LT LTC-0005A User manual

Zhengzhou Linghang Robot Co.,Ltd
Version 21.8
LT Robotic Tool Changer User Manual
Product ：LTC-0005A

Zhengzhou Linghang Robot Co.,Ltd
Preface
Thank you for purchase our LT Robot Tool Changer.
This Brochure describes the basic information of LTC-0005A, About electrical,
Pneumatic and other parts please refer to other user manual.
If you have any questions please contact LT Company.
Note: This brochure introduced the function, application and safety
precautions of tool changer, before install and operate the manual should
be read and understood carefully, otherwise the product may be damaged
or unsafe.
The content of this document is belong to Zhengzhou Linghang Robot
Co.,Ltd (it’s referred to “LT” afterwards), It cannot be copied in part or in whole
without the prior written permission of the LT Company. This manual will be
revised regularly to reflect and incorporate changes to the product without notice.
This document is confidential, it can only use for LT Customers and
authorized agents, without the prior written permission, It shall not be disclosed to
the third party.
We don't guarantee for the accuracy of this document or the suitability of the
equipment for a particular application.
LT will not be responsible for any errors contained in this document or any
incidental or indirect losses arising therefrom.
LT will not be responsible for any errors or omission in this document.
Copyright belongs to Zhengzhou Linghang robot Co., Ltd. all rights reserved.

Zhengzhou Linghang Robot Co.,Ltd
Content
Glossary.................................................................................................................... 1
1.Safety.......................................................................................................................4
1.1Notice description........................................................................................ 4
1.2Safety principle.............................................................................................5
1.3Notices Rules............................................................................................... 6
2.Product Summary.................................................................................................. 7
2.1Master plate assembly................................................................................7
2.2Tool plate assembly.....................................................................................8
2.3Modules.........................................................................................................9
3.Installation............................................................................................................... 9
3.1Master plate................................................................................................ 11
3.2 Install of master plate...............................................................................12
3.3Tool plate.....................................................................................................13
3.4Install of tool plate..................................................................................... 14
3.5Installation diagram of tool plate............................................................. 14
3.6Disassemble tool plate............................................................................. 14
3.7Install of adapter modules........................................................................15
3.8Module removal method...........................................................................16
3.9Air Requirement.........................................................................................16
4、Operation........................................................................................................... 18
4.1Locking sequence..................................................................................... 19
4.2Fault self locking operation...................................................................... 20
4.3Unlocking sequence..................................................................................20
4.4Precautions for tool placement................................................................21
5.Maintenance......................................................................................................... 22
5.1Regular maintenance................................................................................23
5.2Cleaning and lubrication of locking mechanism and locating pin...... 24
5.3Inspection and cleaning of electrical modules...................................... 26
6. Troubleshooting and service procedures........................................................26
6.1Fault handling.............................................................................................27
6.2Air port maintenance process..................................................................30
7.Parameter table................................................................................................... 32
8.Outline Dimensional Drawing............................................................................ 33
9.Recommended Solenoid valve to control tool changers：........................... 34
9.1Single solenoid valve control................................................................... 34
9.2Double solenoid valve control................................................................. 35

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Glossary
Steel ball
snap ring
The steel ring on the tool side,it fits to the locking steel ball during
locking.
Cam
Circular cam attached to the piston that forces the locking balls
outward during the locking process.
Electrical
Module
a wide variety of utility modules that pass electrical power or
electrical signals through Master plate to Tool plate and then to the
end-effector.
End-Effector
A tool installed on a robot to perform a certain function.
adapter
flange
Optional components for the installation between the transition of
robot tool changer to the robot or tools.
Locking ball
Hardened steel ball for locking mechanism with air pressure lost
protection function.The locking cam extrudes the steel ball and
clamps it with the steel ball snap ring on the tool side,Realize the
master plate locking tool plate.
Locking
mechanism
It is used to pull the master plate locking tool plate, which can
ensure reliable locking even in case of air loss until the mechanism
is unlocked normally. The locking mechanism includes locking steel
ball, cam, ball bearing cover, ball race, etc.
Lock Port
Pneumatic port on the Master plate to which air is supplied to Lock
the Master plate to the Tool plate.
Master plate
The half of the Tool Changer that is mounted to a robot. The Master
plate contains the locking mechanism.
Moment
The applied force multiplied by the distance it is from a point
No touch
Design feature of Tool Changer products that allows coupling the
Master plate and Tool plate without physical contact prior to locking.
Piston
Piston located in the Master plate that actuates the locking.
mechanism
Air module
pass air power through the Master plate to the Tool plate and to the
end effector.

