Transcript
Quick-Change Installation and Operation Manual Document #9620-20-b-303 base tool changer-08
Table of Contents B. Base Tool Changer ......................................................................................................2 QC-303—Robotic Tool Changer......................................................................................2 1.
2.
Product Overview ....................................................................................................... 2 1.1
Master Plate Assembly....................................................................................... 2
1.2
Tool Plate Assembly .......................................................................................... 3
Installation .................................................................................................................. 4 2.1
Master Interface ................................................................................................. 4
2.2
Tool Interface ..................................................................................................... 5
2.3
Tool Stand Design ............................................................................................. 5 2.3.1 Tool Locating Features ........................................................................... 6 2.3.2 Tool Stand Sensors ................................................................................ 7
2.4 3.
4.
Pneumatic and Electrical Connections ............................................................... 7
Operation .................................................................................................................... 7 3.1
Coupling Sequence ............................................................................................ 7
3.2
Fail-Safe Operation ............................................................................................ 8
3.3
Uncoupling ......................................................................................................... 8
Maintenance................................................................................................................ 9 4.1
Preventive Maintenance ..................................................................................... 9
4.2
Cleaning, Lubrication, Adjustment and Replacement ....................................... 11 4.2.1 Cleaning and Lubrication of the Locking Mechanism and Alignment Pins (Master Plate). ............................................................. 11 4.2.2 Cleaning the Locking Mechanism and Alignment Pin Bushings (Tool Plate). .......................................................................................... 12
5.
Troubleshooting ....................................................................................................... 13
6.
Recommended Spare Parts ..................................................................................... 13
7.
Specifications ........................................................................................................... 14
8.
Drawings ................................................................................................................... 15 8.1
QC-303 Master Plate Assembly ....................................................................... 15
8.2
QC-303 Tool Plate Assembly ........................................................................... 16
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Quick-Change Installation and Operation Manual Document #9620-20-b-303 base tool changer-08
B. Base Tool Changer QC-303—Robotic Tool Changer 1. Product Overview 1.1
Master Plate Assembly The Master base assembly includes an anodized aluminum body, a hardened stainless-steel locking mechanism, hardened steel alignment pins and self-sealing ports. (See Figure 3.1) The body or Master plate has (4) flat sides for mounting of optional modules. The locking mechanism consists of a cylindrical housing with holes that retain hardened chrome-steel balls. Tapered pins located on the master body mate with holes in the tool body to ensure repeatable alignment during the coupling process. A thin film of grease is applied to the ball bearings and pins to enhance performance and maximize life of the components. A 1/4 NPT connection is available to supply air pressure for coupling and uncoupling the Tool Changer. A proximity sensor is designed into the body of the Master plate to verify Tool plate presence when coupled. The sensor provides a ready-to-lock (RTL) signal through the control/signal Master Module.
Air Supply Lock/Unlock
Master Plate (Body)
Prox Sensor RTL
(9) Ball Bearings (2) Tapered Alignment Pins
Locking Mechanism Self-sealing Port Figure 1.1—Master Plate Assembly
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Quick-Change Installation and Operation Manual Document #9620-20-b-303 base tool changer-08
1.2
Tool Plate Assembly The Tool base assembly includes an anodized aluminum body and a hardened stainless-steel bearing race. The Tool plate has (4) flat sides for mounting of optional modules.
RTL Sensor Target
Tool Plate (Body)
Bushings (2) for Alignment Pin Location
Self-sealed Ports
Bearing Race
Figure 1.2—Tool Plate Assembly
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Quick-Change Installation and Operation Manual Document #9620-20-b-303 base tool changer-08
2. Installation 2.1
Master Interface The Master assembly is attached to the robot arm. The Master plate is designed with mounting features such as a boss and/or bolt and dowel holes. These features are used to accurately position and secure the Master to the robot. Most often a robot interface plate (RIP) is utilized to adapt the Master plate to a specific robot flange that is not compatible with the Master plate mounting features. Custom RIP’s are available upon request. (Refer to drawings in Section 8—Drawings of this manual for technical information on mounting features). All fasteners used to mount the Tool Changer to the robot and to user tools should be tightened to a torque specification of 680 in-lbs. Also, removable (blue) Loctite 242 must be used on these fasteners. Fasteners must have an engagement of at least 2X fastener diameter. A sensor interface plate (SIP) is specified when Tool Changer Lock and Unlock (L/U) sensing is required. The SIP is a special interface plate that contains two (2) sensors for detecting the state of the locking mechanism. (See Figure 4.1 for a typical installation arrangement.)
