robotic/automatic tool changer - ati-ia.com

NEW 2004 CATALOG

Robotic/Automatic Tool ChangerFor Heavy Automation

2 ATI INDUSTRIAL AUTOMATION

Robotic Tool Changers for Heavy Dutyand Spot Welding Applications

The Heavy Automation Robotic Tool Changerline has been developed for the resistance weldingmarket and medium- to heavy-duty material handling.Because these tool changers use modules to pass utili-ties (e.g. water, electrical, pneumatic, etc.), they areable to handle numerous applications by simply select-ing the desired modules. In addition, these modelshave extremely high moment capacity, allowing the toolchangers to be used in heavy-duty applications.

Product Advantages

Commonality: Uses the same locking mechanism(QC-200) and modules used in other material handlingand gun changer products, improving commonality.

Modular: Power, coolant, servo, DeviceNet, and signalfeatures are built into separate modules making mainte-nance easy—increasing commonality.

Extremely High Moment Capacity: Many tool changerswith high moment loads gap (separate between themaster and tool plates) during high-speed moves, causingdisruption to utilities such as servo lines. The heavyautomation series from ATI can take on heavy momentloads and maintain utility functions during dynamic moves.

No exposed hoses or cables for DeviceNet: TheDeviceNet module with lock/unlock valve is internallyplumbed and interfaces with internal cable routing in thetool changer body—making it easy to add and removethe DeviceNet module.

Increased Strength: The QC-200 locking mechanismexceeds 200kg robot load specifications.

Easy Dress: The modules are designed to place electrical,pneumatic and water ports in-line. The secondary powermodule can go on one of two flats 180-degrees apartallowing for left and right dress packages.

Battery Backup for Servo: The servo module has abattery backup option on the tool side to allow the servoto hold information while disconnected from the robot.

Strong Power and Servo Module Housing: The PN2power module and SB5 servo module use an aluminumhousing to prevent damage from cable stress andcrashes.

Weight and Size Reduction: Weight and size are keptas small as possible without reducing reliability or per-formance.

No-Touch Contacts Increase Safety: 200-amp powerand signal modules have contacts that are not touchableon the Master side—increasing safety and world wideacceptance.

High-flow fluid module: The Fluid/Air module has a Cv of1.65 (1.65 gallons of water per minute for 1 psi pressuredrop) allowing for better weld gun and transformer cooling.

Kickless Cable Secondary Current Module: TheSecondary Current Module is designed to accept kicklessor shunt cables, giving maximum flexibility in secondarywelding applications.

TOOL CHANGERS FOR HEAVY AUTOMATION

ATI INDUSTRIAL AUTOMATION 3

Plug

Pass-Through Port(*Note FlowLimitations)

Tool Plate (Body)

Bearing Race

Self-Sealing Port/Lock/Unlock Supply

(2) TaperedAlignment Pins

Master Plate (Body)

Locking Mechanism

(12) Ball Bearings

Specifications Values Comments

Suggested Payload Limit 450 lbs The mass attached to the tool changer. Higher payloads204kg possible with moment rating.

Locking Force @ 80 psi 7000 lbs Axial holding force.3175 kg

Static Moment Capacity (X & Y) 24,000 in-lb Higher dynamic moment possible depending on moduleselection. Failure test exceeded 150,000 in-lb moment.

Static Moment Capacity (Z) 20,000 in-lb (Torsion) Higher dynamic moment possible depending on moduleselection. Failure test exceeded 100,000 in-lb moment.

Positional Repeatability (X,Y, & Z) 0.0006 in Repeatability tested at rated load at one million cycles.0.015 mm

Weight (when coupled) 16.83 lbs(with no accessory modules) 7.63 kg

Unit size when locked 3.43 in87.1 mm

Maximum allowable distance between 0.1 in Normal recommended locking distance. Locking distance variesmaster and tool plates before locking 2.5 mm depending on module selection, lock pressure, payload, etc.

Sensor Information, signal name L/U Proximity sensors (2) with quick disconnect connectors (Lock/Unlock) wired into the DeviceNet Master Module or signal module

to indicate locking mechanism position.

Pneumatic pass-through 1-3/8 “G” or The single port on the QC-200 carries the lock air pressure and(built into the body) 3/8 NPT should only be used with tools that do not consume large

volumes of air or that require pressures higher than 60psi.


The QC-200 is an extremely diverse tool changer withthe ability to perform in a wide variety of applications.This flexibility is due in large part to the many differentmodels of modules designed to pass a variety of utilities,such as:

• Fluid/air modules • 200-amp primary current module for transgun

applications • DeviceNet modules supporting Master and Tool

side nodes and “Quick” connect times• Discrete signal module with tool-ID built-in• Servo module with optional battery backup

• 600-amp module for high power and ground applications

• Secondary Current module available with directinterface to Kickless Cables

• more…

(2) 10 H7, 16 Dp.Equally SpacedCustomer Interface

10 H7, 16 Dp.Customer Interface


76.7DE45-T

B.C. 125

30º

(6) Tapped M10x1.5, 16 Dp.Equally SpacedCustomer Interface

3/8 NPT Port(See Note 1)

Flat A

Flat BFlat C

Flat D

CL

CL

40.1ToolPlate

48.3PV3-T

30.4Pin

87.5Master & SIP(See Note 3)

