Product Manual · 2019. 11. 7. · Product Manual Tool changer TC100 M0403-1 | Swivels | Swivel tool changers | Grippers | Hose packages | Valve u nits | Tool systems. 2 M0403-1 ver

2 M0403-1 ver. 2.4

M0403-1 ver 2.4 3

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without authorization. Infringement hereof will be subject to action in accordance with the applicable laws.

Further copies of this document can be obtained from Robot System Products AB at current prices.

© Robot System Products AB

Robot Systems Products AB Isolatorvägen 4 SE-721 37 Västerås Sweden

4 M0403-1 ver. 2.4

CONTENTS

1 INTRODUCTION ...................................................................................................... 6

1.1 Safety ......................................................................................................................... 7

1.1.1 General ............................................................................................................................... 7 1.1.2 Explanation of warnings ..................................................................................................... 7

1.2 Description of RSP tool changers ............................................................................... 8

1.3 Complementary Equipment ........................................................................................ 8

2 TECHNICAL SPECIFICATIONS .............................................................................. 9

2.1 Description of tool changers and tool attachments ..................................................... 9

2.1.1 Coordinate System Definition ........................................................................................... 10 2.1.2 Tool Changer with air, TC100-8. Article no: P0401.......................................................... 11 2.1.3 Tool Attachment, TA100-8. Article no: P0407 .................................................................. 12 2.1.4 Square Tool Attachment, TA100-8. Article no: P0402 ..................................................... 13 2.1.5 Tool Changer with air and electric signals TC100-8E. Article: P0403 ............................. 14 2.1.6 Tool Attachment, TA100-8E. Article no: P0409 ............................................................... 16 2.1.7 Tool Attachment, TA100-8E. Article no: P0418 ............................................................... 16 2.1.8 Square Tool Attachment, TA100-8E. Article no: P0404 ................................................... 18 2.1.9 Pneumatic diagram for Tool changers P0401 and P0403 ............................................... 19 2.1.10 Circuit diagram E0199-001 for P0403 and P0409/P0404 .............................................. 20

2.2 Options to TC ........................................................................................................... 21

2.2.1 Tool stand kit. Article no: P0423....................................................................................... 21 2.2.2 Limitation of Robot movements ........................................................................................ 21 2.2.3 Connection kits and cables .............................................................................................. 21

3 INSTALLATION ..................................................................................................... 22

3.1 Tightening torques .................................................................................................... 22

3.2 Recommended tools for installation .......................................................................... 22

3.3 Installation of tool changer on robot .......................................................................... 23

3.4 Installation of tool attachment to the gripper/tool ....................................................... 24

3.5 Hints ......................................................................................................................... 26

3.5.1 Programming .................................................................................................................... 26 3.5.2 Sparking ........................................................................................................................... 26 3.5.3 Electrical installation ......................................................................................................... 26 3.5.4 Tool stand ......................................................................................................................... 26 3.5.5 Tool Identification ............................................................................................................. 26

4 MAINTENANCE AND SERVICE ............................................................................ 27

4.1 Maintenance chart .................................................................................................... 27

4.1.1 Required products ............................................................................................................ 27 4.1.2 Recommended tools for maintenance ............................................................................. 28 4.1.3 Wear parts ........................................................................................................................ 28 4.1.4 Activities and intervals on tool changer ............................................................................ 28 4.1.5 Activities and intervals on tool attachment ....................................................................... 29

M0403-1 ver 2.4 5

4.2 Visual inspection ...................................................................................................... 29

4.2.1 Inspection of the tool changer .......................................................................................... 29 4.2.2 Inspection of the tool attachment ..................................................................................... 29

4.3 Cleaning ................................................................................................................... 30

4.3.1 Cleaning and lubrication of tool changer .......................................................................... 30 4.3.2 Cleaning of tool attachment.............................................................................................. 31

4.4 Replacement of wear parts ....................................................................................... 32

4.4.1 Replacement of air sealings ............................................................................................. 32 4.4.2 Replacement of signal pins (TC100-8E only)................................................................... 32 4.4.3 Replacement of O-ring ..................................................................................................... 33

