NEW 2004 CATALOG. Robotic/Automatic Tool Changer. For Heavy Automation

Transcription

1 NEW 2004 CATALOG Robotic/Automatic Tool Changer For Heavy Automation

2 TOOL CHANGERS FOR HEAVY AUTOMATION Robotic Tool Changers for Heavy Duty and Spot Welding Applications The Heavy Automation Robotic Tool Changer line has been developed for the resistance welding market and medium- to heavy-duty material handling. Because these tool changers use modules to pass utilities (e.g. water, electrical, pneumatic, etc.), they are able to handle numerous applications by simply selecting the desired modules. In addition, these models have extremely high moment capacity, allowing the tool changers to be used in heavy-duty applications. Product Advantages Commonality: Uses the same locking mechanism (QC-200) and modules used in other material handling and gun changer products, improving commonality. Modular: Power, coolant, servo, DeviceNet, and signal features are built into separate modules making maintenance easy increasing commonality. Extremely High Moment Capacity: Many tool changers with high moment loads gap (separate between the master and tool plates) during high-speed moves, causing disruption to utilities such as servo lines. The heavy automation series from ATI can take on heavy moment loads and maintain utility functions during dynamic moves. No exposed hoses or cables for DeviceNet: The DeviceNet module with lock/unlock valve is internally plumbed and interfaces with internal cable routing in the tool changer body making it easy to add and remove the DeviceNet module. Increased Strength: The QC-200 locking mechanism exceeds 200kg robot load specifications. Easy Dress: The modules are designed to place electrical, pneumatic and water ports in-line. The secondary power module can go on one of two flats 180-degrees apart allowing for left and right dress packages. Battery Backup for Servo: The servo module has a battery backup option on the tool side to allow the servo to hold information while disconnected from the robot. Strong Power and Servo Module Housing: The PN2 power module and SB5 servo module use an aluminum housing to prevent damage from cable stress and crashes. Weight and Size Reduction: Weight and size are kept as small as possible without reducing reliability or performance. No-Touch Contacts Increase Safety: 200-amp power and signal modules have contacts that are not touchable on the Master side increasing safety and world wide acceptance. High-flow fluid module: The Fluid/Air module has a Cv of 1.65 (1.65 gallons of water per minute for 1 psi pressure drop) allowing for better weld gun and transformer cooling. Kickless Cable Secondary Current Module: The Secondary Current Module is designed to accept kickless or shunt cables, giving maximum flexibility in secondary welding applications. 2 ATI INDUSTRIAL AUTOMATION

3 Specifications Values Comments Suggested Payload Limit 450 lbs The mass attached to the tool changer. Higher payloads 204kg possible with moment rating. Locking 80 psi 7000 lbs Axial holding force kg Static Moment Capacity (X & Y) 24,000 in-lb Higher dynamic moment possible depending on module selection. Failure test exceeded 150,000 in-lb moment. Static Moment Capacity (Z) 20,000 in-lb (Torsion) Higher dynamic moment possible depending on module selection. Failure test exceeded 100,000 in-lb moment. Positional Repeatability (X,Y, & Z) in Repeatability tested at rated load at one million cycles mm Weight (when coupled) (with no accessory modules) Unit size when locked lbs 7.63 kg 3.43 in 87.1 mm Maximum allowable distance between 0.1 in Normal recommended locking distance. Locking distance varies master 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. Tool Plate (Body) Plug Self-Sealing Port/ Lock/Unlock Supply Master Plate (Body) Pass-Through Port (*Note Flow Limitations) (2) Tapered Alignment Pins Bearing Race Locking Mechanism (12) Ball Bearings ATI INDUSTRIAL AUTOMATION 3

