ATI Technologies QC-310 User Manual

Manual,Robotic Tool Changer, QC‑310
Document #9620‑20‑B‑310 Series Base Tool Changer‑27

Table of Contents

B. Tool Changer ...........................................................................................................................B-3

QC-310 Series—Robotic Tool Changer ......................................................................................B-3

1. Product Overview ..................................................................................................................B-3

1.1 Master Plate Assembly ............................................................................................................. B-4

1.2 T ool Plate Assembly .................................................................................................................. B-5

1.3 Optional Modules ......................................................................................................................B-5

2. Installation .............................................................................................................................B-6

2.1 Master Interface .........................................................................................................................B-7

2.2 Master Plate Installation ...........................................................................................................B-8

2.3 Master Plate Removal ...............................................................................................................B-9

2.4 Tool Interface ...........................................................................................................................B-10

2.5 Tool Plate Installation ..............................................................................................................B-11

2.6 Tool Plate Removal ..................................................................................................................B-11

2.7 Pneumatic Requirements .......................................................................................................B-12

2.7.1 Valve Requirements for Air Adapter Modules ................................................................B-12

2.8 Electrical Connections ............................................................................................................B-13

2.8.1 PNP Type Lock, Unlock and RTL Sensors (-SM, -SMA, -SL, -SG, -ST sensor

designations) .................................................................................................................B-13

2.8.2 NPN Type Lock, Unlock and RTL Sensors (-SP, -SE sensor designations) ..................B-13

2.8.3 Namur Type Lock and Unlock Sensors (-SV sensor designation) ................................B-14

3. Operation .............................................................................................................................B-15

3.1 Conditions for Coupling .........................................................................................................B-16

3.2 Fail-Safe Operation .................................................................................................................B-17

3.3 Conditions for Uncoupling .....................................................................................................B-18

3.4 ToolIdentication .................................................................................................................... B-18

3.5 Tool Storage Considerations ................................................................................................. B-19

4. Maintenance .........................................................................................................................B-20

4.1 Preventive Maintenance .........................................................................................................B-20

4.2 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins ....................... B-21

4.3 Pin Block Inspection and Cleaning .......................................................................................B-23

5. Troubleshooting and Service Procedures ........................................................................B-24

5.1 Troubleshooting Procedures ................................................................................................. B-24

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Manual,Robotic Tool Changer, QC‑310
Document #9620‑20‑B‑310 Series Base Tool Changer‑27

5.2 Service Procedures .................................................................................................................B-25

5.2.1 Sensor Replacement Procedures .................................................................................B-25

5.2.1.1 Individual Lock and Unlock Sensor Assemblies Replacement ......................B-26

5.2.1.2 RTL Sensor Cable Replacement Procedure ..................................................B-28

5.2.1.3 RTL Sensor Replacement Procedure ............................................................B-30

5.2.2 V-ring Seal Replacement ...............................................................................................B-31

5.2.3 Alignment Pin Replacement ..........................................................................................B-32

6. Serviceable Parts ................................................................................................................B-34

6.1 Models 9121-310xM-000-000-S0 .............................................................................................B-34

6.2 Models 9121-310xM-000-000-SM, 9121-310xM-000-000-SP, 9121-310xM-000-000-SMA,

9121-310xM-000-000-ST, and 9121-310xM-000-000-SV ........................................................ B-35

6.3 Tool Plate ............................................................................................................................... B-36

7. Specications ......................................................................................................................B-37

8. Drawings ..............................................................................................................................B-38

8.1 QC-310 Tool Changer .............................................................................................................. B-38

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Manual,Robotic Tool Changer, QC‑310
Document #9620‑20‑B‑310 Series Base Tool Changer‑27

B. Tool Changer
QC-310 Series—Robotic Tool Changer

1. Product Overview

ATI Tool Changers enhance the versatility of a robot by enabling the use of multiple customer tools, such as:
grippers, vacuum cup tooling, pneumatic and electric motors, weld guns, and more.

The Tool Changer consists of a Master plate, which is attached to the robot arm, and a Tool plate, which is attached
to customer tooling. When the robot picks up the customer tooling, a pneumatically‑driven locking mechanism
couples the two plates. The patented, fail‑safe locking mechanism utilizes a multi‑tapered cam with ball locking
technology to ensure the Tool Changer does not uncouple if air pressure falls below 60 psi (4.1 bar) during
operation.

The robot can be programmed to select the desired customer tooling by coupling the Master plate to the Tool plate.