4.5 Complete service of tool changer ............................................................................. 33

4.6 Replacement of tool changer .................................................................................... 33

5 SPARE PARTS ..................................................................................................... 35

5.1 Part list for tool changer P0401 and P403 ................................................................ 35

5.2 Part list for tool attachment P0407 and P0409 .......................................................... 37

5.3 Part list for tool attachment P0418 ............................................................................ 38

5.4 Part list for square tool attachment P0402 and P0404 .............................................. 39

6 DISPOSAL AND RECYCLING .............................................................................. 40

6 M0403-1 ver. 2.4

1 INTRODUCTION

Robot System Products is a front-rank provider of peripheral products for high performance robot applications. We provide complete system solutions for your robot installations, aiming to improve your productivity with the most reliable and cost-effective tooling on the market. Continuously we explore emerging technologies, working with leading edge design.

Robot System Products has a wide range of standard robot peripheral products:

• Tool changers

• Swivels

• Swivels with integrated tool changers

• Grippers

• Hose Packages

• Valve units

• Tool systems

• Tool stands

Robot System Products’ tool changers are constructed to maximize the flexibility and reliability of your robot fleet. Through our patented locking device TrueConnect™ robustness and high safety are combined with low weight and compactness. With our swivels you can provide compressed air, water, electrical and data signals as well as weld and servo power to your tools with robot motion capabilities fully maintained. Our swivels with tool changers unites the TrueConnect™ tool changing mechanism with our swivel technology, combining the best out of two technologies.

Robot System Products’ product lines are available for all major robot brands and come with complete documentation. 3D-models for simulation are available for download at: www.rsp.eu.com

http://www.rsp.eu.com/

M0403-1 ver 2.4 7

1.1 Safety

1.1.1 General

The integrator installing the tool changer into the system must follow the safety demands stated in standards and provisions applicable in the country where the tool changer system is to be installed. The products are all prepared for CE-certification.

The user of the Robot System Products tool changer is responsible that law and directives applicable in respective countries, with regards to safety, are followed. The user is also responsible to guarantee that all safety devices are installed correctly.

WARNING! Never carry out service work on a robot that has not been taken out of operation. See safety information for the robot.

WARNING! Only perform work on grippers or tools attached to the tool changer if the air pressure is safely switched off.

WARNING! Be aware that tool changer and tool attachment are heavy and may cause personal injury and equipment damage if dropped.

NOTE! The tool changer shall always be in locked position, also when empty, to avoid unexpected locking if air pressure is lost.

1.1.2 Explanation of warnings

The warnings in this document are specific to the products in this manual. It is expected that the user also pay attention to certain notifications from the robot manufacturer and/or the manufacturers of other components used in the installation.

WARNING!

The warning sign will make you aware that a situation could result in potential serious injury or damage to equipment.

NOTE!

The note sign will alert you about something important to consider.

8 M0403-1 ver. 2.4

1.2 Description of RSP tool changers

Our tool changers enable robots to handle and switch between multiple tools. They are built to ensure reliable and smooth operation, being compact with low weight and robust design and incorporating many safety features. Depending on model and options, electrical signals, weld and servo power, data, water and compressed air are transferred from the robot side to the tool.

The patented locking device TrueConnect™ has a minimum of play and gives a practically, through the lifespan, absolute positioning repeatability. The principle behind the locking mechanism is the uniform distribution of load obtained by pressing looking balls into spherical grooves. In consequence, substantially larger positional tolerances are accepted during docking.

1.3 Complementary Equipment

Complementary equipment is described in separate documents.

Article Note

Cable and Hose Package Complete packages for most robots on the market ready to be

mounted without any modifications.

Tool Stands Tool stands will, combined with tool attachments and

adaptation kits, give a rigid installation for easy tool changing.

Connection kits In order to make electrical installation easier, connection kits

are available for tool changers and tool attachments.

3D-models Available in Solid Works® and STEP-format.