4 MODULES The QC-200 is an extremely diverse tool changer with the ability to perform in a wide variety of applications. This flexibility is due in large part to the many different models 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 direct interface to Kickless Cables more ATI INDUSTRIAL AUTOMATION QC-202* (6) Tapped M10x1.5, 16 Dp. Equally Spaced 80 H7, 6 Dp. Flat C C L B.C. 125 Flat B 40.1 Tool Plate 48.3 PV3-T [5.02"] Coupled (See Note 3) 30.4 Pin 87.5 Master & SIP (See Note 3) 47.1 Master Plate (C) Flat B Part Numbers: (A) Master: DM-PV (B) Tool: DT-PV (C) SIP: M-SIP-G-1152 C L Flat C SIP Plate (See Note 3) Flat D (2) 10 H7, 16 Dp. Equally Spaced C L (B) 158 PV3 Modules C L Flat D 160 Square Master & Tool Flat A 10 H7, 16 Dp. 30º Tool Side (projection only) 76.7 DE45-T 3/8 NPT Port (See Note 1) 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 Passthru 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 (A) 53.3 PV3 Modules 3/8 NPT Port (See Note 1) Flat A DE45 Modules Master Side (projection only) DE45-M 24.5 Exhaust Muffler *QC-202 with DE45, PV3 and Blank SIP 4 ATI INDUSTRIAL AUTOMATION

5 DE45 AND DC45 DEVICENET MODULES Electrical Feed-through Two (2) standard mini style power and signal connectors are provided for ODVA v2.0 certified DeviceNet interfacing on the Master and Tool modules. When the tool changer is coupled, the Master and Tool DeviceNet modules communicate with each other using a springloaded pin block. A flexible boot surrounds the pin block to seal the connection from moisture and liquid while coupled. Pneumatic Valve A double solenoid-actuated pneumatic valve is attached to the DE45 DeviceNet Master module for control of the locking mechanism. A single solenoid with spring return is used on the DC45 module. Tool Stand Interlock The DeviceNet Master module is outfitted with a Tool Stand interlock connector that is wired directly into the unlock solenoid valve circuit. Using this connector, a switch can be integrated that will allow the solenoid valve to uncouple the tool changer only when the Tool is in the Tool Stand. Otherwise, a jumper plug is factory-supplied with the connector to close the solenoid valve circuit. Tool ID The DeviceNet Tool module uses a series of five 0 9 rotary switches for setting Tool ID. This allows the customer to distinguish between the different Tools that are being operated and controlled through the DeviceNet network. Auxiliary Power Connector DeviceNet Bus Connector Tool ID/DIP Switch, located on board in module Tool ID/DIP Switch, located on board in module Single Solenoid, Spring Return Valve (Not Visible) Spring Loaded Pin Block and Rubber Seal Tool Stand Interlock Connector (Jumper Provided) DC45 Tool Module DC45 Master Module ATI INDUSTRIAL AUTOMATION 5

6 ATI INSTATOOL New Innovation Greatly Reduces Time and Complexity for Tool Changes in DeviceNet Environments. DeviceNet is a popular industrial communications bus used to connect industrial devices and reduce or eliminate time-consuming discrete wiring. The Problem With the obvious benefits of DeviceNet technology comes 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 production time. This compounded effect becomes a factor in reducing manufacturing productivity. In an effort to minimize this delay, a new DeviceNet standard (Quick Connect) is being proposed which could potentially reduce this delay to 2 to 3 seconds. This is still 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 and tooling I/O are a thing of the past. By using ATI InstaTool technology, the new tool-side module communicates tool ID and tooling I/O to the master/robot module in just tenths of a second after tool changer coupling. There is no longer a need to establish a DeviceNet node on the tool side, which in turn prevents power-ups from having to negotiate lengthy DeviceNet protocol sequences. Tooling is available on the network in under a second. Best of all, there are no costly upgrades of DeviceNet scanner and master controller equipment required to enjoy the substantial benefits of ATI InstaTool. Maximum Time from Tool Connect to Tool ID Read ATI InstaTool Proposed DeviceNet Estimated Product Advantages Near-Instant Connection and Tool Identification: With InstaTool, tool ID occurs within 150 milliseconds, as compared to up to 8 seconds using current technology. Tool I/O is available within 700 milliseconds. Reduction in Time: No delay means overall cycle time is reduced and production is increased. This advantage is heightened in applications with multiple tool changes. Reduced DeviceNet Node Management: With ATI InstaTool and InstaBus technology, the tool changer master node handles 160 I/O points downstream, resulting in fewer DeviceNet nodes to manage. Tool ID Passes Through Master: Systems with multiple masters and tools can positively identify which tools are connected to each master. Tool Stand Interlock (TSI): A tool stand interlock feature is provided on the tool/slave side for safer tool changer operation. The TSI allows uncoupling only when the tool changer is in the tool stand. s have the option to choose mechanical or proximity sensor switches to close the TSI circuitry. Additional Safety Features: Additional DeviceNet inputs are provided to identify unsafe operating conditions. operating software can be programmed to halt tool changer operation when unsafe conditions exist. Current DeviceNet Time (Seconds) 6 ATI INDUSTRIAL AUTOMATION