Electricity, uid, and other forces of energy transfer to the customer tooling through optional modules that are

attached to the Master and Tool plates. Refer to the ATI website for compatible modules or contact an ATI sales
representative for more details.

For the most current product information and specications on the QC‑310 Series of Tool Changers, click the

following link: QC‑310 Series

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Manual,Robotic Tool Changer, QC‑310
Document #9620‑20‑B‑310 Series Base Tool Changer‑27

1.1 Master Plate Assembly

The Master plate assembly includes the following features:

• An anodized aluminum body.

• A hardened stainless steel locking mechanism (a cam, male coupling, and chrome steel ball

bearings).

• Hardened steel alignment pins that mate with bushings on the Tool plate.

• (4) ats for mounting optional modules. Flat A is dedicated for mounting an air adapter or a valve

adapter and control/signal module combination. Flats B, C, and D are for optional modules.

• Proximity sensor assemblies used to verify the lock/unlock position of the piston and cam.

• Proximity sensors used to verify Tool plate presence when coupled.

• A mounting pattern for a robot arm or a interface plate.

• Routing channels for the RTL, Lock, and Unlock sensor cables.

Extreme pressure grease is applied to the cam, male coupling, ball bearings, and pins to enhance
performance and maximize the life of the Master plate.

Figure 1.1—Master Plate Assembly

Proximity Sensor

Location (RTL Signal)

Ball Bearing (12)

Cam

Male Coupling

Alignment Pin (2)

Lock/Unlock Air supplied
through Air/Valve Adapter
mounted to Flat A

Common Ledge
Feature for Module
mounted to Flat B, C,
and D

Sensor Cable Channel

Cable Retaining Tab

Internal Proximity Sensor Assembly
(Lock/Unlock) [Not Visible]

Proximity Sensor

Location (RTL Signal)

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Manual,Robotic Tool Changer, QC‑310
Document #9620‑20‑B‑310 Series Base Tool Changer‑27

1.2 Tool Plate Assembly

The Tool plate assembly includes the following features:

• An anodized aluminum body.

• A hardened stainless steel bearing race.

• Alignment bushings that mate with pins on the Master plate.

• (4) ats for mounting optional modules. Flat A requires a tool adapter assembly that is compatible

with the air or valve adapter used on the Master Plate. Flats B, C, and D are for optional modules.

• Ferrous metal proximity sensor targets.

• A mounting pattern for customer tooling or a tooling interface plate.

Figure 1.2—T ool Plate Assembly

Alignment Pin Bushing (2)

Alignment Pin Bushing (2)

Proximity Sensor Assembly Target (RTL)

Proximity Sensor Assembly Target (RTL)

Bearing Race

Bearing Race

Proximity Sensor Assembly

Proximity Sensor Assembly

Target (RTL)

Target (RTL)

1.3 Optional Modules

The optional modules are mounted to the Master and Tool plate using a common ledge mounting feature and
pass utilities to customer tooling.

For assistance in choosing the modules for your particular application, visit our website (QC‑310 Series) to
see what is available or contact an ATI sales representative directly.

Common Ledge Feature for

Common Ledge Feature for

Module mounted to Flat A,

Module mounted to Flat A,

B, C, and D

B, C, and D

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Manual,Robotic Tool Changer, QC‑310
Document #9620‑20‑B‑310 Series Base Tool Changer‑27

2. Installation

Mounting the Tool Changer requires the following, refer to Table 2.1:

WARNING: Do not perform maintenance or repair(s) on the Tool Changer or modules unless
the Tool is safely supported or placed in the tool stand, all energized circuits (e.g. electrical,
air, water, etc.) are turned off, pressurized connections are purged and power is discharged

from circuits in accordance with the customer specic safety practices and policies. Injury

or equipment damage can occur with the Tool not placed and energized circuits on. Place
the Tool in the tool stand, turn off and discharge all energized circuits, purge all pressurized
connections, and verify all circuits are de-energized before performing maintenance or
repair(s) on the Tool Changer or modules.

WARNING: Do not use lock washers under the head of the mounting fasteners or allow the
mounting fasteners to protrude above the mating surfaces of the Master and Tool plates.
Allowing fasteners to protrude above the mating surface will create a gap between the Master
and Tool plates and not allow the locking mechanism to fully engage, this can cause damage

to equipment or personal injury. The mounting fasteners must be ush or below the mating

surfaces of the Master and Tool plates.

Head of Mounting Fastener Must Be Flush or

Below Mating Surface. (Do Not Use Lock

Washer under Head of Mounting Fastener.)