47.1MasterPlate

127.6Coupled

(See Note 3)

[5.02"]

(A)

(B)

(C)

133.4DE45

Modules

158PV3

Modules

53.3PV3Modules

101.5DE45-M

24.5ExhaustMuffler

154.9

160Square

Master &Tool

3/8 NPT Port(See Note 1)

Flat A

Flat B Flat C

Flat DCL

CL

SIP Plate(See Note 3)

Part Numbers:(A) Master: 9120-201DM-PV3-0000-0000(B) Tool: 9120-201DT-PV3-0000-0000(C) SIP: 9120-200M-SIP-G-1152

Notes:1. This port is plumbed in line with the Lock/Unlock air supply. This Port should not be used for high flow applications where the pressure could drop below 60 psi. This port is self-sealed on the Master and Pass- thru on the Tool. The Tool-side connection is factory-supplied with a 3/8 NPT plug.2. PV3 master module has (2) 3/8 NPT checked ports, (2) 3/8 NPT pass thru ports and (2) 3/4 NPT vacuum ports. PV3 tool has (4) 3/8 NPT pass thru and (2) 3/4 NPT vacuum ports. 3. Blank SIP shown. Other SIP's available to fit specific robots. Dimension will vary depending on SIP required. 4. Optional modules shown listed below. Consult catalog for other options. DE45 - DeviceNet Module PV3 - Pneumatic/Vacuum Module

Tool Side(projection only)

Master Side(projection only)

www.ati-ia.comATI INDUSTRIAL AUTOMATION QC-202* 9230-20-1972-01

MODULES

*QC-202 with DE45, PV3 and Blank SIP


DE45 AND DC45 DEVICENET MODULES

Electrical Feed-through

Two (2) standard “mini” style power and signal connec-tors are provided for ODVA v2.0 certified DeviceNetinterfacing on the Master and Tool modules. When thetool changer is coupled, the Master and Tool DeviceNetmodules communicate with each other using a spring-loaded pin block. A flexible boot surrounds the pin blockto seal the connection from moisture and liquid whilecoupled.

Pneumatic Valve

A double solenoid-actuated pneumatic valve is attachedto the DE45 DeviceNet Master module for control of thelocking mechanism. A single solenoid with spring returnis used on the DC45 module.

Tool Stand Interlock

The DeviceNet Master module is outfitted with a ToolStand interlock connector that is wired directly into theunlock solenoid valve circuit. Using this connector, aswitch can be integrated that will allow the solenoid valveto uncouple the tool changer only when the Tool is in theTool Stand. Otherwise, a jumper plug is factory-suppliedwith the connector to close the solenoid valve circuit.

Tool ID

The DeviceNet Tool module uses a series of five 0–9rotary switches for setting Tool ID. This allows the customer to distinguish between the different Toolsthat are being operated and controlled through theDeviceNet network.

Auxiliary PowerConnector

Tool ID/DIP Switch, located on board in module

DeviceNet Bus|Connector

DC45 Tool Module

Spring Loaded Pin Block and Rubber Seal

DC45 Master Module

Tool Stand Interlock Connector (Jumper Provided)

Tool ID/DIP Switch, locatedon board in module

Single Solenoid, Spring Return Valve (Not Visible)


New Innovation Greatly Reduces Timeand Complexity for Tool Changes inDeviceNet Environments.

DeviceNet™ is a popular industrial communications busused to connect industrial devices and reduce or elimi-nate time-consuming discrete wiring.

The Problem

With the obvious benefits of DeviceNet technologycomes the inevitable delay that occurs during tool identification—as long as 8 seconds at each tool change.The cumulative effect of these delays is a loss of produc-tion time. This compounded effect becomes a factor inreducing manufacturing productivity.

In an effort to minimize this delay, a new DeviceNetstandard (Quick Connect) is being proposed which couldpotentially reduce this delay to 2 to 3 seconds. This isstill a noticeable delay during an application process.

ATI InstaTool™ solves the problem.

The Solution: ATI InstaTool™ Technology

With ATI InstaTool™, long delays for tool identification andtooling I/O are a thing of the past. By using ATI InstaTool™

technology, the new tool-side module communicatestool ID and tooling I/O to the master/robot module injust tenths of a second after tool changer coupling. Thereis no longer a need to establish a DeviceNet node on thetool side, which in turn prevents power-ups from havingto negotiate lengthy DeviceNet protocol sequences.Tooling is available on the network in under a second.

Best of all, there are no costly upgrades of DeviceNetscanner and master controller equipment required toenjoy the substantial benefits of ATI InstaTool™.

ATI INSTATOOL™

Product Advantages

Near-Instant Connection and Tool Identification:

With InstaTool, tool ID occurs within 150 milliseconds, ascompared to up to 8 seconds using current technology.Tool I/O is available within 700 milliseconds.

Reduction in Time: No delay means overall cycle timeis reduced and production is increased. This advantageis heightened in applications with multiple tool changes.

Reduced DeviceNet Node Management: With ATIInstaTool™ and InstaBus™ technology, the tool changermaster node handles 160 I/O points downstream,resulting in fewer DeviceNet nodes to manage.