7 Node Node Node DeviceNet With and Without ATI InstaTool The illustrations below indicate the fundamental differences between standard DeviceNet connectivity and the new ATI InstaTool technology. DeviceNet Controller Node Node Node Tool Changer Master Side Tool Changer Tool Side Tool ID Standard Network Before ATI InstaTool, the DeviceNet signal passed from the DeviceNet controller, through the master side to the tool side of the tool changer, then on to downstream nodes. With this method, each time a new tool side connection is made, up to an 8-second start-up delay occurs before tool identification and downstream I/O can be read and the application can continue. Node Node DeviceNet Controller Node Node Node Tool Changer Master Side Tool Changer Tool Side InstaTool Tool ID ATI Solution With InstaTool, the DeviceNet signal effectively stops at the tool changer master, creating an always-on connection to that master node. Using patent-pending high-speed technology, the master node handles all I/O communication downstream from the master. The result is a connect time of less than 150 milliseconds for tool ID and under 700 milliseconds for tool I/O. Tool I/O appears at the master node. ATI InstaBus SubNode SubNode SubNode Up to 160 I/O ATI INDUSTRIAL AUTOMATION 7

8 FLUID, AIR AND VACUUM MODULES There are several types of modules that pass fluid, air and vacuum. Module FA44 FSN4 FE44 FSG4 F34 PV1 PV2 PV3 PV4 PV5 PV6 Description (8) 3/8 NPT self-sealing ports (Master side) (4) 3/8 NPT self-sealing ports and (4) pass-through (Tool side) FA44 with stainless steel body (8) 3/8 G self-sealing ports (Master side) (4) 3/8 G self-sealing ports and (4) pass-through (Tool side) FE44 with stainless steel body (2) 3/4NPT self-sealing ports (Master and Tool side) w/stainless steel body (2) 3/8 G self-sealing ports (Master side only) (2) 3/8 G pass-through ports (2) 3/4 G vacuum only ports (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) (2) 3/8 NPT self-sealing ports (Master side only) (2) 3/8 NPT pass-through ports (2) 3/4 NPT vacuum only ports (8) 3/8 NPT pass-through ports (8) 3/8 G pass-through ports (12) G 1/4 open ports NOTE: Self-sealing ports are not to be used for vacuum service. 8 ATI INDUSTRIAL AUTOMATION

9 FLUID/AIR MODULE (FA44) Master Fluid/Air Module (4) 3/8 NPT Valved Air Ports (4) 3/8 NPT Valved Fluid Ports Master Self Sealing Valve Tool Self Sealing Valve Raised Surface (4) 3/8 NPT Un-Valved Air Ports (4) 3/8 NPT Valved Fluid Ports Tool Fluid/Air Module VACUUM/AIR MODULE (PV3) (2) 3/8 NPT Self Sealing Ports PV3 Tool Module PV3 Master Module (2) 3/8 NPT Pass-Through Ports (2) 3/4 NPT Vacuum Ports ATI INDUSTRIAL AUTOMATION 9

