Robot System Products TC60 Series User manual

Product Manual
Tool changers TC60, TC120, TC180
M0623-2
Tool changers | Swivels | Swivels with Tool changers | Grippers | Hose packages | Valve Units | Tool systems

2 M0623-1 ver 2.6

M0623-1 ver 2.6 3
The information in this document is subject to change without prior notice and should not be
regarded as an undertaking from Robot System Products AB. Robot System Products AB
assumes no responsibility for errors that may occur in this document.
Robot System Products AB bears no responsibility for damage that is incurred by the use of this
document, or the software or hardware described in this document.
The document, or parts of it, may not be reproduced or copied without prior permission from
Robot System Products AB. It may neither be imparted to a third party, nor otherwise be used
without authorization. Infringement hereof will be subject to action in accordance with the
applicable laws.
Further copies of this document can be obtained from Robot System Products AB at
current prices.
© Robot System Products AB
Robot Systems Products AB
Isolatorvägen 4
SE-721 37 Västerås
Sweden

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CONTENTS
1 INTRODUCTION......................................................................................................6
1.1 Safety.........................................................................................................................7
1.1.1 General...............................................................................................................................7
1.1.2 Explanation of warnings .....................................................................................................7
1.2 Description of RSP tool changers...............................................................................8
1.3 Complementary Equipment........................................................................................8
2 TECHNICAL SPECIFICATIONS..............................................................................9
2.1 Description of tool changers and tool attachments .....................................................9
2.1.1 Coordinate System Definition...........................................................................................10
2.1.2 Tool changer TC60-8. Article no: P1301..........................................................................11
2.1.3 Tool attachment, TA60-8. Article no: P1302....................................................................12
2.1.4 Tool changer TC120-8. Article no: P1401........................................................................13
2.1.5 Tool attachment, TA120-8. Article no: P1402 ..................................................................14
2.1.6 Tool changer TC180-8. Article no: P1801........................................................................15
2.1.7 Tool attachment, TA180-8. Article no: P1802 ..................................................................16
2.1.8 Pneumatic diagram for P1301, P1401 and P1801...........................................................17
2.2 Options for tool changers and tool attachments........................................................18
2.2.1 Signal interface Souriau, robot side. Article no: P1305....................................................18
2.2.2 Signal interface Souriau, tool side. Article no: P1306 ......................................................19
2.2.3 Circuit diagram E0182-001 for P1305/P1306 ..................................................................20
2.2.4 Signal interface Souriau, robot side. Article no: P1311....................................................21
2.2.5 Signal interface Souriau, tool side. Article no: P1312 ......................................................22
2.2.6 Circuit diagram E0182-002 for P1311/P1312 ..................................................................23
2.2.7 Servo power interface Souriau, robot side. Article no: P1307 .........................................24
2.2.8 Servo power interface Souriau, tool side. Article no: P1308............................................25
2.2.9 Circuit diagram E0182-003 for P1307/P1308 ..................................................................26
2.2.10 High voltage interface, robot side. Article no: P1322.....................................................27
2.2.11 High voltage interface, tool side. Article no: P1323 .......................................................28
2.2.12 Circuit diagram E0182-026 for P1322/P1323 ................................................................29
2.2.13 Air coupling 2 channels, robot side. Article no: P1325...................................................30
2.2.14 Air coupling 2 channels, tool side. Article no: P1326.....................................................31
2.2.15 Magnetic sensors TC Opened/TC Closed. Article no: P1324........................................32
2.2.16 Guide pins. Article no: P1314.........................................................................................33
2.2.17 Parking bracket kit. Article no: P1313 ............................................................................34
2.2.18 Parking bracket kit. Article no: P1331 ............................................................................35
2.2.19 Parking bracket kit. Article no: P1405 ............................................................................36
2.2.20 Parking bracket kit. Article no: P1805 ............................................................................37
2.2.21 Tool stand kit. Article no: P0423.....................................................................................38
2.2.22 Robot Adaptation Kits.....................................................................................................39
2.3 Limitation of Robot movements................................................................................39
2.4 Connection kits and cables.......................................................................................39
3 INSTALLATION.....................................................................................................40
3.1 Tightening torques....................................................................................................40
3.2 Recommended tools for installation..........................................................................40
3.3 Installation of tool changer on robot..........................................................................41
3.4 Installation of tool attachment to the gripper/tool.......................................................43