Master Plate Assembly with DC45 and PV3 Modules
Tool Plate Assembly with DC45 and PV3 Modules
Figure 2.1—Typical Installation If the customer chooses to design and build a robot interface plate, the following should be considered: The interface plate should be designed to include bolt holes for mounting, dowel pins and a boss for accurate positioning on the robot and Master Plate. The interface plate must be properly designed to provide rigid mounting to the Master plate Pinnacle Park 1031 Goodworth Drive Apex, NC 27539 Tel: 919.772.0115 Fax: 919.772.8259 www.ati-ia.com Email:
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Quick-Change Installation and Operation Manual Document #9620-20-b-303 base tool changer-08 boss area and to maintain a gap between the interface plate and the body outside of the boss. The plate design should take into account clearances required for Tool Changer module attachments and accessories.
2.2
Tool Interface The Tool Plate is attached to customer-supplied tooling. The Tool Plate is designed with mounting features such as a recess and/or bolt and dowel holes. These features are used to accurately position and secure the end-effector. Most often an End-effector Interface Plate (EIP) is utilized to adapt the Tool Plate to an end-effector that is not compatible with the Tool Plate mounting features. Custom EIPs can be supplied by ATI to meet customer requirements. (See Figure 2.1) (Refer to the application drawing). When the customer chooses to design and build an EIP, the following should be considered: The interface plate should be designed to include bolt holes for mounting, dowel pins and a boss that mates with tool body recess for accurate positioning. The plate design should take into account clearances required for Tool Changer module attachments and accessories.
2.3
Tool Stand Design CAUTION: Tool Stand design is critical to proper operation of the Tool Changer. Improperly designed Tool Stands can cause misalignments that will cause jamming and/or excessive wear of Tool Changer components. CAUTION: During coupling and lock-up, the Tool Stand must allow for movement (float) in a plane parallel to the mating surfaces of the Master plate and Tool plates, and in a direction perpendicular to this plane towards the Master plate. In most cases, the tools are stored in a Tool Stand when not being used by the robot. During coupling and lock-up the Tool Stand must allow for movement (float) in a plane parallel with the mating surfaces of the Master Plate and Tool Plates (X and Y). Even slight misalignment between the Master Plate and Tool Plate can generate high forces during lock-up if the Tool Plate is not allowed to float into place during lock-up. These high forces can cause excessive wear and even jamming of the end effector and robot. The degree of float required depends on the accuracy of the robot’s positioning and the repeatability of the tool location in the Tool Stand during lock-up. See Figure 2.2 and Table 2.1 for recommended maximum allowable float (offsets) prior to coupling. The Tool Stand should be designed to minimize misalignment during coupling and uncoupling. In some cases greater offsets than shown in Table 2.1 can be accommodated by the Master and Tool Plates, but will increase wear. Ideally, the tool should be hanging vertically in the Tool Stand so that gravity acts to uncouple the Tool Plate from the Master Plate during unlocking. It is possible to design Tool Stands that hold tools in the horizontal position, but care must be taken that the necessary compliance is provided during coupling and uncoupling. In general, “horizontal-position” Tool Stands cause more wear on the locking mechanism and locating features of the tool and Tool Stand. Lock-up should occur with the Master Plate in the No-Touch™ Locking zone (see Table 2.1) but not touching the Tool Plate. As locking occurs, the Master Plate should draw the Tool Plate into the locked position. Tool Stands may also need to incorporate means for covering tools and electrical modules to protect them in dirty environments such as grinding or welding. Alternatively, locating Tool Stands in areas shielded from weld spatter, fluids, adhesives or other debris would eliminate the need for tool covers.