Tool ID Passes Through Master: Systems with multiplemasters and tools can positively identify which tools areconnected to each master.

Tool Stand Interlock (TSI): A tool stand interlock featureis provided on the tool/slave side for safer tool changeroperation. The TSI allows uncoupling only when the toolchanger is in the tool stand. Customers have the optionto choose mechanical or proximity sensor switches toclose the TSI circuitry.

Additional Safety Features: Additional DeviceNet inputsare provided to identify unsafe operating conditions.Customer operating software can be programmed tohalt tool changer operation when unsafe conditions exist.

Maximum Time from Tool Connect to Tool ID Read

0 1 2 3 4 5 6 7 8 9

Current DeviceNet

Proposed DeviceNet Estimated

ATI InstaTool™

Time (Seconds)


ATI InstaBus

SubNode SubNode SubNode

DeviceNet Controller

Node Node Node

Nod

e Tool Changer Master Side

InstaTool

Tool Changer Tool Side

Tool ID

DeviceNet Controller

Node Node Node

Nod

e Tool Changer Master Side

Tool Changer Tool Side

Node Node

Tool ID

Nod

e

Up to160 I/O

Standard Network

Before ATI InstaTool™, the DeviceNet signal passedfrom the DeviceNet controller, through the masterside to the tool side of the tool changer, then on todownstream nodes. With this method, each time anew tool side connection is made, up to an 8-secondstart-up delay occurs before tool identification anddownstream I/O can be read and the application cancontinue.

ATI Solution

With InstaTool™, the DeviceNet signal effectively stopsat the tool changer master, creating an always-onconnection to that master node. Using patent-pendinghigh-speed technology, the master node handles allI/O communication downstream from the master. Theresult is a connect time of less than 150 millisecondsfor tool ID and under 700 milliseconds for tool I/O.Tool I/O appears at the master node.

DeviceNet—With and Without ATI InstaTool™

The illustrations below indicate the fundamental differencesbetween standard DeviceNet connectivity and the new ATIInstaTool™ technology.


FLUID, AIR AND VACUUM MODULES

There are several types of modules that pass fluid, air and vacuum.

NOTE: Self-sealing ports are not to be used for vacuum service.

Module Description

FA44 (8) 3/8 NPT self-sealing ports (Master side)(4) 3/8 NPT self-sealing ports and (4) pass-through (Tool side)

FSN4 FA44 with stainless steel body

FE44 (8) 3/8 ‘G’ self-sealing ports (Master side)(4) 3/8 ‘G’ self-sealing ports and (4) pass-through (Tool side)

FSG4 FE44 with stainless steel body

F34 (2) 3/4NPT self-sealing ports (Master and Tool side) w/stainless steel body

PV1 (2) 3/8 ‘G’ self-sealing ports (Master side only)(2) 3/8 ‘G’ pass-through ports(2) 3/4 ‘G’ vacuum only ports

PV2 (2) 3/8 ‘G’ self sealing ports and (6) 3/8 ‘G’ pass-through (Master side)(8) 3/8 ‘G’ pass-through ports (Tool side)

PV3 (2) 3/8 NPT self-sealing ports (Master side only)(2) 3/8 NPT pass-through ports(2) 3/4 NPT vacuum only ports

PV4 (8) 3/8 NPT pass-through ports

PV5 (8) 3/8 ‘G’ pass-through ports

PV6 (12) ‘G’ 1/4 open ports


Raised Surface

(4) 3/8 NPT Valved Air Ports

Master Self Sealing Valve

Master Fluid/Air Module

Tool Fluid/Air Module

(4) 3/8 NPT ValvedFluid Ports

Tool Self Sealing Valve

(4) 3/8 NPT Un-ValvedAir Ports

(4) 3/8 NPT ValvedFluid Ports

(2) 3/8 NPT Self Sealing Ports

(2) 3/8 NPT Pass-Through Ports

(2) 3/4 NPT Vacuum Ports

PV3 Tool Module PV3 Master Module

FLUID/AIR MODULE (FA44)

VACUUM/AIR MODULE (PV3)


PN2 PRIMARY POWER MODULE

The Primary Current Module used by the spot-weldingversion is designed to carry primary current from a powersupply to a welding transgun attached to the Tool. It consists of three Rhodium-plated copper contacts, eachcapable of carrying 200 Amps when coupled. The voltageshould not exceed 600 Volts. To avoid arcing never

uncouple the Tool Changer without first turning off

the power supply to the Master. Power must be offwhen coupling and uncoupling. In addition, the installationof over-current protection is recommended in the primarypower supply circuit.

Primary Current Module – Master (PN2-M)

Primary Current Module – Tool (PN2-T)

No-Touch Contacts

Cable Entrance

Set Screw

Set Screw

Cable Entrance

Ground Contact


Cable Installation

For cable installation, the power module cover platesare removed from the module bodies by unscrewingthe (6) M4 flat-head screws. This exposes the insulatorblock and the contact bases. The power cable is thenpassed through the cable entrance and its conductorsare attached to the individual contact bases by tighteningthe split-bolt nuts. Each contact can accept up to #2 AWGstranded conductor. The cable is then attached to themodule enclosure through a cord grip.