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3.5 Hints......................................................................................................................... 45
3.5.1 Programming....................................................................................................................45
3.5.2 Sparking ...........................................................................................................................45
3.5.3 Electrical installation.........................................................................................................45
3.5.4 Tool Stand........................................................................................................................45
3.5.5 Tool Identification .............................................................................................................45
4 MAINTENANCE AND SERVICE...........................................................................46
4.1 Maintenance chart.................................................................................................... 46
4.1.1 Required products............................................................................................................46
4.1.2 Recommended tools for maintenance .............................................................................47
4.1.3 Wear parts........................................................................................................................47
4.1.4 Maintenance activities on tool changer............................................................................48
4.1.5 Maintenance activities on tool attachment.......................................................................48
4.2 Visual inspection...................................................................................................... 49
4.2.1 Inspection of the tool changer..........................................................................................49
4.2.2 Inspection of the tool attachment .....................................................................................49
4.3 Cleaning................................................................................................................... 50
4.3.1 Cleaning and lubrication of tool changer..........................................................................50
4.3.2 Cleaning and lubrication of tool attachment.....................................................................52
4.4 Replacement of wear parts....................................................................................... 53
4.4.1 Replacement of air sealing, P1301, P1401 and P1801 ...................................................53
4.4.2 Replacement of signal pins, P1305 and P1311...............................................................54
4.4.3 Replacement of servo power/high voltage interface on tool changer..............................55
4.4.4 Replacement of signal/air interface on tool attachment...................................................56
4.4.5 Replacement of air sealings, P1325 ................................................................................57
4.4.6 Replacement of guide pins (option) .................................................................................58
4.5 Complete service of tool changer............................................................................. 58
4.6 Replacement of tool changer, TC240-1/ TC480-1.................................................... 59
4.7 Replacement of tool attachment, TA240-1/ TA480-1................................................ 61
5 SPARE PARTS .....................................................................................................63
5.1 Tool changer............................................................................................................ 63
5.1.1 Part list for tool changer TC60, P1301.............................................................................63
5.1.2 Part list for tool changer TC 120, P1401..........................................................................64
5.1.3 Part list for tool changer TC180, P1801...........................................................................65
5.1.4 Part list for option to TC, signal/air interface, P1305, P1311 and P1325.........................66
5.1.5 Part list for option to TC, power/high voltage interface ....................................................67
5.1.6 Part list for option to TC, magnetic sensors .....................................................................67
5.2 TOOL ATTACHMENT........................................................................................68
5.2.1 Part list for Tool attachment TA60-8, TA120-8, TA180-8.................................................68
5.2.2 Part list for option to TA, misc. .........................................................................................69
6 DISPOSAL AND RECYCLING..............................................................................70

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1 INTRODUCTION
Robot System Products is a front-rank provider of peripheral products for high performance
robot applications. We provide complete solutions for your robot installations, aiming to improve
your productivity with the most reliable and cost-effective tooling on the market. Continuously we
explore emerging technologies, working with leading edge design.
Robot System Products has a wide range of standard robot peripheral products:
•Tool changers
•Swivels
•Swivels with integrated tool changers
•Grippers
•Hose Packages
•Valve units
•Tool systems
•Tool stands
Robot System Products’tool changers are constructed to maximize the flexibility and reliability
of your robot fleet. Through our patented locking device TrueConnect™ robustness and high
safety are combined with low weight and compactness. With our swivels you can provide
compressed air, water, electrical and data signals as well as weld and servo power to your tools
with robot motion capabilities fully maintained. Our swivels with tool changers unites the
TrueConnect™ tool changing mechanism with our swivel technology, combining the best out of
two technologies.
Robot System Products’product lines are available for all major robot brands and come with
complete documentation. 3D-models for simulation are available for download at:
www.rsp.eu.com

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1.1 Safety
1.1.1 General
The integrator installing the tool changer into the system must follow the safety demands stated
in standards and provisions applicable in the country where the tool changer system is to be
installed. The products are all prepared for CE-certification.
The user of the Robot System Products tool changer is responsible that law and directives
applicable in respective countries, with regards to safety, are followed. The user is also
responsible to guarantee that all safety devices are installed correctly.
WARNING!
Never carry out service work on a robot that has not been taken out of operation.
See safety information for the robot.
WARNING!
Only perform work on grippers or tools attached to the tool changer if the air
pressure is safely switched off.
WARNING!
Be aware that tool changer and tool attachment are heavy and may cause
personal injury and equipment damage if dropped.
NOTE!
The tool changer shall always be in locked position, also when empty, to avoid
unexpected locking if air pressure is lost.
1.1.2 Explanation of warnings
The warnings in this document are specific to the products in this manual. It is expected that the
user also pay attention to certain notifications from the robot manufacturer and/or the
manufacturers of other components used in the installation.
WARNING!
The warning sign will make you aware that a situation could result in potential
serious injury or damage to equipment.
NOTE!
The note sign will alert you about something important to consider.