M0403-1 ver 2.4 9

2 TECHNICAL SPECIFICATIONS

2.1 Description of tool changers and tool attachments

This document presents the Robot System Products TC100-8 and TC100-8E tool changers including tool attachments dedicated for material handling. Likewise presented are adaptation kits, connection kits to facilitate electrical installation and a tool stand kit.

The tool changer TC100-8 transfers compressed air to the tool. It can be equipped with transfer of electrical signals, via spring loaded signal pins, to the tool attachment. The electrical version is designated ’E’. The tool changers TC100-8 and TC100-8E cannot transport fluids.

The spring loaded signal pins of TC100-8E are placed and protected at the centre of the tool changer. The contact surface of the tool attachment and the signal pins are not in connection until at the very end of the docking cycle when the tool attachment is already properly aligned. This guarantees a minimum of wear of the contact surfaces.

The electrical unit is primarily intended for transfer of sensor signals from grippers. In addition it can be used for checking the presence and identifying tools by using signal jumpers and binary coding of signals on the tool attachment.

For other bolt circles adaptation plates between the tool changer and the turning disc on the robot may be needed. Such adaptation plates are available from RSP.

TC100-8E

10 M0403-1 ver. 2.4

2.1.1 Coordinate System Definition

A tool changer adds load to the robot. If the arm and tool loads are not stated correctly during programming the behaviour of the robot and the wear of the equipment will be affected. Information about weight and centre of gravity can, in accordance with the co-ordinate system stated below, be found in the technical specification tables of the tool changer.

NOTE!

For the tool changer and tool changer with tool attachment, the origo is situated in the centre of the robot mounting flange.

M0403-1 ver 2.4 11

2.1.2 Tool changer with air, TC100-8. Article no: P0401

Tool changer TC100-8 transfers 8 pneumatic channels to the tool attachment.

Technical data

Working temperature +10°C−+60°C

Bolt pattern ISO9409-1-100-6-M10

Maximum tool load

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±1 200 N

±1 000 Nm

±1 000 Nm

Weight and centre of gravity

TC100-8

With TA100-8, P0407

With TA100-8, P0402

Weight

Mass centre X / Y / Z

Weight


Weight


2.9 kg

-0.3 / 0.0 / 35.0 mm

4,4 kg

-0.2 / 0.0 / 45.6 mm

5.1 kg

-0.2 / 0.0 / 51.1 mm

Air ducts Pneumatic diagram

Total number of ducts

Dedicated air ducts

Max air pressure

Air flow

Connection, robot side

Air quality

See section 2.1.9

10

Open TC marked Open (6−10 bar)

Close TC marked Close (6−10 bar)

10 bar

800 l/min

G 1/8"

Oil-clean and waterless filtered air, with max

25µm particle content

12 M0403-1 ver. 2.4

2.1.3 Tool attachment, TA100-8. Article no: P0407

Tool attachment TA 100-8 transfers 8 pneumatic channels to the tool.

Technical data



Weight 1.5 kg

Maximum tool load

M10-screws)

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±1 000 N

±1 000 Nm

±1 000 Nm

Maximum tool load

(M8-screws)

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±1 000 N

±1 000 Nm

±600 Nm

Air ducts Number of ducts

Connection, tool side

8

G 1/8”

NOTE! The tool attachment shall be mounted to the tool using six M8-screws.

M0403-1 ver 2.4 13

2.1.4 Square tool attachment, TA100-8. Article no: P0402

Square Tool Attachment TA 100-8 transfers 8 pneumatic channels to the tool and gives together with option P0423 a stable tool stand for easy tool changing.

Technical data



Weight 2.2 kg

Maximum tool load

(M10-screws)

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±1 000 N

±1 000 Nm

±1 000 Nm

Maximum tool load

(M8-screws)

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±1 000 N

±1 000 Nm

±600 Nm



8

G 1/8”


14 M0403-1 ver. 2.4

2.1.5 Tool changer with air and electric signals TC100-8E. Article: P0403

Tool changer TC120-8E transfers 8 pneumatic channels and 10 electrical signals to the tool attachment.