10 PN2 PRIMARY POWER MODULE The Primary Current Module used by the spot-welding version is designed to carry primary current from a power supply to a welding transgun attached to the Tool. It consists of three Rhodium-plated copper contacts, each capable of carrying 200 Amps when coupled. The voltage should 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 off when coupling and uncoupling. In addition, the installation of over-current protection is recommended in the primary power supply circuit. No-Touch Contacts Cable Entrance Set Screw Primary Current Module Master (PN2-M) Cable Entrance Ground Contact Set Screw Primary Current Module Tool (PN2-T) 10 ATI INDUSTRIAL AUTOMATION

11 Cable Installation For cable installation, the power module cover plates are removed from the module bodies by unscrewing the (6) M4 flat-head screws. This exposes the insulator block and the contact bases. The power cable is then passed through the cable entrance and its conductors are attached to the individual contact bases by tightening the split-bolt nuts. Each contact can accept up to #2 AWG stranded conductor. The cable is then attached to the module enclosure through a cord grip. Optional flanges on this enclosure allow the attachment of 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 on the module bodies. Transferring Current The Primary Current modules use advanced patented cone-mating technology to transfer current from the Master to the Tool. The mating conical surfaces provide a large contact area, excellent misalignment capability and allow efficient coupling/uncoupling, without high spring 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 using this contact as the ground circuit, the user can ensure that the Tool is grounded before power is applied (ground is the first to make and last to break contact). If required, the contact tips on either the Master or Tool can be easily replaced without removing the wiring. Additional Features Additional safety features have been designed into the PN2 modules shown here. The contact tips on the Master side are recessed well below the surface and contain a central insulated post. The modules were designed so that the finger of an average human adult cannot touch the metallic parts. The interior of the module housings are insulated electrically with a thick, hard anodized coating and high dielectric paper. PN2 Primary Current Module Values Comments (# Contacts) Current & Voltage 200A, No-Touch, Rhodium-plted conical contacts on Master Specification 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 conductor the 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 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 conductor the contact post. Connection Options Optional Flanges Custom fitting plates available up to 1-1/2NPT. ATI INDUSTRIAL AUTOMATION 11

12 SERVO MODULE A servo module may be provided on the tool changer to provide both power and signal connections to a servo transgun servomotor. The connectors on this module are located such that power and feedback cables can be routed separately. By design, both circuits are electrically isolated from each other and from the tool changer. Also, the circuit has its own EMI/RF shield to protect it from noise. Design Features Both the power and feedback circuits are designed to be water resistant. In both cases, the central pin is first to mate and last to break during a tool change. For safety reasons, it is recommended that this pin be used as designated ground. To avoid unintentional human contact, the master side spring pins are recessed below an insulated surface on both the power and feedback circuits. Important To avoid damage to the contacts, never uncouple the unit without first disconnecting and discharging the power that passes through these pins. This is especially true if high-voltage circuits are involved. Compliant spring probes are provided on the Master side and fixed contact pins on the Tool side. Both the power and feedback connectors are electrically isolated from the servo module by mounting them in G-10/FR-4 plates. SERVO MODULES (SB4/SB5) Master Servo Module Amphenol, Military-Style Connectors (Both Sides) Spacer Block Power Side Contacts Signal Side Contacts Tool Servo Module Battery Backup Housing 12 ATI INDUSTRIAL AUTOMATION

13 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. ATI INDUSTRIAL AUTOMATION 13

14 OPTIONAL MODULES FOR QC-200 * Module Option * Description Flat Signal DV19-M 19-pin Signal module w/ Integrated Double Solenoid Valve. A Designation 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" DV11-T Discrete signal module with 11-pin pass-through, Signal module w/ internal Tool ID, Mates with DV19. Designation is "V1T" DV7-T Discrete signal module with 7-pin pass-through, Signal module w/ internal Tool ID, Mates with DV19. Designation is "V7T" DeviceNet/ DC45 DeviceNet module with single-solenoid spring return valve A InstaTool DE45 DeviceNet module with double-solenoid valve, TSI connection A DQS InstaTool Master Module, Single Solenoid Valve A DQD InstaTool Master Module, Double Solenoid Valve DQM InstaTool Tool Module, Mechanical Switch TSI DQP InstaTool Tool Module, Proximity Sensor TSI Pneumatic FA44-M Master air module with (8) 3/8 NPT self-sealing port passage kits B, D FA44-T Tool air module with (4) self-sealing and (4) pass-through 3/8 NPT port passage kits FA80-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, D self-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 C Power 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, D applications and equipment SB Series of Servo Modules with specifications tied to a variety of B, D applications and equipment, w/ Battery backup on tool side *This list represents the most frequently requested modules. Others are available. 14 ATI INDUSTRIAL AUTOMATION