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1.2 Description of RSP tool changers
Our tool changers enable robots to handle and switch between multiple tools. They are built to
ensure reliable and smooth operation, being compact with low weight and robust design and
incorporating many safety features. Depending on model and options, electrical signals, weld
and servo power, data, water and compressed air are transferred from the robot side to the tool.
The patented locking device TrueConnect™ has a minimum of play and gives a practically,
through the lifespan, absolute positioning repeatability. The principle behind the locking
mechanism is the uniform distribution of load obtained by pressing looking balls into spherical
grooves. In consequence, substantially larger positional tolerances are accepted during docking.
A built-in spring ensures that the tool remains in place in the tool changer even if the air pressure
drops.
1.3 Complementary Equipment
Complementary equipment is described in separate documents.
Article
Note
Valve unit
Mounted at the rear of the upper arm. Shuts off the air
automatically during tool changing.
Cable and Hose Package
Complete packages for most robots on the market ready to be
mounted without any modifications.
Tool Stands
Tool stands will, combined with tool attachments and
adaptation kits, give a rigid installation for easy tool changing.
Connection kits
In order to make electrical installation easier, connection kits
are available for tool changers and tool attachments.
3D-models
Available in Solid Works® and STEP-format.

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2 TECHNICAL SPECIFICATIONS
2.1 Description of tool changers and tool attachments
The RSP product family of TC60-8, TC120-8 and TC180-8 is designed for maximum flexibility
and to be used for various applications for which a large number of options can be combined in
different configurations. These options are generally useable within the product family. This
document presents:
oThe Robot System Products TC60-8, TC120-8 and TC180-8 tool changers including
tool attachments.
oOptions to configure tool changers and tool attachments. These options can as well be
ordered as accessories for retrofitting.
oConnection kits to facilitate electrical installation.
An adaptation plate between the tool changer and the turning disc on the robot may be needed,
depending on the robot model. Such adaptation plates are available from RSP.
Three guide pins can be mounted as an option in order to align the tool attachment with the tool
changer before the electrical connector is connected, which significantly extends the lifetime for
not spring-mounted signal pins.
The figure below is an example of a configuration with different options:
TC 60-8 with different options mounted.

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2.1.1 Coordinate System Definition
A tool changer adds load to the robot. If the arm and tool loads are not stated correctly during
programming the behaviour of the robot and the wear of the equipment will be affected.
Information about weight and centre of gravity can, in accordance with the co-ordinate system
stated below, be found in the technical specification tables of the tool changer.
NOTE!
For the tool changer and tool changer with tool attachment, the origo is situated in
the centre of the robot mounting flange.

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2.1.2 Tool changer TC60-8. Article no: P1301
The tool changer TC60-8 transfers 8 pneumatic channels to the tool attachment, has inlets for
Open TC and Close TC, 3 positions for options and 1 for magnetic sensors.
To be used together with P1302.
Technical data
Working temperature
+10°C - +60°C
Bolt pattern
ISO 9409-1-80-6-M8
Maximum tool load
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±600 N
±600 Nm
±500 Nm
Weight and centre of gravity
1.8 kg
0.0 / 0.0 / 26.0 mm
2.8 kg
0.0 / 0.0 / 35.0 mm
P1301
P1301 and P1302
Weight
Mass centre X / Y / Z
Weight
Mass centre X / Y / Z
Air ducts
Pneumatic diagram
Total number of ducts
Dedicated air ducts
Max air pressure
Air flow
Connection, robot side
Air quality
Pne0182-001 (see section 2.1.8)
10
Open TC marked O (6-10 bar)
Close TC marked C (6-10 bar)
10 bar
400 l/min
G 1/8”
Oil-clean and waterless filtered air, with max
25µm particle content

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2.1.3 Tool attachment, TA60-8. Article no: P1302
The tool attachment TA60-8 transfers 8 pneumatic channels to the tool and has 3 positions for
options.
To be used together with P1301.
Technical data
Working temperature
+10°C - +60°C
Bolt pattern
ISO 9409-1-80-6-M8
Weight
1.0 kg
Maximum tool load
(M8-screws)
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±600 N
±600 Nm
±500 Nm
Maximum tool load
(M6-screws)
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±600 N
±600 Nm
±250 Nm
Air ducts
Total number of air ducts
Connection, tool side
8
G 1/8”
Note! Tools can be mounted to the tool attachment using six M8-screws,
alternatively the tool attachment can be mounted to the tool using six M6-screws.