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Sensor plate
seals the pneumatic chamber and provides mounting points for the
Lock/Unlock switches.
Tool Plate
The half of the Tool Changer to which various tools or end-effector
are mounted.
Tool stand
Stand that holds Tools not being used by the robot. This is usually
supplied by the customer and is specific to the application.
Unlock port
The master plate unlocks the port of the air supply circuit to drive
the master plate to be separated from the tool plate.
Arc
Prevention
makes it possible to couple/uncouple without switching off electrical
module power. Arcing can damage and shorten the life of the
electrical power contacts. Arc Prevention extends the life of all
electrical power contacts by eliminating arcing caused by inductive
loads and high inrush current during coupling/uncoupling.
Coupling
Lock
Discrete
Refers specifically to modules that pass discrete signals and/or
power from Master to Tool. The number of discrete pass-through
signals is limited by either the number of pins on the connector or
the number of pins at the pin block interface between Master and
Tool. Some Discrete modules also provide the user the ability to
control the Tool Changer by providing “Latch” and “Unlatch” signals
to an integrated valve that locks and unlocks the Tool Changer. The
Tool Changer Locked, Unlocked, Ready-to-Lock, and TSI switch
signals can also be provided to the user, these discrete modules
are referred to as Discrete Control/Signal Module.
Ethernet
Switch
An Ethernet network component connecting multiple
communication partners with each other
Fieldbus
A generic term referring to any one of a number of industrial
computer networking standards. Examples include: CAN, Modbus,
and PROFINET.
Gigabit
Ethernet
The interface that can realize 1000mdps transmission rate by CAT6
standard

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Latch
Command that is issued to lock (couple) the Master and Tool
Plates.
Lock
The physical action of the coupling the Master and Tool Plates
together.
Locked
A proximity sensor output signal indicating that the coupling
mechanism is in the Locked position.
Lock Sensor
A proximity sensor that detects the position of the
pneumatically-actuated piston when it is in the locked or missed
tool position.
Teach Tool
A device convenient for teaching when teaching by robot.
Tool ID
An individual or set of push button switches on the control/signal
Tool module that provides a unique identification number for each
tool when using multiple tools. The tool-ID also provides the tool not
present indication.
Tool Present
A hard-connect input (sourced from the Tool) indicating the Master
and Tool are electrically connected to each other.
Trip Dog
A physical device used to trip a mechanical switch, use in the Tool
Stand Interlock circuit.
Uncoupling
See unlock
Unlatch
The input signal supplied to the ATI Master module to uncouple the
Tool Changer.
Unlock
The physical action of the uncoupling the Master and Tool Plates.
Unlocked
A proximity sensor output signal indicating that the coupling
mechanism is in the Unlocked position.
Unlock
sensor
A proximity sensor that detects the position of the
pneumatically-actuated piston when it is in the unlocked position.

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1. Safety
This section describes the general safety guidelines to be followed for this
product，The mentioned warning instructions and safety precautions are
applicable to this product. Refer to other application manuals for more specific
warning instructions.
1.1 Notices:
The following notice is for the products covered by this manual. Users should
pay attention to all notifications from robot manufacturers and robot parts
manufacturers.
Danger: inform information or instructions that failure to comply
will result in death or serious injury. The Notice provides
information on the nature of the dangerous situation, the
consequences of not avoiding the danger and the methods to avoid it.
Warning: Notice of information or instructions that may result in
death or serious injury if not observed. The notification provides
information on the nature of the hazardous situation, the
consequences of not avoiding the hazard and the methods to avoid it.
Note: inform information or instructions that failure to comply may
result in moderate injury or equipment damage. The notification
provides information on the nature of the hazardous situation, the
consequences of not avoiding the hazard and the methods to avoid
it.
Notice: Notice of specific information or instructions for maintaining, operating,
installing or setting up the product. Failure to follow these information or
instructions may cause equipment damage. The notice emphasizes, but is not limited
to, specific grease types, best operating practices, and maintenance techniques.