Optional flanges on this enclosure allow the attachmentof PG29, 1-1/4 NPT or 1-1/2 NPT strain relief connectors.This flange has set-screws that must be tightened to prevent the cord grip from loosening with robot motion.After attaching the cables, the covers are re-installed onthe module bodies.

Transferring Current

The Primary Current modules use advanced patentedcone-mating technology to transfer current from theMaster to the Tool. The mating conical surfaces providea large contact area, excellent misalignment capability

and allow efficient coupling/uncoupling, without highspring forces or excessive wear. To enhance safety,

the central contact on the tool side module projects

0.078" (2mm) above the other 2 contacts. By usingthis contact as the ground circuit, the user can ensurethat the Tool is grounded before power is applied (groundis the first to make and last to break contact). If required,the contact tips on either the Master or Tool can be easilyreplaced without removing the wiring.

Additional FeaturesAdditional safety features have been designed into the PN2 modules shown here. The contact tips on theMaster side are recessed well below the surface andcontain a central insulated post. The modules weredesigned so that the finger of an average human adultcannot touch the metallic parts. The interior of the mod-ule housings are insulated electrically with a thick, hardanodized coating and high dielectric paper.

PN2 Primary Current Module Values Comments

(# Contacts) Current & Voltage (3) @ 200A, No-Touch, Rhodium-plted conical contacts on Master Specification 1000A @ 20% duty cycle, side. Central, ground contact on Tool side is first to

make and last to break.

Cable Sizes Supported #4 Thru #2 AWG Split-bolt terminals are used to attach the conductorthe contact post.

Connection Options Optional Flanges PG29, 1-1/4" or 1-1/2" NPT flanges can be used to attach desired strain relief.

HA6 High Current Module Values Comments

(# Contacts) Current & Voltage (2) @ 600A, 800 V Max. No-Touch, Silver-plated, conical contacts on Specification Master side.

Cable Sizes Supported #4 Thru #2 AWG Split-bolt terminals are used to attach the conductorthe contact post.

Connection Options Optional Flanges Custom fitting plates available up to 1-1/2NPT.


SERVO MODULE

A servo module may be provided on the tool changer toprovide both power and signal connections to a servotransgun servomotor. The connectors on this module arelocated such that power and feedback cables can berouted separately. By design, both circuits are electricallyisolated from each other and from the tool changer.Also, the circuit has its own EMI/RF shield to protect itfrom noise.

Design Features

Both the power and feedback circuits are designed to bewater resistant. In both cases, the central pin is first tomate and last to break during a tool change. For safetyreasons, it is recommended that this pin be used asdesignated ground. To avoid unintentional human contact,the master side spring pins are recessed below an insu-lated surface on both the power and feedback circuits.

Important

To avoid damage to the contacts, never uncouple theunit without first disconnecting and discharging the

power that passes through these pins. This is especiallytrue if high-voltage circuits are involved. Compliant springprobes are provided on the Master side and fixed contactpins on the Tool side. Both the power and feedbackconnectors are electrically isolated from the servo module by mounting them in G-10/FR-4 plates.

Power Side ContactsSignal Side Contacts

Spacer Block

Master Servo Module

Amphenol, Military-StyleConnectors (Both Sides)

Battery Backup Housing

Tool Servo Module

SERVO MODULES (SB4/SB5)


SB4/SB5 Module Values Comments

(# Contacts) Motor Current (6) 25A, 600VAC Max. Spring-loaded, gold-plated and serrated pins on Master side.& Voltage Specification Central contact on Tool Side is first to make and last to break.

(# Contacts) Encoder Current 19) 3A, 24VDC Max. Spring-loaded, gold-plated and serrated pins on Master side.& Voltage Specification Central contact on Tool Side is first to make and last to break.

Shielding Optional Flanges Internal shielding provided per customer specification.

Connection Options Supplied with military style Amphenol/Bendix connectors or as specified by the customer.

Battery Backup Option 6VDC Tool-side circuit provided for maintaining memory while uncoupled.


OPTIONAL MODULES FOR QC-200*

*This list represents the most frequently requested modules. Others are available.

Module Option* Description Flat

Signal DV19-M 19-pin Signal module w/ Integrated Double Solenoid Valve. ADesignation is "V9M”

DV15-T Discrete signal module with 15-pin pass-through, Signal module w/ internal Tool ID, 0-9. Mates with DV19. Designation is "V5T"



DeviceNet/ DC45 DeviceNet module with single-solenoid spring return valve AInstaTool DE45 DeviceNet module with double-solenoid valve, TSI connection A

DQS InstaTool Master Module, Single Solenoid Valve ADQD InstaTool Master Module, Double Solenoid ValveDQM InstaTool Tool Module, Mechanical Switch TSIDQP InstaTool Tool Module, Proximity Sensor TSI

Pneumatic FA44-M Master air module with (8) 3/8 NPT self-sealing port passage kits B, DFA44-T Tool air module with (4) self-sealing and (4) pass-through 3/8 NPT

port passage kitsFA80-T Tool air module with (8) 3/8 NPT self-sealing port passage kits FA08-T Tool air module with (8) pass-through 3/8 NPT port passages kits PV1-6 Series of Air/Vacuum Modules B, D

Fluid Air FSG4-M Master stainless steel fluid/air module with (8) 3/8 G (BSPP) B, Dself-sealing port passage kits

