LT LTC-0040A User manual
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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.
Preface
Thank you for purchasing our LT Robot Tool Changer.
This Brochure describes the basic information of LTC-0040A, About
electrical, Pneumatic and other parts please refer to other user manual.
If you have any questions please contact LT Company.
The contents of this document belong to Zhengzhou Linghang Robot Co.,Ltd.
(it's referred to "LT" afterwards), It can’t be copied in part or in whole withoutthe
prior written permission of LT Company. This manual will be revised regularly to
reflect and incorporate changes to the product without additional notice.
This document is confidential, only LT customers and authorized agents can
use it, and it shouldn’t be disclosed to the third party without the prior written
permission
We don't guarantee for the accuracy of this document and the suitability of the
equipment for a particular application.
LT will not be responsible for any errors contained in this document and any
incidental, indirect losses arising therefrom.
LT will not be responsible for any errors and omission in this document.
Copy right belongs to Zhengzhou Linghang robot Co., Ltd. all rights reserved.
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Content
Preface..........................................................................................2
Content.................................................................................3
Glossary............................................................................... 5
1. Safety....................................................................................... 7
1.1 Notices........................................................................... 8
1.2 General safety rules........................................................8
1.3 Safety notes..................................................................10
2. Product overview................................................................... 10
2.1 Master Plate components............................................. 11
2.2 Tool plate components.................................................12
2.3 Optional modules......................................................... 13
3. Installation............................................................................. 13
3.1 Master Plate................................................................. 15
3.2 Installation of master plate...........................................16
3.3 Tool plate..................................................................... 17
3.4 Tool Plate installation.................................................. 18
3.5 Disassembling Plate..................................................... 19
3.6 Optional modules installation...................................... 19
3.7 Modules installation.....................................................20
3.8 The method of remove modules.................................. 21
3.9 Air requirement............................................................21
3.10 Solenoid valve requirements and connections........... 21
3.11 Signal status table of Lock/unlock and tool plate in
position sensor................................................................... 24
4. Operation............................................................................... 24
4.1 Locking sequence.........................................................25
4.2 Fault self locking operation......................................... 26
4.3 Unlocking sequence..................................................... 27
4.4 Tool identification........................................................27
5. Regular Maintenance............................................................. 29
5.1Maintain the checklist regularly....................................29
5.2 Install fasteners and adaptor flanges............................ 30
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5.3 Cleaning and lubrication of locking mechanism and
locating pin.........................................................................30
5.4 Inspection and cleaning of electrical modules............. 32
6. Troubleshooting and service procedures............................... 32
6.1 General Fault handling.................................................33
6.2 Emergency inspection and treatment of quick tool
changers with external interference and impact.................35
6.3 Sensor’s checking, adjustment, replacement............... 36
7. Parameter table.......................................................................39
8. Dimensional outline drawing of Plates.................................. 40
9. Recommended Solenoid valve to control tool changers........ 41
9.1 Single solenoid valve control.......................................41
9.2 Double solenoid valve control(safer control way)....... 42
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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 ofthe 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 ofTool Changer products that allows coupling the Master
plate and Tool plate without physical contact priorto locking.
Piston
Piston located in the Master plate that actuates the locking mechanism.
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Air module
pass air power through the Master plate to the Tool plate and to the end
effector.
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 ofall 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
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Gigabit
Ethernet
The interface that can realize 1000mdps transmission rate by CAT6
standard
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 theTool
Changer.
Unlock
The physical action ofthe 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.
1.Safety
This section describes the general safety guidelines to be followed for this
product, The mentioned warning instructions and safety precautions are applicable
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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.
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 part
manufacturers.
Danger: All the information and instructions should be followed,
otherwise the to complyi nformati on on the nature of the ngerous
s ituati on, the consequences of not avoiding the danger and the methods
to avoid it.
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
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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.
Warning: Pls remove all temporary protective materials (cover, plug,
tape, etc.) from the locking surface of the tool changers and modules
before operation. Otherwise, the tool changer, module and end-arm
tools might be damaged and cause personal injury.
expected during operation. Please refer to the product specifications in each
models of this manual.Pls pay attention to dynamic load which caused by
acceleration and deceleration of robot’s movement. In the case of high acceleration
or deceleration, these forces may be much bigger than the static force.
It is the User's responsibility to ensure that in locking status and during
locking process ,there has no foreign matters between master plate and tool plate,
otherwise will cause serious injury.
User is responsible to learn the functions of robot tool changer,and operate
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.
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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 end-arm 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.
1.3
Safety notes:
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
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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 Plate 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 airforthe 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.
Cam
Locking Ball
Luck/Unlock status
sensor
Tool plate in
position sensor
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Ball Bearing housing cover
Lock/Unlock air port PT1/8(need match
with special offered electrical magnet
Air port PT1/8
2.2
Tool plate component
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.
Steel ball snap ring
Aluminum alloy body
Positioning pin hole
Air port PT1/8
In-position sensor
detection point
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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
2.3
Optional modules
This model has 2 module mounting interface , can install electrical module ,
bus communication module, Servo motor module, Ultrasonic module, air and
liquid module, to learn more details of modules pls check below link:
https://www.ltautotools.com/products/LTC-0040A-tool-changer.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 liquid glue) 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 holder or tool station, turnoff
all electrical, air, water etc., and the electrical 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.