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Quick-Change Installation and Operation Manual Document #9620-20-b-303 base tool changer-08
Cocking Offset (About X and Y) X, Y and Z Offset Figure 2.2—Offset Definitions
Model
No-Touch Zone Z Offset (Max)* (mm)
X and Y Offset (Max)† (mm)
Cocking Offset (Max) (degrees)
Twisting Offset (Max) (degrees)
QC-303
±2.5
±2
±0.7
±1
Table 2.1 – Maximum Recommended Offsets Prior to Coupling Notes: * Maximum values shown. Decreasing actual values will minimize wear during †
coupling/uncoupling. Actual allowable values may be higher in some cases but higher offsets will increase wear during coupling.
2.3.1
Tool Locating Features The tool must be positively and repeatably located in the Tool Stand. A variety of methods may be used to accomplish this. Whatever method is chosen it is important that the required compliance or “float” be built into the locating system. A common method is to use tapered dowel pins in holes. As the Tool Plate is lifted during locking, the taper lets the tool float into its locked position even with small deviations in robot position. Other tool locating feature methods include balls and detents, dowel pins in notched V-grooves, etc. Please consult ATI for recommendations or assistance with locating feature design for your particular tooling. Straight cylindrical dowel pins should not be used as they provide too much surface engagement. During coupling and uncoupling the tool can bind on these pins due to misalignment of the Master and Tool Plates. Robot programming and locational repeatability are vital in tool pick-up and drop-off.
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Quick-Change Installation and Operation Manual Document #9620-20-b-303 base tool changer-08
2.3.2
Tool Stand Sensors It is highly suggested that the customer provide a sensor that detects the presence of a properly seated tool in the Tool Stand. The sensor may be used prior to coupling to ensure there is a tool properly seated in the stand. Sensors may also be used as the robot starts to move away after uncoupling. This provides a fail-safe measure in the event that a tool should become jammed in the stand or if the tool should fail to release properly from the robot. Proximity sensors should be located so that the sensing face is vertical to prevent swarf or other debris from falling on the sensor and creating false readings.
2.4
Pneumatic and Electrical Connections The air supply used for coupling and uncoupling the Tool Changer should be clean, dry and non-lubricated. A supply pressure in the range of 60 to 100 psi is acceptable for operation of the locking mechanism, with a setting of 80 psi suggested. The air should be filtered 50 micron or better. CAUTION: Do not use the Tool Changer in the fail-safe condition for extended periods of time. Do not transport the Tool Changer in the failsafe condition. Possible damage to the locking mechanism could occur.
3. Operation The Master locking mechanism is pneumatically driven to couple and uncouple with the bearing race on the Tool Plate. The Master Plate utilizes air ports from a control module to provide lock and unlock pressure to the locking mechanism. CAUTION: Safe, reliable operation of the Tool Changer is dependent on a continuous supply of compressed air at a pressure of 60–100 PSI. Robot motion should be halted if the air supply pressure drops below 60 PSI for any reason. ATTENTION: All Tool Changers are initially lubricated using MobilGrease® XHP222 Special grease. The end user must apply additional lubricant to the locking mechanism components and alignment pins prior to start of service (See Section 4.2—Cleaning, Lubrication, Adjustment and Replacement). Tubes of lubricant for this purpose are shipped with every Tool Changer. Note: MobilGrease® XHP222 Special is a NLGI #2 lithium complex grease with molybdenum disulfide.