Mating Surface

CAUTION: Thread locker applied to fasteners must not be used more than once. Fasteners
might become loose and cause equipment damage. Always apply new thread locker when
reusing fasteners.

CAUTION: Do not use fasteners that exceed the thread depth in the Tool Changer. Refer to

Section 8—Drawings for details on mounting hole thread depth. Secure the Tool Changer with

the proper length fasteners. This is true for both robot and tool interfaces.

Table 2.1—FastenerSize,Class,andTorqueSpecications

Mounting Conditions

Master plate to Interface plate (6061-T6 aluminum)
Minimum thread engagement of 0.71” (18 mm) [1.5X fastener Ø].

Master plate to Interface plate (6061-T6 aluminum)
Minimum thread engagement of 0.94” (24 mm) [1.5X fastener Ø].

Master plate to Robot (steel; USS ≥ 90KSI)
Minimum thread engagement of 0.47” (12 mm) [1.0X fastener Ø].

Master plate to Robot (steel; USS ≥ 90KSI)
Minimum thread engagement of 0.63” (16 mm) [1.0X fastener Ø].

Tool Interface Plate (aluminum) to Tool plate (7075-T6 aluminum)
Minimum thread engagement of 0.59” (15 mm) [1.5X fastener Ø]

Tool plate (6061-T6 aluminum) to Tool Interface Plate (aluminum)
Minimum thread engagement of 0.59” (15 mm) [1.5X fastener Ø].

Tool plate (6061-T6 aluminum) to Tool Interface Plate (aluminum)
Minimum thread engagement of 0.71” (18 mm) [1.5X fastener Ø].

Tool Interface Plate (aluminum) to Tool plate (7075-T6 aluminum)
Minimum thread engagement of 0.94” (24 mm) [1.5X fastener Ø].

Notes:

1. Conrm available engagement with robot manufacturer

2. Removable (blue) Loctite 242® must be used on mounting fasteners.

Fastener Size and

Property Class

M12-1.75

Class 12.9

M16-2.0

Class 12.9

M12-1.75

Class 12.9

M16-2.0

Class 12.9

M10-1.5

Class 12.9

M10-1.5

Class 12.9

M12-1.75

Class 12.9

M16-2.0

Class 12.9

Recommended

Torque

70 ft-lbs
(95 Nm)

165 ft-lbs
(225 Nm)

100 ft-lbs
(135 Nm)

240 ft-lbs
(325 Nm)

38 ft-lbs
(52 Nm)

38 ft-lbs
(52 Nm)

70 ft-lbs
(95 Nm)

165 ft-lbs
(225 Nm)

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Manual,Robotic Tool Changer, QC‑310

A boss and two dowel pins can

Document #9620‑20‑B‑310 Series Base Tool Changer‑27

2.1 Master Interface

The Master plate is typically attached to the robot arm. An interface plate can adapt the Master plate to a

specic robot arm. Alignment features (dowel holes and bosses) accurately position and bolt holes secure

the Master plate to the robot arm or an interface plate. Custom interface plates are available from ATI upon

request (refer to the drawings for technical information on mounting features.)

CAUTION: Do not use more than two alignment features when securing a Master plate
to an interface plate. Using more than two alignment features can cause damage to
equipment. Use either two dowel pins or a single dowel pin, along with a boss/recess
feature to align the Master plate with the interface plate.

CAUTION: Do not use dowel pins that are too long or do not allow the interface plate

and Master body to mate ush. Using dowel pins that are too long will cause a gap

between the interface plate and Master body and damage the equipment. Use dowel
pins that will not extend further than allowed by the Master body.

Incorrect Mounting of Master Plate

be difficult to align and can

cause damage to equipment.

Interface Plate

Optional Boss

Correct Mounting of Master Plate

(or a single dowel

used as alignment features.

Two dowel pins

with a boss/recess)

pin along

Interface Plate

Dowel pins that are

too long can cause a

gap between interface

plate and Master Plate.

Master Plate

GapGap

Correct size dowel

pins allow the interface

plate and Master

plate to mount flush.

Master Plate

If the customer chooses to design and build an interface plate, consider the following points:

• The interface plate should include bolt holes for mounting and either two dowel pins or a dowel
pin and a boss for accurate positioning on the robot and Master plate. The dowel and boss features
prevent unwanted rotation. Refer to the robot manual for robot mounting features.

• The thickness of the interface plate must be sufcient to provide the necessary thread engagement

for the mounting bolts.

• Dowel pins must not extend out from the surface of the interface plate farther than the depth of the
dowel holes in the Master plate.