15 HOW TO ORDER QC-200 Optional Modules for Flat D FA44, FE44, F34: Fluid/Air Modules PV1, PV2, PV3, PV4, PV5, PV6: Air/Vacuum Modules SE01-SE12, SB01-SB12: Servo Module 0000: No module in place Optional Modules for Flat C PN2: Primary Current Module 0000: No module in place HA6: High power module Optional Modules for Flat B FA44, FE44, F34: Fluid/Air Modules PV1, PV2, PV3, PV4, PV5, PV6: Air/Vacuum Modules SE/SB: Servo Module 0000: 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 ProfiBus G 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 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 porting 2: NPT porting ATI INDUSTRIAL AUTOMATION 15

16 QC-303 Robotic Tool Changer for Heavy Material Handling QC-303 with DeviceNet, FA Product Advantages No-Touch Locking technology allows up to 10 mm plate separation when locking. Detection Sensor detects when the Tool plate is within 1.5 mm of the Master plate, signaling readyto-lock. Self-sealing pneumatic ports on the Master side seal when the master and tool separate. Specifications Suggested Payload Limit Locking 80 psi Static Moment Capacity (X & Y) Static Moment Capacity (Z) Positional Repeatability (X,Y, & Z) Weight (when coupled) (with no accessory modules) Unit size when locked Maximum allowable distance between master and tool plates before locking Pneumatic Pass-through Ports (qty) size Values 1,003 lbs 455 kg 7,940 lbs 35,333 N 29,100 lb-in 3,870 Nm 25,000 lb-in 2,825 Nm.0006 in.015 mm 39.7 lbs 18.0 kg 4.22 in mm 0.40 in 10 mm (2) 1/4" NPT 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 *This list represents the most frequently requested modules. Many others are available. 16 ATI INDUSTRIAL AUTOMATION

17 HOW TO ORDER QC-303 Optional Modules for Flat D FA44, FSN4: Fluid/Air Modules FE44, FSG4: Fluid/Air Modules (Support Plates Not Required) F34: Fluid/Air Modules PV1, PV2, PV3, PV4, PV5, PV6: Air/Vacuum Modules 0 : No module in place Optional Modules for Flat C (2) J16 Patterns to support Various Modules (ex. R21, T19, S19, J16) No module in place Optional Modules for Flat B Same as Flat D M: Master T: Tool Signal Module for Flat A * see chart pg. 15 * Please visit for an updated, comprehensive list of modules. As always, consult your ATI Account Manager with any questions regarding product selection for your application. ATI INDUSTRIAL AUTOMATION QC-303* (2) 10 H7, 20 Dp. Equally Spaced (2) 1/4 NPT Port (See Note 1) 100 H7, 4 Dp. (6) Tapped M10x1.5, 20 Dp. Equally Spaced C L C L Flat C B.C. 160 Flat B 52.1 Tool Plate (B) [6.21"] Coupled (See Note 3) 45 Male Coupling Master & SIP (See Note 3) 55 Master Plate (C) 158 FA44 Modules Flat B Part Numbers: (A) Master: DM-FA (B) Tool: DT-FA (C) SIP: M-SIP-G-1175 C L Flat C C L SIP Plate (See Note 3) (2) 1/4 NPT Port (See Note 1) 215 Square Master & Tool Flat D Flat D Flat A 76.7 DE45-T (A) 64 FA44 Modules Flat A DE45-M 58.2 Tool Side (projection only) DE45 Modules 24.5 Exhaust Muffler 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 Master Side (projection only) *QC-303 with DE45, FA44 and Blank SIP ATI INDUSTRIAL AUTOMATION 17