3.1
Coupling Sequence CAUTION: The locking mechanism must be in the unlock position when attempting to couple the Tool Changer. Failure to adhere to this condition may result in damage to the unit and/or the robot. Position the Master above the Tool and move the Master into locking position. The mating surfaces of the Master and Tool should be parallel and not touching. Make sure that the tapered alignment pins from the Master enter the alignment holes on the Tool. The alignment pins should be relatively concentric with the alignment holes such that they do not rub against the edge. The locking mechanism allows the Master to “pull up” the Tool with relatively large gaps between the two sides. It is recommended that the mating faces of the Master and Tool not be touching, but be within 0.04” (1 mm) of each other when coupling to minimize stress and wear on the locking mechanism.
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Quick-Change Installation and Operation Manual Document #9620-20-b-303 base tool changer-08 RTL (Ready-To-Lock) sensing is built into the Tool Changer, providing the ability to sense Tool proximity to the Master prior to locking. The mating faces of the Master and Tool must be positioned within approximately 0.02–0.03” (0.50–0.75mm) of each other for the sensor to detect Tool presence. A RTL signal is not required to couple the Tool Changer, but is recommended as a further confirmation of coupling prior to removing the Tool from the Tool Stand. TM
CAUTION: No-Touch locking technology allows the unit to couple with a separation distance between the Master and Tool. Direct contact of the Master and Tool mating surfaces is not suggested or required just prior to coupling. Contact may result in damage to the unit and/or the robot. Verify that the RTL signal is read as “on” (true). Turn the Lock command on. The solenoid valve is shifted to the Lock position and air is supplied to the locking mechanism to couple the Tool Changer. A sufficient delay must be programmed between the Lock command being activated and reading the state of the Locked/Unlocked signals, so that the locking process is completed before checking the locked state. Read the Locked and Unlocked signals via the control module. The Locked signal should read “on” (true) and the Unlocked signal should read “off” (false). If the locking mechanism has been actuated and both the Locked and Unlocked signals are read as “off” (false), then a “missed tool” condition has occurred (for example, the Tool is not in the stand or is not positioned properly). In this case an error should be generated and the robot program halted. The situation requires manual inspection to determine the cause of the problem. The locking mechanism must be in the Unlocked state before another attempt is made to couple or damage could occur to the robot and/or the Tool Changer.
3.2
Fail-Safe Operation In the event of air supply loss to the locking mechanism the Tool Changer will not uncouple. A slight separation between the Master and Tool Plates occurs just after air loss, but at this point the locking balls become trapped and cannot move without air pressure being applied to the unlock port. This feature provides the Tool Changer with a fail-safe mechanism. ATI’s patented fail-safe design prevents the Tool Plate from being released in the event of airpressure loss to the Lock port, thereby increasing safety and reliability. Positional accuracy may not be maintained during air loss but will be regained once air pressure is re-established to the Lock port.
3.3
Uncoupling The Tool Changer should be positioned in the Tool Stand in the same location as that when coupling took place. CAUTION: This Tool Changer is equipped with a Tool Stand Interlock (TSI) feature that physically breaks the unlock solenoid circuit. Use of the TSI will prevent any unwanted unlock software commands from being recognized until the circuit is made. Turn the Lock command off. Issue the Unlock command. The solenoid valve is shifted to the Unlock position and air is supplied to the locking mechanism to uncouple the Tool Changer.
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Quick-Change Installation and Operation Manual Document #9620-20-b-303 base tool changer-08 A sufficient delay must be programmed between Unlock command being activated and reading the state of the Locked/Unlocked signals, so that the locking process is completed before checking the locked state. Read the Locked and Unlocked signals. The Unlocked signal should read “on” (true) and the Locked signal should read “off” (false). Any other condition indicates a problem and the robot program should be halted. Once the Lock and Unlock signals are verified to be in the proper state the Master Plate may be moved away from the Tool Plate in the axial direction. The robot and Master Plate can now proceed to another Tool for coupling and subsequent operations.
4. Maintenance ATTENTION: The cleanliness of the work environment strongly influences the trouble-free operation of the changer. The dirtier the environment, the greater the need for protection against debris. Protection of the entire EOAT, the master, the tool and all of the modules may be necessary. Protective measures include the following: 1) Placement of tools stands away from debris generators, 2) covers incorporated into the Tool Stands (see Section 2.3—Tool Stand Design), and 3) guards, deflectors, air curtains, and similar devices built into the EOAT and the Tool Stand.