M0403-1 ver 2.4 15

Technical data



Maximum tool load Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±1 200 N

±1 000 Nm

±1 000 Nm

Weight and centre of gravity

TC100-8E

With TA100-8E, P0409



Weight


Weight


Weight


Weight


3.0 kg

1.4 / -0.2 / 34.6 mm

4,5 kg

1.3 / -0.2 / 45.3 mm

4.5 kg

0.9 / -0.1 / 45.3 mm

5.2 kg

0.5 / -0.2 / 50.7 mm

Air ducts Pneumatic diagram

Total number of ducts

Dedicated ducts

Max air pressure

Air flow

Connection, robot side

Air quality

See section 2.1.9

10

Open TC marked Open (6−10 bar)

Close TC marked Close (6−10 bar)

10 bar

800 l/min

G 1/8"

Oil-clean and waterless filtered air, with max

25µm particle content

Electrical signals Circuit diagram

Total number of signals

Dedicated signals

Max current

Max voltage

Connections

E0199-001 (see section 2.1.10)

11

24 V, TC Opened (signal when unlocked)

24 V, TC Coupled (signal when locked)

2 A

60 V

Souriau UT001412PHT

16 M0403-1 ver. 2.4

2.1.6 Tool attachment, TA100-8E. Article no: P0409

Tool attachment TA 100-8E transfers 8 pneumatic channels and 10 electrical signals to the tool.

Technical data



Weight 1.5 kg

Maximum tool load

(M10-screws)

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±1 000 N

±1 000 Nm

±1 000 Nm

Maximum tool load

(M8-screws)

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±1 000 N

±1 000 Nm

±600 Nm



8

G 1/8”

Electrical signals Total number of signals

Dedicated signals


10

24 V DC

0 V DC

1.0 m cable (10x0.5mm²) with free end


M0403-1 ver 2.4 17

2.1.7 Tool attachment, TA100-8E. Article no: P0418

Tool attachment TA 100-8E transfers 8 pneumatic channels and 16 electrical signals to the tool.

Technical data



Weight 1.5 kg

Maximum tool load

(M10-screws)

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±1 000 N

±1 000 Nm

±1 000 Nm

Maximum tool load

(M8-screws)

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±1 000 N

±1 000 Nm

±600 Nm



8

G 1/8”


Dedicated signals


16

4 x 24 V DC

4 x 0 V DC

4 x M12 4S


18 M0403-1 ver. 2.4

2.1.8 Square tool attachment, TA100-8E. Article no: P0404

Tool attachment TA 100-8E transfers 8 pneumatic channels and 10 electrical signals to the tool and gives together with option P0423 a stable tool stand for easy tool changing.

Technical data



Weight 2.2 kg

Maximum tool load

(M10-screws)

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±1 000 N

±1 000 Nm

±1 000 Nm

Maximum tool load

(M8-screws)

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±1 000 N

±1 000 Nm

±600 Nm



8

G 1/8”


Dedicated signals


10

24 V DC

0 V DC

1.0 m cable (10x0.5mm²) with free end


M0403-1 ver 2.4 19

2.1.9 Pneumatic diagram for Tool changers P0401 and P0403

20 M0403-1 ver. 2.4

2.1.10 Circuit diagram E0199-001 for P0403 and P0409/P0404

M0403-1 ver 2.4 21

2.2 Options to tool changers

2.2.1 Tool stand kit. Article no: P0423

This tool stand kit, mounted on a stand, gives in combination with square tool attachments

P0402 or P0404 a robust tool stand for easy tool changing.

Technical data

Weight 0.7 kg

Maximum load 180 kg

2.2.2 Limitation of Robot movements

There can be some limitations on the movement of axis 5 for some robot models. Contact Robot System Products for more information.