• If a boss is used on the Master plate, a recess of proper depth and diameter must be machined into
the interface plate to correspond with the boss on the Master plate.

• Mounting bolts that are too long can create a gap between the interface plate and the Master plate,

which can damage equipment.

• The interface plate must provide rigid mounting to the Master plate.

• The interface plate design must account for clearances required for Tool Changer module

attachments and accessories.

Flush

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Manual,Robotic Tool Changer, QC‑310
Document #9620‑20‑B‑310 Series Base Tool Changer‑27

2.2 Master Plate Installation

Tools required: 10 mm or 12 mm hex key, torque wrench
Supplies required: Clean rag, Loctite® 242

1. Clean the mounting surfaces.

2. If required, install the interface plate to the robot arm, align using the boss or dowel pins and secure with
customer supplied fasteners.

3. Align the dowel pins to the corresponding holes in the Master plate and secure the Master plate to the
robot arm or interface plate with customer supplied fasteners.

4. For rst time installation of fasteners with pre‑applied adhesive no additional Loctite is required. If
fasteners are being reused, apply Loctite to threads (see Table 2.1 for fastener specications).

NOTICE: If an ATI interface plate is used, fasteners to mount the Master plate are supplied with
the interface plate.

5. Connect utilities to the appropriate module and Master plate connections. For pneumatic lock and unlock
connection, refer to Section 2.7—Pneumatic Requirements.

6. Safely resume normal operation.

Figure 2.1—Typical Master Plate Installation

Robot Arm

Dowel Pin (Customer Supplied)

Socket Head Cap Screws

(See Table 2.1)

(Customer Supplied)

Robot Interface Plate,
ATI or customer supplied
(If required)

RIP mounting hardware
(Customer supplied)
(If required)

Master Plate

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Manual,Robotic Tool Changer, QC‑310
Document #9620‑20‑B‑310 Series Base Tool Changer‑27

2.3 Master Plate Removal

Refer to Figure 2.1.

Tools required: 10 mm or 12 mm hex key

1. Place the Tool in a secure location.

2. Uncouple the Master and Tool plates.

3. Turn off and de‑energize all energized circuits (e.g. electrical, air, water, etc.).

4. Disconnect all utilities (e.g. electrical, air, water, etc.).

NOTICE: Support the Master plate while removing the fasteners.

5. Remove the socket head cap screws connecting the Master plate to the robot arm or interface plate.

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Manual,Robotic Tool Changer, QC‑310

Correct Mounting of Tool Plate

Interface Plate

Incorrect Mounting of Tool Plate

Document #9620‑20‑B‑310 Series Base Tool Changer‑27

2.4 Tool Interface

The Tool plate is attached to the customer’s tooling. An interface plate can adapt the Tool plate to customer
tooling. Alignment features (dowel holes and a recess) accurately position and bolt holes to secure the Tool
plate to customer tooling. Custom interface plates can be supplied by ATI (refer to the application drawing).

CAUTION: Do not use more than two alignment features when securing a Tool plate
to an interface plate. Using more than two alignment features can cause damage to
equipment. Use either two dowel pins or a single dowel pin, along with a boss/recess
feature to align the Tool plate with the interface plate.

CAUTION: Do not use dowel pins that are too long or do not allow the interface plate

and Tool body to mate ush. Using dowel pins that are too long will cause a gap

between the interface plate and Tool body and damage the equipment. Use dowel pins
that will not extend further than allowed by the Tool body.

Boss and two dowel pins

as alignment features can be

difficult to align and can

damage equipment.

Dowel pins

are too long and

cause a gap between

interface plate and Tool.

Tool Plate

Gap

single dowel pin along with a

proper size allowing

interface plate and Tool

Plate to mount flush.

Two dowel pins (or a

boss/recess) used as

alignment features.

Dowel pins are

Interface Plate

Tool Plate

If the customer chooses to design and build a tool interface plate, consider the following points:

• The interface plate should include bolt holes for mounting and either two dowel pins or a dowel
pin and a boss for accurate positioning on the customer tooling and Tool plate. The dowel and boss
features prevent unwanted rotation.

• Dowel pins must not extend out from the surface of the interface plate farther than the depth of the
dowel holes in the Tool plate.

• The thickness of the interface plate must be sufcient to provide the necessary thread engagement

for the mounting bolts. Fasteners should meet minimum recommended engagement lengths while
not exceeding the maximum available thread depth. Use of bolts that are too long can cause damage
to the tool side changer.