18 QC-500 Robotic Tool Changer for Heavy Material Handling QC-500 with DeviceNet, FSN4 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 force acting on the piston. Large piston diameter and outward ball travel increase moment capacity. All locking parts are made of R c 58 stainless steel. Integrated Lock/Unlock Sensing for safety. Mounts Directly to most 500 Kg Robots (no SIP required) Specifications Suggested Payload Limit Locking 80 psi Static Moment Capacity (X & Y) Static Moment Capacity (Z) Positional Repeatability (X,Y, & Z) Weight (when coupled) (with no accessory modules) Unit size when locked Maximum allowable distance between master and tool plates before locking Pneumatic Pass-through Ports Values 1,325 lbs 600 kg 14,000 lbs 62,300 N 43,000 lb-in 4,680 Nm 31,000 lb-in 3,500 Nm.0006 in.015 mm 63.3 lbs 28.7 kg 5.8 in mm 0.1 in 2.5 mm (2) 1/4 BSPP G or 1/4 NPT 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. 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 *This list represents the most frequently requested modules. Many others are available. 18 ATI INDUSTRIAL AUTOMATION

19 HOW TO ORDER SY QC-500 Optional Modules for Flat D FA44, FSN4: Fluid/Air Modules FE44, FSG4: Fluid/Air Modules (Support Plates Not Required) F34: Fluid/Air Modules PV1, PV2, PV3, PV4, PV5, PV6: Air/Vacuum Modules 0000: No module in place Optional Modules for Flat C 3) J16 Patterns to support Various Modules (ex. R21, T19, S19, J16) Use 0 to designate a missing module 000: No module in place Optional Modules for Flat B Same as Flat D M: Master T: Tool Signal Module for Flat A * see chart pg. 15 * Please visit for an updated, comprehensive list of modules. As always, consult your ATI Account Manager with any questions regarding product selection for your application. 1: G Porting 2: NPT Porting ATI INDUSTRIAL AUTOMATION QC-502* *QC-502 with DE45 and FSN4 ATI INDUSTRIAL AUTOMATION 19

20 QC-602 Robotic Tool Changer for Extreme Material Handling The QC-602 Robotic Tool Changer from ATI is by far the strongest tool changer on the market today. The QC-602 was designed to meet the extreme payload and moment demands of heavy industrial and aerospace applications. With a payload capacity of 2,500 pounds, the QC-602 is in a class of it s own, setting a new standard in heavy capacity tool changers. QC-602 with TW19, MT8, V114 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 force acting on the piston. Large piston diameter and outward ball travel increase moment capacity. All locking parts are made of Rc58 stainless steel. Integrated Lock/Unlock Sensing for safety, Highest Moment Capacity: 3 locking mechanism design creates static moment capacity of 122,000 lb-in. (X & Y) Specifications Suggested Payload Limit Locking 80 psi Static Moment Capacity (X & Y) Static Moment Capacity (Z) Positional Repeatability (X,Y, & Z) Weight (when coupled) (with no accessory modules) Unit size when locked Maximum allowable distance between master and tool plates before locking Sensor Information, Signal Name Mounting Surface/ Lock/Unlock Air Supply Pneumatic pass-through ports Values 2,500 lbs 1,130 kg 21,000 lbs 9,525 kg 122,000 lb-in 13,750 Nm 49,000 lb-in 5,500 Nm.0006 in.015 mm lbs 58.1 kg 5.51 in mm 0.1 in 2.54 mm L/U (Lock/Unlock) Proximity Sensors RTL (Ready-to-Lock) Proximity Sensors Custom patterns for Master plate and Tool plate based on three (3) QC-200 locking mechanisms 3/8 NPT 3/8 NPT Two (2) air ports which are unchecked Option * Description Flat TW19 19-pin, 5A/250VAC, MS cylindrical threaded connector, cables attached A 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 *This list represents the most frequently requested modules. Many others are available. 20 ATI INDUSTRIAL AUTOMATION