FSG4-T Tool stainless steel fluid/air module with (4) self-sealing fluid and (4) pass-through air 3/8 R (BSPP) port passage kits

FSG0-T Tool stainless steel fluid/air module with (8) pass-through air 3/8 G (BSPP) port passage kits

FSN4-M Master stainless steel fluid/air module with (8) 3/8 NPT self-sealing port passage kits

FSN4-T Tool stainless steel fluid/air module with (4) self-sealing fluid and (4) pass-through air 3/8 NPT port passage kits

FSN8-T Tool stainless steel fluid/air module with (8) self-sealing fluid 3/8 NPT port passage kits

FSN0-T Tool stainless steel fluid/air module with (8) pass-through air 3/8 NPT port passage kits

F34 Stainless steel fluid/air block with (2) fl" NPT self-sealing ports B, D

Primary PN2 Primary-Power module with no-touch design for #4/#2 cable 200A/600V CPower HA6 High-Power Module, 600A/800V, Two Contacts C

HA6-1 High-Power Module, 600A/800V, One Contact

Servo SE Series of Servo Modules with specifications tied to a variety of B, Dapplications and equipment

SB Series of Servo Modules with specifications tied to a variety of B, Dapplications and equipment, w/ Battery backup on tool side


HOW TO ORDER

9120-20 - - - QC-200

Optional Modules for Flat ‘D’

FA44, FE44, F34: Fluid/Air ModulesPV1, PV2, PV3, PV4, PV5, PV6: Air/Vacuum ModulesSE01-SE12, SB01-SB12: Servo Module0000: No module in place

Optional Modules for Flat ‘C’

PN2: Primary Current Module0000: No module in placeHA6: High power module

Optional Modules for Flat ‘B’

FA44, FE44, F34: Fluid/Air ModulesPV1, PV2, PV3, PV4, PV5, PV6: Air/Vacuum ModulesSE/SB: Servo Module0000: No module in place

M: Master T: Tool

Signal Module for Flat ‘A’*

‘B’ – InterBus‘C’ – DeviceNet with single solenoid valve‘D’ – DeviceNet with double solenoid valve‘N’ – No modules‘BP’ – ProfiBusG Series – Discrete Signal Module (No integrated valve)

Tool Changer I/O Supported (Lock, Unlock, RTL, Tool ID)Ex. TW19

V Series – Discrete Signal Module w/ Double Solenoid Valve Tool Changer I/O Supported (Lock, Unlock, RTL, Valve Control, Tool ID), Tool Stand Interlock on Master Side

S Series – Discrete Signal Module w/ Single Solenoid Valve Tool Changer I/O Supported (Lock, Unlock, RTL, Valve Control, Tool ID), Tool Stand Interlock on Master Side

F Series – Discrete Signal Module w/ Double Solenoid Valve Tool Changer I/O Supported (Lock, Unlock, RTL, Valve Control, Tool ID), Tool Stand Interlock on Tool Side

‘QS’ – InstaTool master w/ single solenoid valve‘QD’ – InstaTool master w/ double soleniod valve‘QM’ – InstaTool tool w/ mechanical switch Tool Stand Interlock‘QP’ – InstaTool tool w/ proximity sensor Tool Stand Interlock

* Please visit www.ati-ia.com for an updated, comprehensive list of modules. As always, consult your ATI Account Manager with any questions regarding product selection for your application.

Model

1: “G” porting2: “NPT” porting


QC-303

Product Advantages

No-Touch Locking technology allows up to 10mm plate separation when locking.

Detection Sensor detects when the Tool plate iswithin 1.5 mm of the Master plate, signaling ready-to-lock.

Self-sealing pneumatic ports on the Master sideseal when the master and tool separate.

Robotic Tool Changer for Heavy

Material Handling

Specifications Values

Suggested Payload Limit 1,003 lbs455 kg

Locking Force @ 80 psi 7,940 lbs35,333 N

Static Moment Capacity (X & Y) 29,100 lb-in3,870 Nm

Static Moment Capacity (Z) 25,000 lb-in2,825 Nm

Positional Repeatability (X,Y, & Z) .0006 in.015 mm



Maximum allowable distance between 0.40 inmaster and tool plates before locking 10 mm

Pneumatic Pass-through Ports (qty) size (2) 1/4" NPT

*This list represents the most frequently requested modules. Many others are available.

Option* Description Flat

TW19 19-pin, 5A/250VAC, MS cylindrical threaded connector, cables attached A

DE45/DC45 DeviceNet Master module with double-solenoid valve A

FSN4 Stainless steel fluid/air, (4) self-sealing fluid, (4) pass-through air 3/8 NPT ports B, D

PV_ Series of Vacuum Modules with variety of Specifications B, D

FN2/FN4 (2) or (4) Self-Sealing Air/Fluid Ports, 3/8 NPT, SS C

J16 16-pin, 5A/250VAC, miniature MS quick-disconnect connector C

T19 19-pin, 5A/250VAC, MS cylindrical threaded connector C

V34 Vacuum Port. "G" C

MT8 20-amp 8-pin electrical module 500 VAC 700 VDC C

MT14 13-amp 14-pin electrical module 500 VAC 700 DC C

F34 Stainless steel fluid/air block with (2) fl" NPT self-sealing ports B, D

QC-303 with DeviceNet, FA


52.1Tool Plate

105.7Master & SIP(See Note 3)