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2.1.4 Tool changer TC120-8. Article no: P1401
The tool changer TC120-8 transfers 8 pneumatic channels to the tool attachment, has inlets for
Open TC and Close TC, 3 positions for options and 1 for magnetic sensors. To be used together
with P1402.
Technical data
Working temperature
+10°C - +60°C
Bolt pattern
ISO 9409-1-100-6-M10
Maximum tool load
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±1000 N
±1000 Nm
±1000 Nm
Weight and centre of gravity
2.6 kg
0.0 / 0.0 / 28.0 mm
4.0 kg
0.0 / 0.0 / 37.0 mm
P1401
P1401 and P1402
Weight
Mass centre X / Y / Z
Weight
Mass centre X / Y / Z
Air ducts
Pneumatic diagram
Total number of ducts
Dedicated air ducts
Max air pressure
Air flow
Connection, robot side
Air quality
Pne0182-001 (see section 2.1.8)
10
Open TC marked O (6-10 bar)
Close TC marked C (6-10 bar)
10 bar
800 l/min
G 1/8”
Oil-clean and waterless filtered air, with max
25µm particle content

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2.1.5 Tool attachment, TA120-8. Article no: P1402
The tool attachment TA120-8 transfers 8 pneumatic channels to the tool and has 3 positions for
options. To be used together with P1401.
Technical data
Working temperature
+10°C - +60°C
Bolt pattern
ISO 9409-1-100-6-M10
Weight
1.3 kg
Maximum tool load
(M10-screws)
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±1000 N
±1000 Nm
±1000 Nm
Maximum tool load
(M8-screws)
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±1000 N
±1000 Nm
±600 Nm
Air ducts
Total number of air ducts
Connection, tool side
8
G 1/8”
Note! Tools can be mounted to the tool attachment using six M10-screws,
alternatively the tool attachment can be mounted to the tool using six M8-screws.

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2.1.6 Tool changer TC180-8. Article no: P1801
The tool changer TC180-8 transfers 8 pneumatic channels to the tool attachment, has inlets for
Open TC and Close TC, 3 positions for options and 1 for magnetic sensors. To be used together
with P1802.
Technical data
Working temperature
+10°C - +60°C
Bolt pattern
ISO 9409-1-125-6-M10
Maximum tool load
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±1800 N
±1800 Nm
±1250 Nm
Weight and centre of gravity
3.4 kg
0.0 / 0.0 / 28.0 mm
5.2 kg
0.0 / 0.0 / 37.0 mm
P1801
P1801 and P1802
Weight
Mass centre X / Y / Z
Weight
Mass centre X / Y / Z
Air ducts
Pneumatic diagram
Total number of ducts
Dedicated air ducts
Max air pressure
Air flow
Connection, robot side
Air quality
Pne0182-001 (see section 2.1.8)
10
Open TC marked O (6-10 bar)
Close TC marked C (6-10 bar)
10 bar
1200 l/min
G 1/8”
Oil-clean and waterless filtered air, with max
25µm particle content

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2.1.7 Tool attachment, TA180-8. Article no: P1802
The tool attachment TA180-8 transfers 8 pneumatic channels to the tool and has 3 positions for
options. To be used together with P1801.
Technical data
Working temperature
+10°C - +60°C
Bolt pattern
ISO 9409-1-125-6-M10
Weight
1.8 kg
Maximum tool load
(M10-screws)
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±1800 N
±1800 Nm
±1250 Nm
Maximum tool load
(M8-screws)
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±1800 N
±1800 Nm
±750 Nm
Air ducts
Total number of air ducts
Connection, tool side
8
G 1/8”
Note! Tools can be mounted to the tool attachment using six M10-screws,
alternatively the tool attachment can be mounted to the tool using six M8-screws.

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2.1.8 Pneumatic diagram for P1301, P1401 and P1801

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2.2 Options for tool changers and tool attachments
2.2.1 Signal interface Souriau, robot side. Article no: P1305
Transfers 17 electrical signals to the tool attachment through spring loaded signal pins. Can be
mounted at 3 different positions on the tool changer.
To be used together with option P1306 on the tool attachment.
Technical data
Weight
0.2 kg
Electrical signals
Circuit diagram
Total number of signals
Max current
Max voltage
Connection, robot side
E0182-001 (see section 2.2.3)
12
1A
60V
Souriau UT001412PH

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2.2.2 Signal interface Souriau, tool side. Article no: P1306
Transfers 12 signals to the tool. To be mounted on the tool attachment and used together with
option P1305 on the tool changer.
Technical data
Weight
0.1 kg
Electrical signals
Number of signals
Connection, tool side
12
1.0 m cable (7x2x0.5mm²) with free end

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2.2.3 Circuit diagram E0182-001 for P1305/P1306