2.2.3 Connection kits and cables

Part

number

Description

P8006 Electrical connection kit for P0403, 12-pole female Souriau (straight, socket 0,5–1,5 mm2)

P8006-1 Electrical connection kit for P0403, 12-pole female Souriau (angled, socket 0,3–0,5 mm2)

P8006-2 Electrical connection kit for P0403, 12-pole female Souriau (angled, socket 0,5–1,5 mm2)

P8116-40 Cable kit for P0403, 12-pole female Souriau and cable (4 meter, free end)

I0615 M12 4P connector with cable 5 meter free end for P0418 (requires 4 items)

22 M0403-1 ver. 2.4

3 INSTALLATION

3.1 Tightening torques

Tightening torques for mounting (screw class 8.8)

Dimension Torque

M4 3 Nm

M5 6 Nm

M6 10 Nm

M8 24 Nm

M10 47 Nm

M12 82 Nm

M16 200 Nm

3.2 Recommended tools for installation

Tools Applications

Complete set of Allen keys For dismounting and mounting.

Torque wrench For all socket head cap screws

Torx key For dismounting and mounting

M0403-1 ver 2.4 23

3.3 Installation of tool changer on robot

Action Note

1 Safety Read the safety section (1.1).

2 Service position Place the robot in service position.

3 Power off Switch the power off and lock the

circuit breaker.

NOTE! Read the safety chapter for

the robot.

4 Mount guide pin for adaptation plate

Press the enclosed guide pin into the

robot flange.

NOTE! Only if adaptation plate is

used.

5 Fit adaptation plate

Lift the adaptation plate and fit the

guide pin to the guide hole in robot

flange.


used.

6 Mount adaptation plate

Mount the adaptation plate with the

enclosed screws. Use an Allen key for

tightening (see tightening torques

above).


used.

24 M0403-1 ver. 2.4

7 Fit tool changer

Lift the tool changer to the robot

flange (or adaptation plate). The

arrow on the front of the tool changer

indicates the position of the hole for

the guide pin. Make sure that the

guide pin is fitted to the guide hole in

the tool changer.

WARNING! The tool changer is

heavy and may cause personal injury

and equipment damage if dropped.

8 Mount tool changer

Mount the tool changer with the

enclosed screws. Use an Allen key for

tightening (see tightening torques

above).

9 Connect air hoses

Connect the air hoses according to

markings. NOTE! Pneumatic diagram

is found in section 2.1.9.

10 Connect electrical signals

(TC100-8E only)

Connect signal contact Souriau.

11 Power on Unlock the circuit breaker and switch

the power on.

3.4 Installation of tool attachment to the gripper/tool

Action Note


2 Mount guide pins

Press two guide pins into the hole on the tool.

M0403-1 ver 2.4 25

3 Fit tool attachment

Lift and fit the tool attachment, using the guide

pins, into its appropriate guide holes.

4 Mount tool attachment

Mount the tool attachment using a torque

wrench with either M8 or M10 screws:

o M8-screws are put in from the tool

attachment side to threaded M8-holes

in the gripper/tool.

o M10-screws are put in from the

gripper/tool side to the threaded M10-

holes in the tool attachment.

See tightening torques above.

5 Connect air hoses Connect the air hoses according to markings.

NOTE! Pneumatic diagram is found in section

2.1.9.

6 Connect signals (TA100-8E

only).

Connect the four M12 4S connectors (P0418)

or the cable with free end (P0409 and P0404)

to the gripper/tool.

26 M0403-1 ver. 2.4

3.5 Hints

3.5.1 Programming

The following will ensure a correct docking position.

Action

1 Attach a spare tool attachment to the tool changer.

2 Position the spare tool attachment above the tool attachment that is mounted on the

tool.

3 The correct position is found when the tool attachments are parallel, centered and

the engraved arrows are on the same line.

4 Save the position. The robot can move to this position with high speed.

5 Dismount the spare tool attachment.

6 Go back to the saved position and move the tool changer (in axis 6 direction) the

remaining distance to the tool attachment (mounted on the tool).

7 Save the position. The robot should move the final distance to this position with low

speed.

3.5.2 Sparking

WARNING! Electrical signals and power must be switched off and disconnected when docking the tool attachment. This is to prevent sparking between signal pins and tool attachment.