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1.2 General safety rules
Before purchase and installation, the customer shall verify that the selected
tool changer has met the maximum allowable moment and allowable torque
expected during operation. Please refer to the product specifications in each
models of this manual。Special attention Dynamic load caused by acceleration
and deceleration of robot.In the case of high acceleration or deceleration, these
forces may be many times the static force.
It is the customer's responsibility to ensure that during locking and locking，
there has no foreign matter between master plate and tool plate, otherwise will
result in serious injury.
Danger: the gap between the master plate and the tool plate is a pinch
point.All personnel shall be prevented from placing any part of their
body or clothing in the gap, especially during the operation of the
locking mechanism.
Customer responsible for learn the functions of robot tool changer，And
implement appropriate fasteners and software to safely operate the tool changer.
It shall be controlled to avoid endangering personnel or equipment during locking
or unlocking.
All pneumatic fittings and piping must be able to withstand repeated
movements of the application without failure.The wiring of electrical and
pneumatic pipelines must minimize the possibility of sprains, kinks, cracks, etc.
Failure of key electrical or pneumatic pipelines to work properly may cause injury
to personnel and equipment.
Disconnect all power, pneumatic and fluid circuits during maintenance.
Warning: before operation, remove all temporary protective
materials (cover, plug, tape, etc.) from the locking surface of the
tool changer and module. Otherwise, the tool changer, module and
arm end tools will be damaged and personal injury may be caused.

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1.3 Safety notes:
Warning: do not maintain or repair the tool changer or module ，
Unless the tool is safely supported or placed on the tool stand ， All
energized circuits (such as electrical, air, water, etc.) have been
closed, the high-voltage connection has been cleaned, and the power supply has
been discharged from the circuit in accordance with the customer's safe operation
procedures and policies.Personal injury or equipment damage may result if not
placed in the tool holder and the circuit is energized. Place the tool on the tool
holder, close and discharge all energized circuits, release all pressurized
connections, and confirm that all circuits are powered off before maintaining or
repairing the tool changer or module.
Warning: during operation, the area between the master plate and
the tool plate must be kept clean. If the area is not kept clean, the
tool changer, module or arm end tool will be damaged and
personal injury may be caused.
Warning: the tool changer is only used for the intended application
and the application approved by the manufacturer. Using the tool
changer in unexpected use will cause damage to the tool changer,
module or arm end tool, and may cause personal injury.

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2. Product overview
The LT robot tool changer enhances the universality of the robot by using a
variety of tools (such as fixtures, vacuum suction cups, pneumatic and electric
motors, welding guns, etc.). The tool changer includes a master plate installed on
the robot arm and a tool plate installed on the customer's tool. When the robot
picks up the tool, the pneumatically driven locking mechanism connects the two
plates. The fault self-locking mechanism of the patent adopts multi conical cam
with ball locking technology，Ensure during operation，If the air pressure less than
60psi (4.1 bar)，too changer will not release. The robot can select the required
tools through programming，Master plate connect to tool plate. Electricity, fluid and
other energy are transferred to the end tools through optional modules attached to
the master and tool plate.
2.1 Master components
The master plate components includes an anodized aluminum body，
Hardened stainless steel locking mechanism and hardened steel locating pin.The
locking mechanism includes a cam，One ball cage and chrome steel ball bearing.
The master plate has two flat sides，used for install optional modules,can install
relevant modules according the projects application, Through“L”and“U” the
pneumatic ports provides locking and unlocking air for the locking mechanism，A
vent is provided for the end effector through the digital pneumatic port on the
master plate. The locating pin is matched with the bushing to ensure that the
positioning can be repeated during the combination process. Grease shall be
used for cams, Ball cages and balls to improve performance and maximize the
service life of the master plate components.

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2.2 Tool plate components
The tool plate components consists of an anodized aluminum body and a
hardened stainless steel ball snap ring. Tool plate provides two flat interface for
install modules. Tool plate has air pass port，to supply end effector.
Cam
Locking ball
Locating pin
Unlock/ Lock
M5 interface
Pass port
M5 interface
ball cage

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2.3 Optional modules
This model has 1 module mounting interface，can install electrical module，
more modules please find from website:
https://www.ltautotools.com/ltc-19.html；
3. Installation
The end effector is usually connected to the tool plate through the tool
adapter flange. We can provide standard and customized tool adapter flanges as
required. All fasteners used to install the tool changer on the robot and tools shall
be tightened to the torque value as indicated. In addition, removable (blue) Loctite
242 anaerobic adhesive shall be used for fasteners.The pneumatic pipeline and
cable are fixed and tied together, and must be able to move freely during
operation.
Warning: before maintaining or repairing the tool changer, be
sure to place the tool on the tool support or stop, turn off all
electrical, air, water, etc., and the power supply has been
discharged from the circuit according to the customer's specific safety operation
procedures and policies. And confirm that the air pressure and liquid pressure have
been released.
Passport M5
interface
Aluminum
Locating pin hole
Steel ball snap ring