21 HOW TO ORDER 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 * Please visit for an updated, comprehensive list of modules. As always, consult your ATI Account Manager with any questions regarding product selection for your application. ATI INDUSTRIAL AUTOMATION QC-602* (6) Tapped M10, 32 Dp. Equally Spaced 3 Places ±0.013 Flat A ± ±0.013 B.C Places Part Numbers: (A) Master: G3M-0-0-MT8-0-V114 (B) Tool: G3T-0-0-MT8-0-V V114 Modules 54.1 Tool Plate [5.51"] Coupled 85.9 Master Plate Pin Amphenol Connector MS3102E22-14S Flat E TW19-T 76.2 V114 Modules (Typ) TW19-T ± º (Typ) Flat B Flat D (Typ) Flat C C L Flat C MT8-T 80.6 MT8-T (2) 10 H7, 10 Dp. Amphenol Connector MS 3106E22-23S Amphenol Connector MS3102E22-23P 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) mm. 3. V114 modules have (1) 1-1/4 NPT vacuum pass thru port Tool Side (projection only) *QC-602 with TW19, MT8 and V114 ATI INDUSTRIAL AUTOMATION 21

22 QC-602 CONTINUED ATI INDUSTRIAL AUTOMATION QC-602* ±0.013 R97.5 (Typ) ±0.013 Eye Bolt Location Master & Tool (See Note 1) Flat E B.C. 125 Flat A (6) Thru Holes For M10 SHCS C'Bored From Far Side Equally Spaced 3 Places (See Note 2) ± TW19-M Amphenol Connector MS3102E28-12P 3/8 NPT Port Unlock Air Supply 3/8 NPT Port Lock Air Supply ± TW19-M C L (2) 10 H7, 10 Dp. Flat D A C L Flat C2 A Flat C1 Flat B 3/8 NPT Ports Pass-Thru Air View A-A Removed 71.7 MT8-M 82.3 MT8-M Master Side (projection only) *QC-602 with TW19, MT8 and V114 MODULAR TOOL STANDS The ATI TSL (Tool Stand, Large) Modular Tool Stand System, or TSL, is compatible with larger size ATI Tool Changers. The Stand is designed for durability, longevity, and maximum flexibility to fit most customers applications. The configurable system allows you to specify tool height, offset, shielding, and sensing. To save space, the TSL can even store 2 tools on the same post. ATI TSL Stands are currently in use in major automotive plants across the nation. Product Advantages Stainless Steel Alignment Pins Offer High Repeatability. Compliant Tool option available. Large Base Plate distributes tool weight evenly. 6 inch Steel Post Weldment Provides Outstanding Support. Optional Tool Presence Sensing and Shield Position Sensing. Tool-to-Post Plate options to fit every application. Tool Stand Interlock Option provides additional safeguard for Tool Drop-Off. Optional Leather Guards for Shield. The ATI Tool Stand System consists of the following main assemblies. These can be assembled to form a complete solution, or can be used separately as your application requires. Part Number Prefix 9120-TSL-PM 9120-TSL-HE 9120-TSL-SM 9120-TSL-DSA 9120-TSL-DS 9120-TSL-TP 9120-TSL-SS Name Post Module (with Compliant Tool ) Horizontal Extension Module Sensor Module Debris Shield Actuator Debris Shield Tooling Bracket Tool Stand Interlock 22 ATI INDUSTRIAL AUTOMATION