55MasterPlate

45Male

Coupling

157.7Coupled

(See Note 3)

[6.21"]

58.2

(B)(C)

(A)

158FA44

Modules

64FA44

Modules

133.4DE45

Modules

101.5DE45-M

215Square

Master &Tool

24.5ExhaustMuffler

198.1


Flat C

Flat D

Flat A

Flat B

Part Numbers:(A) Master: 9120-303DM-FA44-000-0(B) Tool: 9120-303DT-FA44-000-0(C) SIP: 9120-300M-SIP-G-1175

SIP Plate(See Note 3)

(2) 1/4 NPT Port(See Note 1)CL

CL

B.C. 160


76.7DE45-T

(2) 10 H7, 20 Dp.Equally Spaced

Customer Interface

(6) Tapped M10x1.5, 20 Dp.Equally Spaced

Customer Interface

Flat C

Flat A

Flat D

Flat B


(2) 1/4 NPT Port(See Note 1) CL

CL

Notes:1. Ports are checked on master and tool.2. FA44 master module has (8) 3/8 NPT checked ports. FA44 tool has (4) 3/8 NPT checked ports and (4) 3/8 NPT pass thru ports.3. Blank SIP shown. Other SIPs available to fit specific robots. Dimension will vary depending on SIP required.4. Optional modules shown listed below. Consult catalog for other options. DE45 - DeviceNet Module FA44 - Pneumatic Module


HOW TO ORDER

9120-303 - - - QC-303


FA44, FSN4: Fluid/Air ModulesFE44, FSG4: Fluid/Air Modules (Support Plates Not Required)F34: Fluid/Air ModulesPV1, PV2, PV3, PV4, PV5, PV6: Air/Vacuum Modules‘0’: No module in place


(2) J16 Patterns to support Various Modules(ex. R21, T19, S19, J16)

‘000’ - No module in place


Same as Flat ‘D’

M: Master T: Tool

Signal Module for Flat ‘A’* – see chart pg. 15


*QC-303 with DE45, FA44 and Blank SIP


Product Advantages

No-Touch Locking technology allows up to 0.1 in.plate separation when locking.

Patented Fail-safe locking mechanism

• Locking mechanism design results in low forceacting on the piston.

• Large piston diameter and outward ball travelincrease moment capacity.

• All locking parts are made of Rc58 stainless steel.

Integrated Lock/Unlock Sensing for safety.

Mounts Directly to most 500 Kg Robots

(no SIP required)

QC-500

Robotic Tool Changer for Heavy

Material Handling


Suggested Payload Limit 1,325 lbs600 kg

Locking Force @ 80 psi 14,000 lbs62,300 N






Maximum allowable distance between 0.1 inmaster and tool plates before locking 2.5 mm

Pneumatic Pass-through Ports (2) 1/4 BSPP “G” or 1/4 NPT




DE45/DC45 DeviceNet Master module with double-solenoid valve A

FSN4 Stainless steel fluid/air, (4) self-sealing fluid, (4) pass-through air 3/8 NPT ports B, D

PV_ Series of Vacuum Modules with variety of Specifications B, D

FN2/FN4 (2) or (4) Self-Sealing Air/Fluid Ports, 3/8 NPT, SS C

J16 16-pin, 5A/250VAC, miniature MS quick-disconnect connector C

T19 19-pin, 5A/250VAC, MS cylindrical threaded connector C

V34 Vacuum Port. fl "G" C

MT8 20-amp 8-pin electrical module 500 VAC 700 VDC C

MT14 13-amp 14-pin electrical module 500 VAC 700 DC C

PN2 13-amp 14-pin electrical module 500 VAC 700 DC C

QC-500 with DeviceNet, FSN4


HOW TO ORDER


9120-50 - - - QC-500


FA44, FSN4: Fluid/Air ModulesFE44, FSG4: Fluid/Air Modules (Support Plates Not Required)F34: Fluid/Air ModulesPV1, PV2, PV3, PV4, PV5, PV6: Air/Vacuum Modules0000: No module in place


3) J16 Patterns to support Various Modules(ex. R21, T19, S19, J16) Use ‘0’ to designate a missing module

000: No module in place


Same as Flat ‘D’

M: Master T: Tool

Signal Module for Flat ‘A’* – see chart pg. 15


1: “G” Porting 2: “NPT” Porting

-SY

*QC-502 with DE45 and FSN4


Product Advantages

No-Touch Locking technology allows up to 0.1 in.plate separation when locking.

Patented Fail-safe locking mechanisms

• Locking mechanism design results in low forceacting on the piston.

• Large piston diameter and outward ball travelincrease moment capacity.

• All locking parts are made of Rc58 stainless steel.

Integrated Lock/Unlock Sensing for safety,

Highest Moment Capacity: 3 locking mechanism designcreates static moment capacity of 122,000 lb-in. (X & Y)

QC-602

Robotic Tool Changer for ExtremeMaterial Handling

The QC-602 Robotic Tool Changer from ATI is by far thestrongest tool changer on the market today. The QC-602was designed to meet the extreme payload and momentdemands of heavy industrial and aerospace applications.With a payload capacity of 2,500 pounds, the QC-602 isin a class of it’s own, setting a new standard in heavycapacity tool changers.


