the sander a few millimeters off the plate so that the
needles remain engaged in the sanding disc, wait one second before the next motion command.
a. This lift height may change depending on the disc and pad combination.
Figure 3.17—Lift

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6. AWAY: Using Figure 3.8 as a reference, move the sander up 12.0 inches and 9° travel to the
right (approximately 1.9 inches of lateral travel).
a. Make sure to move far enough away from the needles so that the disc is completely
removed (at least the distance of one and a half disc diameters).
b. Slowing down the motion during this step may help with teaching and makes analyzing the
process easier.
c. The angle of travel may vary depending on media grit and backing material.
• Heavier grits will require a larger roll radius, thus a larger angle of travel
(approx. 20°)
• Lighter grits can be shallower at 9°
• Too shallow of a retreat angle can cause the needles to dig into the backing pad
and may cause damage.
Figure 3.18—Away
7. Retract the needles, set compliance to the original setting and return HOME.
3.2 Normal Operation
The following sections describe the normal operating conditions for AMC.
3.2.1 Air Quality
The air supply should be dry, ltered, and free of oil. A coalescing lter with elements rated for 5
micron or better is required. The air must be supplied to the media remover at 4.1 bar (60 psi).
Particulate can impede airow and operation. Any water in the system damages the AMC system.

Manual, AOV Media Changer System
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Pinnacle Park • 1031 Goodworth Drive •Apex, NC 27539 • Tel: [phone] • Fax: [phone] • www.ati-ia.com
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4. Troubleshooting and Service Procedures
4.1 Troubleshooting
The following section provides troubleshooting information to help diagnose conditions with the product
and resolve these conditions.
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.
Deburring and media changing process is an iterative, learning task. The following table is presented to
assist in solving media changing problems.
Table 4.1—Troubleshooting
Symptom Possible Cause Resolution
The stack of new discs is dispensing
an extra partially and/or fully ejected
discs after fetching media.
Improper loading can cause
serious binding that cannot
be corrected by the hopper’s
internal springs.
Repeat the pad insertion step twice
to ensure that the stack of new discs
is aligned for the next fetch process.
There are frequent check errors.
The I/O may not be receiving
the signal from the sensor.
Check the wiring to the robot I/O and
verify that there is:
1. No damage to the wire
2. The connections are secure
3. The wires are connected properly
to the correct ports
There is debris build up on
the media checker. Remove debris on the surface of the media checker.
The media removal stopped
removing media.
The needles are damaged. Check the needles and make sure they are still intact and replace any
damaged needles.
The needles have worn
out over time causing the
needles to not penetrate the
sanding discs as deeply.
Adjust the needle depth on the
remover and reevaluate the removal
procedure as renements may be
required.
The needles are not extending or
retracting.
Air is not being supplied to
the media remover.
Check the air line and verify there
are no leaks and that the tubing is
securely inserted into the air ttings.
The needle depth is set to
zero mm and needs to be
adjusted.
Adjust the needle depth setting on
the media remover.