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Note: in the design of adap'ter flange and tool flange plate, the
positioning criteria of masterplate and adapter flange and the
positioning criteria of tool plate and toolflange 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.
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 scre^w 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.
The screw must be lower than
the mating surface of the master
plate and tool plate.
electrical or pneumatic pipeline failure and may result in personal injury
or equipment damage.
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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 ISO9409-63-6-M6 , if the robot Sixth axis fit
the size ISO9409-63-6-M6 then tool changer master plate can connect
with robot directly, adapter flange is not needed, Otherwise adapter flange
is needed to connect the robot Sixth axis with master plate;
The master plate with two locating pin holes and a locating cam.
Based on positioning design, positioning can be done with two locating pin
holes or one of two locating pin holes plus one locating cam, otherwise
there will be missing or over positioning.
Locating Cam
Positioning holes
If adapter flange is needed,
please consider the following points during design:
1.
The adapter flange shall include bolt holes for installation, as well as
two locating pin or a locating pin and a cam for accurate positioning on the
robot and the master plate. The pin and cam function prevents unnecessary
rotation. For the installation function of the robot, please refer to the robot
manual.
2.
The thickness of the adapter flange must be sufficient to provide the
necessary thread engagement for the mounting bolts.
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3.
The pin shall not protrude from the surface of the adapter flange
beyond the depth of the pin hole on the master plate.
4.
If cams 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.
5.
Too long mounting bolts will form a gap between the adapter flange
and the master plate, then cause damaging of equipment.
6.
The adapter flange must be installed on the master plate firmly.
7.The design of adapter flange must consider the clearance required
for module accessories.
3.2
Installation of master plate
Tool required : 5 mm Allen wrench, torque wrench, Cleaning cloth ,
Loctite242 Thread anaerobic adhesive, Keep tools in a safe place.
3.2.1
Release master plate and tool plate.
3.2.2
Close and completely disconnect all energy connections; For
example: electrical, air, etc.
3.2.3
Clean install interface.
3.2.4
Using the alignment function, place the adapter flange on the
robot arm and fasten it with screws.
3.2.5
Connect all "lock / unlock" and "through" air utilities to the
master plate.
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Use adaptor flange to connect with robot sixth axis
Robot Sixth
Axis
Locating pin
Adaptor Flange
Locating pin
Socket head
cap screw
Master Plate
Master Plate
locating boss
Master Plate
connecting screw
3.3
Tool plate
Tool plate connect to relevant tools. The adapter flange can adapt the tool
plate to the corresponding tool. Accurately position by locating hole and fix the
tool plate to the corresponding tool through the bolt holes.
Note: do not use more than two alignment functions when fixing
the tool plate to the adapter flange. Using more than t'wo 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 points:
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3.3.1 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.
3.3.2 The pin shall not protrude from the surface of the transition flange
beyond the depth of the pin hole on the tool disc.
3.3.3 The thickness ofthe 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.
3.3.4 The adapter flange design must consider the clearance required for
module accessories and accessories.
3.3.5 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 M10.
3.4
Tool Plate installation
Tools Requirements :4mm Allen wrench, torque wrench, cleaning cloth,
LOCTITE 242 thread anaerobic adhesive, keep tools in a safe place.
3.4.1 Clean the mounting surface;
3.4.2 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);
3.4.3 Align with the pin shaft and install the tool disc on the adapter flange
with M8 screws (Gluing LOCTITE242 )；
3.4.4 Install the tools on the adapter flange.
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Tool Plate connecting
screw
Tool Plate
Adapter flange
Locating pin
3.5
Disassembling Plate
Tools needed: 4mm Allen wrench, and pls keep tools in a safe place;
3.5.1
Release master plate and tool plate;
3.5.2
Turn off and completely disconnect all energy connections, such as
electrical, air, liquid etc;
3.5.3
Remove the fasteners that fix the tool plate to the tool adapter flange
or customer tool;
3.5.4
Romove tool plate;
3.6
Optional modules installation
Optional modules are usually installed well on the tool changer by the
LT company before shipment. The following steps described the
installation or removal order in site if needed. The tool changer can fit to
many different types of modules. Some modules will need an adapter plate
to be installed on the tool changer. ( Take module No. LMO-GS03A for
example )
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Master Plate
LMO-GS03AM
Tool Plate
Module Locating
Pin
Module mounting
screws
LMO-GS03AT
3.7
Modules installation
Tools needed: 3mm Allen wrench, cleaning cloth, LOCTITE
242 thread anaerobic adhesive, and pls keep tools in a safe place;
3.7.1
Release master plate and tool plate;
3.7.2
Turn off and completely disconnect all energy connections, such
as electrical, air, liquid etc;
3.7.3
Clean the mounting surface;
3.7.4
Align the optional module with the mounting surface of the
master plate or tool plate;
3.7.5
If fasteners with pre applied adhesive are not used, apply
LOCTITE 242 thread sealant to the mounting fasteners; use 3mm Allen
wrench and use 4pieces M4 Install the screw fixing module;
3.7.6
Before operation, please remove all protective covers, plugs,
tapes and all other unnecessary tools from the module;
3.7.7
Recover normal operation safely;
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