Suggested Payload Limit 2,500 lbs1,130 kg

Locking Force @ 80 psi 21,000 lbs9,525 kg






Maximum allowable distance between 0.1 inmaster and tool plates before locking 2.54 mm

Sensor Information, Signal Name L/U (Lock/Unlock) Proximity SensorsRTL (Ready-to-Lock) Proximity Sensors

Mounting Surface/Customer Interface Custom patterns for Master plate and Tool plate based on three (3) QC-200 locking mechanisms

Lock/Unlock Air Supply 3/8 NPT

Pneumatic pass-through ports 3/8 NPT – Two (2) air ports which are unchecked



MT8 20-amp 8-pin electrical module 500 VAC 700 VDC C1, C2

J16 16-pin, 5A/250VAC, miniature MS quick-disconnect connector C1, C2, E

V114 Vacuum Port. 1 1/4 "G". E


QC-602 with TW19,MT8, V114


HOW TO ORDER

B.C. 132.503 PlacesCustomerInterface

225.17CustomerInterface


322.71(Typ)

231.140±0.013CustomerInterface


(2) 10 H7, 10 Dp.Customer Interface


260.4(Typ)

80.6MT8-T

90.2

67MT8-T

50.8TW19-T

121.5TW19-T 76.2

V114Modules

101.6V114

Modules

20º(Typ)

33.125±0.013CustomerInterface57.374±0.013

CustomerInterface

Flat E

Flat C1Flat C2

Flat A

Flat BFlat D


CL

Notes:1. Two (2) additional eye bolt holes are provided on the facing surfaces of both the master body and the tool body.2. Length of SHCS mounting screws = (Desired length of thread engagement in customer robot) + 75.2mm.3. V114 modules have (1) 1-1/4 NPT vacuum pass thru port.

(6) Tapped M10, 32 Dp.Equally Spaced3 PlacesCustomer Interface

Amphenol ConnectorMS3102E22-14S

135.1Pin

85.9MasterPlate

54.1ToolPlate

139.91Coupled

[5.51"]

Amphenol ConnectorMS3102E22-23P

Amphenol ConnectorMS 3106E22-23S

Part Numbers:(A) Master: 9120-602G3M-0-0-MT8-0-V114(B) Tool: 9120-602G3T-0-0-MT8-0-V114


9120-602 QC-602

Type of Lock Sensing

C – AC E – NPN G – PNP 0 – No module in place

Optional Modules for Flat ‘E’

(1) J16 Pattern V114 Vacuum Module 0 – No module in place

Flat ‘D’

Blank – for future development

Optional Modules for Flat ‘C1’ and ‘C2’

(1) J16 Pattern to support Various Modules(ex. R21, T19, S19, J16, MT8) 0 – No modules in place

Flat ‘B’

Blank – for future development

M: Master T: Tool

Signal Module for Flat ‘A’*

TF19, TW19, TF26


-0- - -0- -

*QC-602 with TW19, MT8 and V114


MODULAR TOOL STANDS

The ATI TSL (Tool Stand, Large)Modular Tool Stand System, orTSL, is compatible with larger sizeATI Tool Changers. The Stand isdesigned for durability, longevity,and maximum flexibility to fit mostcustomers’ applications. The con-figurable system allows you tospecify tool height, offset, shielding,and sensing. To save space, the

TSL can even store 2 tools on the same post. ATI TSLStands are currently in use in major automotive plantsacross the nation.

Product Advantages

Stainless Steel Alignment Pins Offer High Repeatability.

Compliant Tool Interface option available.

Large Base Plate distributes tool weight evenly.

6 inch Steel Post Weldment Provides OutstandingSupport.

Optional Tool Presence Sensing and Shield PositionSensing.

The ATI Tool Stand System consists of the following main assemblies.These can be assembled to form a complete solution, or can be usedseparately as your application requires.

Part Number Prefix Name

9120-TSL-PM Post Module (with Compliant Tool Interface)

9120-TSL-HE Horizontal Extension Module

9120-TSL-SM Sensor Module

9120-TSL-DSA Debris Shield Actuator

9120-TSL-DS Debris Shield

9120-TSL-TP Tooling Interface Bracket

9120-TSL-SS Tool Stand Interlock



260.01Customer Interface

B.C. 125


(2) 10 H7, 10 Dp.Customer Interface

82.3MT8-M

71.7MT8-M

133.9TW19-M

63.5TW19-M


90.2

R97.5(Typ)31.248±0.013

CustomerInterface


A A

(6) Thru Holes For M10 SHCSC'Bored From Far SideEqually Spaced3 PlacesCustomer Interface(See Note 2)

Flat AFlat E

Flat C1Flat C2

Flat BFlat D


CL

Amphenol ConnectorMS3102E28-12P

Eye Bolt LocationMaster & Tool(See Note 1)

3/8 NPT PortLock Air SupplyCustomer Interface3/8 NPT Port

Unlock Air SupplyCustomer Interface

3/8 NPT PortsPass-Thru AirCustomer Interface

CL

View A-ARemoved


*QC-602 with TW19, MT8 and V114

Tool-to-Post Interface Plate options to fit every application.