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Warning: pneumatic fittings and pipelines must be able to
withstand repeated movements of the application without failure.
The wiring of electrical and pneumatic lines must minimize the
possibility of over stress, pull-out or kink. Failure to do so may result in critical
electrical or pneumatic pipeline failure and may result in personal injury or
equipment damage.
Warning: do not use a washer under the head of the mounting screw, and
do not let the mounting screw protrude above the mating surface of the
master plate and the tool plate. If the mounting screw protrudes above the
mating surface, a gap will be formed between the master plate and the tool
plate, resulting in the failure of the locking mechanism to fully engage,
which may cause equipment damage or personal injury. The mounting
screws must be flush or below the mating surface of the master plate and
tool plate.
Note: in the design of adapter flange and tool flange plate,
the positioning criteria of masterplate and adapter flange and the
positioning criteria of tool plate and tool flange shall be followed.
Otherwise, the connection may be loose;
Note: after the connecting screw uses the thread fastening
glue, if it is removed and reused, the thread fastening glue shall be
applied again.Otherwise, the screw may become loose. Always use
new thread locking compound when reusing fasteners.
The screw must be lower than
the mating surface of the
master plate and tool plate.

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3.1 Master Plate
Master plate usually install on Sixth axis flange of the robot，Master plate
match with the size of ISO9409-31.5-4-M5，if the robot Sixth axis fit the size
ISO9409-31.5-4-M5can connect directly do not use adapter flange,
Otherwise need custom the adapter flange to connect the robot Sixth axis
with master plate；The master plate own with a locating pin hole and a locating
boss.
If the customer chooses to design the adapter flange, please consider the
following points:
a.The adapter flange shall include bolt holes for installation, as well as a
locating pin and a boss for accurate positioning on the robot and the master plate.
The pin and boss function prevents unnecessary rotation. For the installation
function of the robot, please refer to the robot manual.
b.The thickness of the adapter flange must be sufficient to provide the
necessary thread engagement for the mounting bolts.
c.The pin shall not protrude from the surface of the adapter flange beyond the
depth of the pin hole on the master plate.
d.If bosses are used on the master plate, grooves of appropriate depth and
diameter must be machined on the adapter flange to correspond to the bosses on
the master plate.
e.Too long mounting bolts will form a gap between the adapter flange and the
master plate, thus damaging the equipment.
locating pin hole
Locating boss

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Locating pin
Master plate
locating boss
Master plate
Locating pin
f.The adapter flange must be firmly installed on the master plate.
g.The design of adapter flange must consider the clearance required for
module accessories.
3.2 Installation of master plate
Tool required：4 mm Allen wrench, torque wrench.
Other required：Cleaning cloth，Loctite242 Thread anaerobic adhesive.
A.Keep tools in a safe place.
B.Release master plate and tool plate.
C.Close and completely disconnect all energy connections; For example:
electrical, air, etc.
D.clean install interface.
E.Using the alignment function, place the adapter flange on the robot arm and
fasten it with screws.
F.Connect all "lock / unlock" and "through" air utilities to the master plate.
Use adapter flange connect to robot sixth axis
Robot Sixth
AXIS
Adapter flange
Socket head cap
screw
Master plate
connecting
screw

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3.3Tool plate
Tool plate connect to relevant tools.The adapter flange can adapt the tool
plate to the corresponding tool.（Locating pin hole）Accurately position and fix the
tool plate to the corresponding tool through the bolt hole.
Note: do not use more than two alignment functions when fixing the tool plate to the
adapter flange. Using more than two alignment functions may
damage the device. Use two locating pins to align the tool plate
with the adapter flange.
Note: do not use too long locating pins. Using an excessively long locating pin will
create a gap between the adapter flange and the tool plate and damage the
equipment. When using pins, the length of the pins shall not exceed the allowable
range of the tool plate.
If the customer choose to design and build a tool adapter flange, consider the
following:
The adapter flange shall include bolt holes for installation and two locating
pins for accurate positioning on customer tools and tool plates. The pin prevents
unnecessary rotation.
the pin shall not protrude from the surface of the transition flange beyond the
depth of the pin hole on the tool disc.
The thickness of the transition flange must be sufficient to provide the
necessary thread engagement for the mounting bolts. Fasteners shall meet the
recommended minimum joint length without exceeding the maximum available
thread depth. Using too long bolts may damage the tool disc.
The adapter flange design must consider the clearance required for module
accessories and accessories.
The center of the adapter flange must have a threaded hole to manually
return the locking mechanism to the unlocked position under adverse conditions,
such as accidental power failure or air pressure drop. The minimum center
threaded hole is M6.