4.1
Preventive Maintenance The Tool Changer and optional modules are designed to provide a long life with regular maintenance required. A visual inspection and preventative maintenance schedule is provided in the table below depending upon the application. Detailed assembly drawings are provided in Section 8—Drawings of this manual.
ATTENTION: All Tool Changers are initially lubricated using MobilGrease® XHP222 Special grease. The end user must apply additional lubricant to the locking mechanism components and alignment pins prior to start of service (See Section 4.2—Cleaning, Lubrication, Adjustment and Replacement). Tubes of lubricant for this purpose are shipped with every Tool Changer. Note: MobilGrease® XHP222 Special is a NLGI #2 lithium complex grease with molybdenum disulfide.
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Quick-Change Installation and Operation Manual Document #9620-20-b-303 base tool changer-08
Application(s)
General Usage Material Handling Docking Station
Welding/Servo/ Deburring, Foundry Operations (Dirty Environments)
Tool Change Frequency
Inspection Schedule
> 1 per minute
Weekly
< 1 per minute
Monthly
All
Weekly
Checklist Balls/Alignment Pins/Holes/Bearing Race Inspect for lubrication and wear. A NLGI #2, lithium-based grease with molybdenum disulfide additive is suggested for locking mechanism and alignment pin lubrication. Over time, lubricants can become contaminated with process debris. Therefore, it is recommended to thoroughly clean the existing grease and replace with new as needed. See Section 4.2—Cleaning, Lubrication, Adjustment and Replacement. Excessive alignment pin/bushing wear may be an indication of poor robot position during pickup/drop-off. Adjust robot position as needed. Check Tool Stand for wear and alignment problems. Wear on the balls/bearing race could be an indication of excessive loading. Mounting Hardware/Interface Connections Inspect for proper torque and interference or wear, abrasions, cuts of hoses, and electrical cables. Tighten and correct as required. O-rings/Rubber Bushings Inspect for wear, abrasion, and cuts. Exposed o-rings and rubber bushings may be subject to damage during normal operation. Replace damaged o-rings and rubber bushings as needed. Electrical Contacts Inspect for wear and abrasion. Exposed contacts may be subject to damage during normal operation. Clear debris from the area of the contacts using compressed air. Do not directly clean contacts as abrasion may occur and the performance of the contact may be compromised.
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Quick-Change Installation and Operation Manual Document #9620-20-b-303 base tool changer-08
4.2
Cleaning, Lubrication, Adjustment and Replacement 4.2.1
Cleaning and Lubrication of the Locking Mechanism and Alignment Pins (Master Plate). 1. The locking mechanism must be in the unlock state before cleaning. 2. Use a clean rag to thoroughly remove the existing lubricant and debris from the balls, the male coupling, the cam and the alignment pins.
Cleaning balls and outer surfaces of male coupling. (QC-210 shown)
3.
Cleaning balls, cam and inner surfaces of male coupling. (QC-210 shown)
Check each ball to make sure it moves freely in the male coupling. Additional cleaning may be necessary to free up any balls that are sticking in place.
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Quick-Change Installation and Operation Manual Document #9620-20-b-303 base tool changer-08
4.
4.2.2
Apply a liberal coating of lubricant to the balls, the male coupling (inside and out), and the alignment pins.
Cleaning the Locking Mechanism and Alignment Pin Bushings (Tool Plate). 1. Use a clean rag to thoroughly remove the any lubricant and debris from the bearing race and the bushings. 2. No re-lubrication is necessary on the Tool Plate components.
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Quick-Change Installation and Operation Manual Document #9620-20-b-303 base tool changer-08
5. Troubleshooting Symptom
Possible Cause / Correction
Check these conditions prior to any further troubleshooting.