Tool Stand Interlock Option provides additional safe-guard for Tool Drop-Off.

Optional Leather Guards for Shield.

QC-602 – CONTINUED


Post ModuleThe ATI TSL Post Module includes a welded steelvertical post, a base plate, and a vertically-com-pliant interface for your tooling. Height, tool orientation, and compliance stiffness can all bespecified by the customer. ATI also offers a con-figuration of the TSL Post Module that allows forup to two tools to be mounted on the same post.

Horizontal Extension ModuleThe TSL Horizontal Extension Module is an optionthat provides more tool clearance than the standardTSL Post Module. ATI offers a standard extensionlength of 10". Other lengths are available uponcustomer request.

Sensor ModuleThe TSL Sensor Module is an option that providesTool Presence detection. The standard model mountsdirectly to the TSL Post Module and incorporatesa proximity switch that senses a face on the TSLTooling Interface Bracket. The Sensor Modulecomes equipped with a collision guard.

Debris Shield ActuatorThe TSL Debris Shield Actuator (DSA) positions theDebris Shield in the open or closed position. Onsingle tool stands, the DSA module can be orientedso that the shield swings in the vertical or horizontalplane. The shield will swing 135 degrees rotation-ally for most arrangements. The powerclamp comesequipped with integrated position sensing.

Debris ShieldThe TSL Debris Shield mounts to a tubular arm thatin turn is mounted to the Shield Actuator Unit. TheDebris Shield is designed to cover the Tool ChangerTool Side unit when the Tool is in storage. TheDebris Shield provides ample protection from dust,weld spatter and other debris through the use ofleather side guards.

Tooling Interface BracketThe TSL Tooling Interface Bracket mounts directlyto your tooling, and is equipped with heavy-dutyalignment pin and bushings that directly couplewith the Post Module Compliant Interface.

9120-TSL-PM-236A-C500Dual Post Module with

Compliant Tooling InterfaceCustomer can

Specify Overall Height

9120-TSL-TP-4115Tooling Interface Bracket

BlankSee 9230-20-1991

9120-TSL-SMA-3371Tool PresenceSensor Module

3700-20-3527Sheild Arm

9120-TSL-DSA-135-3525Debris Shield Actuator135 SwingWith Intergrated Shield Position Sensing

EXPLODED VIEW

9120-TSL-DS-17-B3528Debris Shield, 17" Wide

With Leather Side Guards

ISOMETRIC VIEW

107

37

125

51102

19Plate Thickness

184

(Overall HeightTBD By Customer)

TOP VIEW

SIDE VIEW

13MaximumVertical

Compliance 206

FRONT VIEW

337

362

19

762

508

19

(8) 20Thru

235210

135 ShieldSwing

(8) M12 TAPThru

www.ati-ia.comATI INDUSTRIAL AUTOMATION 9230-20-1824TSL

Other ATI Products

Robotic Crash Protection Device – Protector

Designed to prevent damage to robotic end-effectors resulting from robot crashes. Featuresinclude: Automatic reset, high-repeatability, andlarge moment rotation.

Robotic and CNC Deburring Tools –

Flexdeburr and Speedeburr

These air-driven robotic tools cover a wide varietyof automated deburring applications with fast cycletimes and clean, accurate cuts. Flexdeburr isdesigned for removal of parting lines and flash,while Speedeburr is specially designed for edgedeburring and chamfering.

Robotic Rotary Joint

A device that allows unlimited rotation of end-of-armtooling without tangling or twisting robot lines. Utilizesadvanced slip-ring technology to pass electrical andpneumatic signals from robot to tooling.

Multi-Axis Force/Torque Sensor – F/T

Measures the full six components of force andtorque. High overload protection and high signal-to-noise ratio. Used in robotic and research applications.

Automated Assembly Alignment Device –

Compensator

An insertion device using Remote CenterCompliance technology, that helps assemblymachines automatically align close-fitting parts, preventing jamming and galling.

Company Profile

ATI Industrial Automation is a world-leading developer of Automatic Tool Changers, Multi-AxisForce/Torque Sensing Systems, Compliance Devices,Robotic Crash Protection Devices, Robotic DeburringTools, and Robotic Rotary Joints. Our products arefound in thousands of successful applicationsaround the world.

Since 1982, our engineers have been developingcost-effective, state-of-the-art products and solutionsto improve manufacturing productivity.

Our Mission is to provide customers around theworld with high-quality robotic peripheral devices,tooling and sensors that enhance customer prof-itability by increasing the effectiveness, flexibility,safety and productivity of their automation applications.We accomplish this through continuous improvementof existing products, product customization andnew product innovation.

Our engineering-centric staff focuses on providingcustomer solutions to robotic, automation andsensing appplications.

Our Quality Policy

ATI Industrial Automation strives to provide customer satisfaction through continual improvementof on-time delivery, quality and reliability, and a constant focus on innovation and profitability.

© Copyright by ATI Industrial Automation, Inc. 2004. All rights reserved. 9205-60-1001-05 November, 2005

Pinnacle Park1031 Goodworth DriveApex, NC 27539 USA

+1 919.772.0115 +1 919.772.8259 faxE-mail: [email protected]

robotic/automatic tool changer - ati-ia.com

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