3.5.3 Electrical installation

Connection kits for the tool changer and tool attachment are available (see section 2.2.3).

3.5.4 Tool stand

NOTE! To guarantee reliability and a long service-life for the tool changer, the tool stand must be stable, both in terms of its design and attachment.

NOTE! The tool stand must not be spring-loaded!

See section 2.2.1 for suitable tool stand equipment.

3.5.5 Tool Identification

Jumpers on signals at the tool attachment can be used to give information about which tool attachment that is docked in the tool changer.

M0403-1 ver 2.4 27

4 MAINTENANCE AND SERVICE

4.1 Maintenance chart

The tool changer and tool attachment must be maintained regularly to ensure proper function. The specified intervals are approximate and valid under normal conditions. Under extreme conditions, such as dirty environments or extreme robot movements, the intervals should be shortened.

Consider the table as a guide and update as your production experience of each system increases.

WARNING! Risk of getting squeezed between piston and ball holder when the piston is taking closed position.

NOTE! Only perform work on grippers or tools attached to the tool changer if the air pressure is safely switched off.

NOTE! Tool changers must only be dismantled and repaired by Robot System Products during the warranty period. Otherwise the warranty will not be valid.

4.1.1 Required products

Product Specification Note

Grease,

3HXG1000-413

Magnalube-G, Teflon

grease

O-rings

Grease I0876 MolykoteBR2Plus Locking balls and guide pins.

Cleaning agent Denatured alcohol or

similar

Signal pins at tool changer and

signal contacts at tool

attachment.

Cleaning agent Denatured alcohol or

similar

For tool changer and tool

attachment.

Glue Loctite 480 (or similar) For gluing the air sealings.

Cloth Lint free cloth For cleaning.

NOTE! Chemical resistance protective gloves are recommended when using grease or cleaning agents such as denatured alcohol. Safety goggles are recommended when working with cleaning agents such as denatured alcohol. Adequate ventilation should be provided when chemical substances are used.

28 M0403-1 ver. 2.4

4.1.2 Recommended tools for maintenance

Tools Applications

Complete set of Allen keys For dismounting and mounting.

Pair of pliers For dismounting the signal pins.

Screw driver For removing the air sealings.


4.1.3 Wear parts

Wear parts should be replaced before considerable damage occurs. The interval depends on the number of tool changes and its working environment. Generally, the more contaminated environment, the closer maintenance intervals.

The following parts are considered as wear parts:

o Air sealings

o Signal pins

o O-rings

4.1.4 Activities and intervals on tool changer

Equipment Maintenance

activity

Interval Description

Tool changer Inspection 2 weeks Visual inspection of tool changer (see section

4.2.1).

Tool changer Cleaning 1 month Cleaning of tool changer, interval depending on

the environment (see section 4.3.1).

Looking balls Clean and

lubricate

1 month Check, wipe clean and lubricate looking balls

(see section 4.3.1).

Signal pins Cleaning 1 month Wipe the pins clean (see section 4.3.1).

Air sealings Replace 18

months

Wear parts, interval is depending on number of

tool changes and the environment (see section

4.4.1).

Signal pins Replace 18

months

Wear parts, interval is depending on number of


4.4.2).

O-ring Replace 18

months

Wear part, interval is depending on number of


4.4.3).

Tool changer Service 5 years Complete service, to be done by Robot System

Products (see section 4.5).

M0403-1 ver 2.4 29

4.1.5 Activities and intervals on tool attachment

Equipment Maintenance

activity

Interval Description

Tool attachment Inspection 2 weeks Visual inspection of tool attachment (see section

4.2.2).

Tool attachment Cleaning 1 months Cleaning of tool attachment, interval depending

on the environment (see section 4.3.2).

Grooves Cleaning 1 months Wipe the grooves for the locking balls clean (see

section 4.3.2).

Signal contacts Cleaning 1 months Wipe the contact surface clean (see section

4.3.2).