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Tool Plate
Adapter flange
Locating pin
3.4Tool Plate installation
Tools Requirements：3 mm Allen wrench, torque wrench.
Required items: cleaning cloth, LOCTITE 242 thread anaerobic adhesive.
1、Clean the mounting surface；
2、Install the tooling adapter flange on the customer's tooling, align it with the
pin shaft, and fasten it with bolts (coated with LOCTITE 242 glue);Align with the
pin shaft and install the tool disc on the adapter flange with M8 screws（Gluing
LOCTITE242）；
3、Install the tools on the adapter flange.
3.5 Tool Plate installation
3.6Remove Tool Plate
1、Tools requirements：3mm Allen wrench；
2、Keep tools in a safe place；
3、Release master plate and tool plate；
4、Close and completely disconnect all energy connections; For example:
electrical, air, etc.；
Install the screws

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Tool plate
Master Plate
Module mounting screws
LMO-S12AM
LMO-S12AT
5、Remove the fasteners that fix the tool plate to the tool adapter flange or
customer tool;；
6、Remove the tool plate；
3.7Optional modules installation
Optional modules are usually installed on the tool changer by the LT company
before shipment. The following steps described the field installation or removal as
required. The tool changer can select many different types of modules. Some
modules will require an adapter plate to be installed on the tool changer.（Take
LMO-S12Afor example）
Tools Requirement：2mm Allen wrench；
Required items: cleaning cloth, LOCTITE 242 thread anaerobic adhesive.
1.Keep tools in a safe place；
2.Release master plate and tool plate；
3.Close and completely disconnect all energy connections; For example:
electrical, air, etc.；
4.Clean the mounting surface；
5.Align the optional module with the mounting surface of the master plate or
tool plate；
Modules
Locating pin

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6.If fasteners with pre applied adhesive are not used, apply LOCTITE 242
thread sealant to the mounting fasteners；use 2mm Allen wrench and use
4pieces M2.5Install the screw fixing module;
7.Before operation, please remove all protective covers, plugs, tapes, etc.
from the module;
8.Safely and normal operation;
3.8 The method of remove modules
Tools Requirement：2mm Allen wrench；
1.Keep tools in a safe place；
2.Release master plate and tool plate；
3.Close and completely disconnect all energy connections; For example:
electrical, air, etc.；
4.Use 3mm Allen wrench to remove 4pieces M2.5 Socket head cap screw.
5.Remove modules from master plate and tool plate.
3.9 Air requirement
The normal operation of the locking mechanism requires a continuous supply
of clean, dry and unlubricated air under the following conditions:
•The pressure range is 60 to 100 psi（4.1-6.9Pa），suggested 80 psi。
•Minimum filtering：40micron。
To lock or unlock the tool changer, a constant supply of compressed air is
required.
If there is a loss of air pressure in the locked state, the cam profile will prevent
the master plate and tool plate from unlocking, and the tool changer will enter the
fault self-locking state.
Note: do not use the tool changer under the condition of fault
self-locking. The locking mechanism may be damaged. Before
resuming normal operation, re-establish the air pressure and
ensure that the tool changer is in the safe locking position.
3.8.1Solenoid valve requirements and connections
The customer provides 2-position 4-way valve or 2-position 5-way valve to
drive the locking mechanism in the master plate. When air is supplied to the

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locked or unlocked port on the master plate, the opposite port must be vented to
the atmosphere(That is, when air is supplied to the locking port, the unlocking port
must be unlocked to the atmosphere) Failure to vent trapped air or vacuum at the
inactive port may inhibit the operation of the locking mechanism and prevent
locking or unlocking.
Note: when connected to the three-way valve, the locking
mechanism will not work properly because this type of valve cannot
discharge residual air or vacuum from the tool changer. This may
cause product damage, incidental tools or personal injury. Connect the lock and
unlock air supply to the 2-position 4-way valve or the 2-position 5-way valve.
2 position 5 way valve
supply of clean,
dry and
unlubricated air
（60 to 100psi）
The exhaust port leads
to the atmosphere
Locking port
Unlock port