23 Post Module The ATI TSL Post Module includes a welded steel vertical post, a base plate, and a vertically-compliant interface for your tooling. Height, tool orientation, and compliance stiffness can all be specified by the customer. ATI also offers a configuration of the TSL Post Module that allows for up to two tools to be mounted on the same post. Debris Shield The TSL Debris Shield mounts to a tubular arm that in turn is mounted to the Shield Actuator Unit. The Debris Shield is designed to cover the Tool Changer Tool Side unit when the Tool is in storage. The Debris Shield provides ample protection from dust, weld spatter and other debris through the use of leather side guards. Horizontal Extension Module The TSL Horizontal Extension Module is an option that provides more tool clearance than the standard TSL Post Module. ATI offers a standard extension length of 10". Other lengths are available upon customer request. Debris Shield Actuator The TSL Debris Shield Actuator (DSA) positions the Debris Shield in the open or closed position. On single tool stands, the DSA module can be oriented so that the shield swings in the vertical or horizontal plane. The shield will swing 135 degrees rotationally for most arrangements. The powerclamp comes equipped with integrated position sensing. Sensor Module The TSL Sensor Module is an option that provides Tool Presence detection. The standard model mounts directly to the TSL Post Module and incorporates a proximity switch that senses a face on the TSL Tooling Bracket. The Sensor Module comes equipped with a collision guard. Tooling Bracket The TSL Tooling Bracket mounts directly to your tooling, and is equipped with heavy-duty alignment pin and bushings that directly couple with the Post Module Compliant. ATI INDUSTRIAL AUTOMATION TSL (8) M12 TAP Thru (8) 20 Thru Sheild Arm 9120-TSL-DSA Debris Shield Actuator 135 Swing With Intergrated Shield Position Sensing TSL-SMA-3371 Tool Presence Sensor Module 135 Shield Swing TSL-DS-17-B3528 Debris Shield, 17" Wide With Leather Side Guards TOP VIEW 9120-TSL-PM-236A-C500 Dual Post Module with Compliant Tooling can Specify Overall Height 9120-TSL-TP-4115 Tooling Bracket Blank See (Overall Height TBD By ) Maximum Vertical Compliance EXPLODED VIEW ISOMETRIC VIEW Plate Thickness SIDE VIEW FRONT VIEW ATI INDUSTRIAL AUTOMATION 23

24 Other ATI Products Robotic Crash Protection Device Protector Designed to prevent damage to robotic endeffectors resulting from robot crashes. Features include: Automatic reset, high-repeatability, and large moment rotation. Robotic and CNC Deburring Tools Flexdeburr and Speedeburr These air-driven robotic tools cover a wide variety of automated deburring applications with fast cycle times and clean, accurate cuts. Flexdeburr is designed for removal of parting lines and flash, while Speedeburr is specially designed for edge deburring and chamfering. Robotic Rotary Joint A device that allows unlimited rotation of end-of-arm tooling without tangling or twisting robot lines. Utilizes advanced slip-ring technology to pass electrical and pneumatic signals from robot to tooling. Multi-Axis Force/Torque Sensor F/T Measures the full six components of force and torque. High overload protection and high signal-tonoise ratio. Used in robotic and research applications. Automated Assembly Alignment Device Compensator An insertion device using Remote Center Compliance technology, that helps assembly machines automatically align close-fitting parts, preventing jamming and galling. Company Profile ATI Industrial Automation is a world-leading developer of Automatic Tool Changers, Multi-Axis Force/Torque Sensing Systems, Compliance Devices, Robotic Crash Protection Devices, Robotic Deburring Tools, and Robotic Rotary Joints. Our products are found in thousands of successful applications around the world. Since 1982, our engineers have been developing cost-effective, state-of-the-art products and solutions to improve manufacturing productivity. Our Mission is to provide customers around the world with high-quality robotic peripheral devices, tooling and sensors that enhance customer profitability by increasing the effectiveness, flexibility, safety and productivity of their automation applications. We accomplish this through continuous improvement of existing products, product customization and new product innovation. Our engineering-centric staff focuses on providing customer solutions to robotic, automation and sensing appplications. Our Quality Policy ATI Industrial Automation strives to provide customer satisfaction through continual improvement of on-time delivery, quality and reliability, and a constant focus on innovation and profitability. Pinnacle Park 1031 Goodworth Drive Apex, NC USA fax info@ati-ia.com Copyright by ATI Industrial Automation, Inc All rights reserved November, 2005