Tool attachment Cleaning 1 months Cleaning of tool attachment, interval depending

on the environment (see section 4.3.2).

4.2 Visual inspection

4.2.1 Inspection of the tool changer

Visually check the following:

Check Note

Air sealings Not worn, damaged or dirty

Locking balls Greased. Not dirty

O-ring Not damaged or dirty

Signal pins (TC100-8E only) Not damaged or dirty

Cables Not squeezed or damaged

All parts No wear

All parts No damage

All parts No dirt

4.2.2 Inspection of the tool attachment

Visually check the following:

Check Note

Air sealing contact surface Not damaged or dirty

Signal contact surface (TA100-8E only) Not worn or dirty

Cables Not squeezed or damaged

All parts No wear

All parts No damage

All parts No dirt

30 M0403-1 ver. 2.4

4.3 Cleaning

4.3.1 Cleaning and lubrication of tool changer

Action Note

1 Clean locking balls

Wipe the locking balls with a cloth.

2 Check locking balls

Check each ball to make sure it moves

freely. Additional cleaning may be

necessary to free any balls stuck in

place.

3 Lubricate looking balls

Apply a small amount of grease

(Molykote BR2Plus) on the locking

balls.

NOTE! It is important that this is done

or there might else be a risk that the

tool attachment jams.

4 Clean signal pins (TC100-8E only)

Clean only the contact surfaces!

NOTE!

Avoid cleaning solvent in the spring

housing.

5 General cleaning Clean the tool changer in general.

M0403-1 ver 2.4 31

4.3.2 Cleaning of tool attachment

Action Note

1 Clean grooves

Wipe the grooves for the locking

balls with a cloth.

2 Clean contact surfaces (TA100-8E only)

Clean the signal contact surface

with a cloth.

3 General cleaning

Clean the tool attachment in

general.

32 M0403-1 ver. 2.4

4.4 Replacement of wear parts

4.4.1 Replacement of air sealings

4.4.2 Replacement of signal pins (TC100-8E only)

Replace a signal pin when the spring jams, or become bent.

Action Note

1 Remove air sealings

Remove the air sealings with a screw driver.

NOTE! There are totally 8 air sealings.

2 Clean sealing holes Wipe clean the sealing holes. Remove all

remaining parts of sealing and glue.

3 Replace air sealing Glue the new air sealing in the sealing groove.

Use a small amount of Loctite 480 (or similar).

Press the sealing 60-120 seconds until the glue

hardens.

Action Note

1 Power off Switch the power off and lock the circuit

breaker.

2 Remove signal pins

Pull out the signal pins with a pair of pliers.

NOTE! There are totally 10 signal pins.

3 Replace signal pins

Fit the new signal pins by pushing them into

the sleeves.

NOTE! The brass coloured part of the signal

pins should be pressed fully into the sleeve.

4 Power on Unlock the circuit breaker and switch the power

on.

M0403-1 ver 2.4 33

4.4.3 Replacement of O-ring

Action Note

1 Remove O-ring

Remove the O-ring on the ball holder at the

tool changer.

2 Clean surface Clean the surface at the O-ring location.

3 Mount new O-ring

4 Apply grease Add a small amount of grease (Magnalube-G)

on the new O-ring.

4.5 Complete service of tool changer

We recommend a complete service on tool changers to be carried out every 5 years. This will ensure proper function and increase the lifespan of the tool changer considerably. We further recommend that the maintenance shall be carried out by qualified RSP personnel. Please contact us for a quotation.

The 5 year tool changer service at Robot System Products includes inspection and cleaning of the full unit, replacement of all wear parts including sealings and signal pins.

4.6 Replacement of tool changer

Recommended tools

Tools Applications

Complete set of Allen keys For dismounting and mounting of tool

changer


Dismounting the tool changer

Action Note


2 Dismount tool Leave tool, with tool attachment

mounted, in tool stand.

3 Service position Place the robot in service position.

NOTE! The tool change function shall

be in locked position.

34 M0403-1 ver. 2.4

4 Power off Switch the power off and lock the circuit

breaker.