• The plate design must account for clearances required for Tool Changer module attachments and

accessories.

• If a boss is to be used on the interface plate, a boss of proper height and diameter must be machined
into the interface plate to correspond with the recess in the Tool plate.

• The interface plate must have a hole in its center for manually returning the locking mechanism
to the unlocked position under adverse conditions (i.e. unintended loss of power and/or air
pressure). The center access hole with a minimum diameter of 1” (25.4 mm) prevents debris from
contaminating the locking mechanism. Greater protection is provided by leaving the race cover and
grommet in place.

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Manual,Robotic Tool Changer, QC‑310
Document #9620‑20‑B‑310 Series Base Tool Changer‑27

2.5 Tool Plate Installation

Tools required: 8 mm, 10 mm, or 12 mm hex key, toque wrench
Supplies required: Clean rag, Loctite 242

1. Clean the mounting surfaces..

2. If required, install the tool interface plate to the customer tooling, align using the boss or dowel pins and
secure with customer supplied fasteners.

3. Align the dowel pins to the corresponding holes in the Tool plate and secure the Tool plate to the tool
interface plate or customer tooling with customer supplied fasteners.

4. For rst time installation of fasteners with pre‑applied adhesive no additional Loctite is required. If
fasteners are being reused, apply Loctite to threads (see Table 2.1 for fastener specications).

NOTICE: If an ATI interface plate is used, fasteners to mount the Tool plate is supplied with the
interface plate.

5. Connect utilities to the appropriate module and Tool plate connections.

6. Safely resume normal operation.

Figure 2.2—Standard Tool Plate Installation

2.6 Tool Plate Removal

Tools required: 8 mm, 10 mm, or 12 mm hex key

M10-1.5 Socket Head Cap Screws
(See Table 2.1)
(Customer Supplied)

Tool Plate

Dowel Pins (Customer Supplied)

Tool Stand/Tool Interface Plate
(Customer Supplied)
(if required)

1. Place the Tool in a secure location.

2. Uncouple the Master and Tool plates.

3. Turn off and de‑energize all energized circuits (e.g. electrical, air, water, etc.).

4. Disconnect all utilities (e.g. electrical, air, water, etc.).

5. Remove the socket head cap screws connecting the Tool plate to the tooling or tool interface plate.

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Manual,Robotic Tool Changer, QC‑310

)

integrated valve

Document #9620‑20‑B‑310 Series Base Tool Changer‑27

2.7 Pneumatic Requirements

Proper operation of the locking mechanism requires a constant supply of clean, dry, non‑lubricated air, with

the following conditions:

• Pressure range of 60 to 100 psi (4.1 ‑ 6.9 bar) Suggested 80 psi.

• Filtered minimum: 40 microns.

To lock or unlock the Tool Changer, a constant supply of compressed air is required. If there is a loss of air
pressure in the locked state, the cam prole prevents the master plate and tool plate from unlocking, and the

Tool Changer goes into the fail‑safe condition.

CAUTION: Do not use the Tool Changer in a fail-safe condition. Damage to the locking
mechanism can occur. Re-establish air pressure and ensure the Tool Changer is in a
secure lock position before returning to normal operations.

2.7.1 Valve Requirements for Air Adapter Modules

NOTICE: No valve is required when using a valve adapter module. The valve adapter

module has an integrated solenoid valve and only requires the customer to supply a
single air source to the valve adapter.

A customer supplied 2‑position 4‑way or 5‑way valve with either 4‑port or 5‑port conguration

must be used to actuate the locking mechanism in the Master plate. It is imperative that when
air is supplied to the Lock or Unlock Port on the Master plate, that the opposite port be vented
to atmosphere (i.e., when air is supplied to the Lock Port, the Unlock Port must be open to the
atmosphere.) Failure to vent trapped air or vacuum on the inactive port may inhibit operation of the
locking mechanism and prevent coupling or uncoupling.

Air Adapter without

CAUTION: The locking mechanism will not function properly when connected
to a 3-way valve as this type of valve is incapable of venting trapped air or
vacuum from within the Tool Changer. This could result in damage to the

product, attached tooling, or injury to personnel. Connect the Lock and Unlock

supply air to a 2-position 4-way or 5-way valve with either 4-port or 5-port

conguration.

Figure 2.3—Lock and Unlock Pneumatic Connections

4 or 5-way Valve

Supply Clean, Dry,
Non-lubricated Air

Lock Port

Unlock Port

Exhaust
Open to Atmosphere

60 – 100 psi (4.1 – 6.9 Bar

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