Ensure that the Quick-Change has proper pneumatic and electrical connections, air is supplied at a minimum of 60psi (4.1 Bar), that no air or vacuum can be trapped in a de-energized Lock or Unlock Port (pressure must be vented to atmosphere). Check air supply
Unit will not lock or unlock
Verify that ball bearings are moving freely. Clean and lubricate as needed to restore smooth operation (see Section 4—Maintenance). Verify the control module is operating correctly. Verify that the Master and Tool are within the specified No-Touch zone when attempting to lock.
6. Recommended Spare Parts Assembly Master Plate
Part Number 9120-303NM-0-000-0
Complete QC-303 Master Plate, No Options
8590-9909999-08
PNP Proximity Sensor
9005-20-1060
Alignment Pin
3700-20-1452 3700-20-1453 9120-303M-Seals 9000-20-1009
Includes U-cup (3410-0001068-01), 14mm x 2mm Buna O-ring (3410-0001065.01), 6mm x 2mm Buna O-ring (3410-0001066-01), 8mm x 1mm Buna O-ring (3410-0001064-01), Spring (3700-20-1459) Check Valve Valve Stem QC-303 Master Seal Kit Prox Cable Assembly (3 Inputs)
3700-20-1511
Male coupling
3700-20-1514 3410-0001046-01 3410-0001048-01
Ball bearing, 24m O-ring, P30, 1.16” ID, 0.137” CS O-ring, AS568A Nitrile, 133mm ID, 1.5mm CS
9120-303NT-0-000-0
Complete QC-303 Tool Plate, No Options
3700-20-1508 3410-00011370-01 3410-0001067-01 3700-20-1457 3700-20-1460 3540-0101750-21 3700-20-3289 3690-2600001-11
Bearing Race O-ring, 16mm x 1.5mm, Buna N O-ring, 10mm x 2mm, Buna N Check Valve Piston Spring 1/16” Dia. X ¾” Dowel Pin, SS Plug, Plastic Retaining Ring, Internal, 13/16”
9120-F2-M-KIT
Locking Mechanism
Tool Plate
Description
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Quick-Change Installation and Operation Manual Document #9620-20-b-303 base tool changer-08
7. Specifications Master and Tool Plates Suggested Payload Limit
1003 lbs (455kg)
Operating Temperature Range
-20–150 F o (-30–66 C)
Operating Pressure Range
60–100psi (4.1-6.9bar)
Locking mechanism supply pressure operating range. Supply to be clean, dry and filtered to 50 micron or better.
Coupling Force @ 80psi
7940lbs (35333N)
Axial holding force.
Static Moment Capacity (x, y)
29,100in-lb (3870Nm)
Maximum recommended working load for optimum performance of the Tool Changer.
25,000in-lb (2825 Nm)
(Torsion).
Positional Repeatability
0.0006in (0.015mm)
Repeatability tested at rated load at one million cycles.
Weight (coupled)
25.5 lbs. 14.2 lbs.
Master Tool
Max. Recommended distance between Master and Tool Plate
0.10in (2.5mm)
No-Touch locking technology allows the Master and Tool Plates to lock with separation when coupling.
Sensor Information, signal name
L/U (Lock/Unlock)
Proximity sensors (2) with quick disconnect connectors wired into the DeviceNet Master Module to indicate locking mechanism position.
RTL (Ready-To-Lock)
Proximity sensor with quick disconnect connector wired into the Signal Master Module to indicate Master and Tool mating surfaces within close proximity of each other.
Master Plate SIP
Customer-Specified Robot Pattern
Tool Plate
Meets ISO 9409-1-A160
(z)
Mounting Surface/Customer Interface
The mass attached to the Tool Changer.
o
TM
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Quick-Change Installation and Operation Manual Document #9620-20-b-303 base tool changer-08
8. Drawings 8.1
QC-303 Master Plate Assembly
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Quick-Change Installation and Operation Manual Document #9620-20-b-303 base tool changer-08
8.2
QC-303 Tool Plate Assembly
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