NOTE! Read the safety chapter for the

robot.

5 Pneumatic air off NOTE! The pressure in the pneumatic

system must be released before

dismounting begins.

6 Dismount hoses

Dismount the air hoses from the tool

changer.

NOTE! Make sure that no dirt enters

into the air hoses.

7 Release electrical connectors

(TC100-8E only)

NOTE! Handle the contact with care, as

it is sensitive to mechanical damage.

Make sure that no dirt enters the

contacts.

8 Remove screws

Remove the screws holding the tool

changer to the robot flange.

WARNING! The tool changer is heavy

and may cause personal injury and

equipment damage if dropped.

NOTE! Be careful not to damage the

signal pins at the tool side of the tool

changer.

9 Dismount tool changer

NOTE! A guide pin is mounted between

the tool changer and the robot flange

10 Clean the robot flange/adaptation

plate

11 Mount replacement tool changer Follow instructions in section 3.3.

M0403-1 ver 2.4 35

5 SPARE PARTS

5.1 Part list for tool changer P0401 and P403

36 M0403-1 ver. 2.4

Item Description Part number Wear part Pcs

1 Bolt M10x50 21212519-501 6

2 O-ring I0231 X 1

3 Air sealing I0230 X 8

4 Ball 2213874-12 8

5 O-ring I0113 1

6 O-ring I0228 1

7 O-ring I0184 1

8 Signal pin I0042 X 1

9 O-ring I0229 1

10 Spring I0768 1

11 O-ring I0113 1

12 O-ring I0266 1

13 Proximity switch I0234 1

14 O-ring I0090 8

15 Pin 5217649-3 12

16 Connector I0200 1

17 O-ring 21520392-3 1

18 Guide pin CPK 8x60 1

M0403-1 ver 2.4 37

5.2 Part list for tool attachment P0407 and P0409


1 Cable gland I0269 1

2 Circuit board A0199-213 1

3 Cover P0196-011 1

4 O-ring I0235 1

5 Screw 21212519-226 4

38 M0403-1 ver. 2.4

5.3 Part list for tool attachment P0418


1 M12-connector I0237 4


3 Cover P0196-011 1

4 O-ring I0235 1

5 Screw 21212519-226 4

M0403-1 ver 2.4 39

5.4 Part list for square tool attachment P0402 and P0404


1 Cable gland I0269 1


3 Cover P0196-011 1

4 O-ring I0235 1

5 Screw 21212519-232 4

40 M0403-1 ver. 2.4

6 DISPOSAL AND RECYCLING

Taking care of spent equipment

Used equipment must be taken care of in an environmentally-friendly way.

When disposed of, a major share of the material, or its energy content, can be recycled. The quantities possible to recycle vary depending on technical resources and practises in respective country. Non-recyclable components shall be handed over to an authorized environmental waste treatment facility for destruction or disposal.

Electronics

Electronic equipment shall be sent to an authorized recycling company or sorted into different component materials and treated as such.

Metals

Metals can, in general, be melted down, recycled and used in new products. They shall be sorted according to type and surface coating and handed over to an authorized recycling facility.

Metal components of steel and aluminium are substantial in size and easy to identify. Copper is primarily used in transmission of power for spot welding. Silver or gold plating of contact surfaces may occur.

Plastics

Thermoplastics can, in general, be re-heated and recycled without any major loss of quality. They shall be handed over to an authorized recycling facility. POM occurs in swivel housings, etc. PTFE in some sealings.

Rubber

Rubber shall be handed over to an authorized environmental waste treatment facility either for recycling, disposal or destruction. Rubber occurs in O-rings.

Other material

All other material shall be sorted and handed to an authorized environmental waste treatment facility in accordance with national legislation.

M0403-1 ver 2.4 41

42 M0403-1 ver. 2.4

Documents

Product Manual · 2019. 11. 7. · Product Manual Tool changer TC100 M0403-1 | Swivels | Swivel tool changers | Grippers | Hose packages | Valve u nits | Tool systems. 2 M0403-1 ver