Manual Changer QMT 6600 QMT 7600 - ABB Ltd · 3HXC 7412-1 Rev.0, Sep 2002 i Contents Product Manual...

Product ManualManual Changer

QMT 6600QMT 76003HXC 7412-1 Rev.0, Sep 2002

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The information in this document is subject to alteration without prior notice and should not be regarded as an

undertaking from ABB Automation Technology Products AB. ABB Automation Technology Products AB assumes

no responsibility for errors that may occur in this document.

ABB Automation Technology Products AB bears no responsibility for damage that is a consequence of using this

document or the software or hardware described in this document.

The document, or parts of it, may not be reproduced or copied without prior permission from ABB Automation

Technology Products AB. It may neither be imparted nor otherwise used without authorisation. Infringement hereof

will be subject to action in accordance with applicable laws.

Further copies of this document can be obtained from ABB Automation Technology Products AB at current prices.

(c) ABB Automation Technology Products AB

Article number: 3HXC 7412-1 Rev.0, Sep 2002

ABB Automation Technology Products AB

Arc Welding & Application Equipment

Robot Peripherals

SE-721 75 Västerås

Sweden

3HXC 7412-1 Rev.0, Sep 2002 i

Contents

Product ManualManual ChangerQMT 6600 QMT 7600

Specification Flap 1:

Description 1

Safety instructions 5

Technical specifications and requirements 7

Variants (and options) 11

Installation and operation Flap 2:

Unpacking and handling 1

Mechanical installation 3

Maintenance Flap 3:

Maintenance intervals 1

Maintenance instructions 3

Spare parts 5

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3HXC 7412-1 Rev.0, Sep 2002 Specification i

Flap 1: SpecificationChapter 1: Description 1

General 1

Terms and concepts 1Definitions 1Software requirements IRB 6600 2

Principle layout 2QMT Faceplate with clamping ring 2

Principle layout 3QMT Tool plate 3

Chapter 2: Safety instructions 5

Description 5

Safety with mechanical installation 5

Safety with commissioning 5Checking the working area 5

Safety with mechanical maintenance 5Checking the working area 5

Chapter 3: Technical specifications and requirements 7

Technical data 7Performance QMT 6600/175 7Performance QMT 6600/225 7Performance QMT 7600 7

Dimensions 7QMT 6600/175 Faceplate 8QMT 6600/175 Tool plate 8QMT 6600/225Faceplate 9QMT 6600/225 Tool plate 9QMT 7600 Faceplate 10QMT 7600Tool plate 10

Chapter 4: Variants (and options) 11

Variants (and options) for QMT 6600, QMT 7600 11Ordering list 11

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Description

3HXC 7412-1 Rev.0, Sep 2002 1-1

Chapter 1: Description

General

The manual tool changer QMT equips the robot with the capacity to rapidly install tools and

change during maintenance. Using the QMT-faceplate considerably reduces the times connected

with tool replacement and maintenance.

The tool changer is supplied fitted to the robot, but can also be supplied separately for retrofitting.

Fig. 1: Manual Changer, QMT

Terms and concepts

Definitions The table below lists terms and concepts used in the documentation.

High performance - High precision

The tool changer displaces the TCP minimally, which gives a very high handling capacity as well

as very high precision when working.

Types QMT is available in three different designs:

QMT 6600/175 adapted to an IRB 6600 (175 kg)

QMT 6600/225 adapted to an IRB 6600 (225 kg)

QMT 7600 adapted to an IRB 7600

For more information about the different robots, see the product specifications for respective

robots.

Interface to the robot

The new QMT-faceplate, which is mounted on the tool changer's robot side, replaces the robot's

original faceplate.

Clamping ring

Tool plateClamping ring

Faceplate

Securing hole,

QMT_001

axis 6 bracket

Name Definition

QMT Quick Mounting Tool

TCP Tool Center Point

IRB Industrial Robot from ABB

Description

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Interface to the customer

The tool changer QMT 7600 has the same customer interface and appearance as the original

faceplate.

Software requirements IRB 6600

The following only applies to IRB 6600.

The software limitation on axis 5 is ±114° permitted working area.

For modification, see the robot's Programming Manual.

Principle layout

QMT Faceplate with clamping ring

The illustration shows the principle layout of the unit.

Fig. 2: QMT 6600, QMT 7600

Component parts The table refers to the positions in the illustration above.

QMT_002

6

4 3512

Description Item

QMT Faceplate 1.

Locking plate 2.

Screw x 2 3.

Plain washer x 2 4.

Clamping ring x 2 5.

Guide pin 6.

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Description

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Principle layout

QMT Tool plate The illustration shows the principle layout of the unit.

Fig. 3: QMT Tool plate

Component parts The table refers to the positions in the illustration above.

QMT_003

1 2

Description Item

QMT Tool plate 1.

Guide pin 2.

Description

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Safety instructions

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Chapter 2: Safety instructions

Description

There are safety instructions in this chapter for all steps that involve a risk of personal injury or

material damage. In addition, they are written out by the instruction for each step.

General warnings where the intention is to avoid difficulties are only set out by the instruction in

question.

Personal injury or damage to the product may result if the safety instructions or the local safety

directives are not observed.

Key to symbols The different types of warnings are set out in the following chapters according to the table below:

Safety with mechanical installation

Read carefully through the safety instructions, before any activity/action is carried out within the

robot's working area.

Safety with commissioning

Checking the working area

The working area must be checked before the system is commissioned.

Safety with mechanical maintenance

Checking the working area

The working area must be checked before any maintenance is performed on the system.

Symbol Importance

Warns for the risk of personal injury or serious damage to the product. Always follow the instructions expressed in association with this symbol.

Draws your attention to the fact that damage to the product can occur if a measure is not performed or is performed incorrectly.

Information about important details.

Safety instructions

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Technical specifications and requirements

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Chapter 3: Technical specifications and requirements

Technical data

Performance QMT 6600/175

The table below contains important technical and performance data for the manual changer

QMT 6600/175.

Performance QMT 6600/225


QMT 6600/225.

Performance QMT 7600


QMT 7600.

Dimensions

The table below specifies the dimensions of the manual changers QMT 6600/7600.

Function Weight

Faceplate 4.6 kg

Tool plate 4.5 kg

Clamping ring x 2 2.2 kg/each

Function Weight

Faceplate 4.6 kg

Tool plate 4.5 kg


Function Weight

Faceplate 8.5 kg

Tool plate 8.5 kg


Component Dimensions

Faceplate 6600/175 D = 200 mm, t = 37

Faceplate 6600/225 D = 200 mm, t = 37

Faceplate 7600 D = 250 mm, t = 44.5

Clamping ring 6600/175 D = 244 mm, t = 42

Clamping ring 6600/225 D = 244 mm, t = 42

Clamping ring 7600 D = 300 mm, t = 42

Tool plate 6600/175 D = 244 mm, t = 30

Tool plate 6600/225 D = 244 mm, t = 30

Tool plate 7600 D = 300 mm, t = 37


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QMT 6600/175 Faceplate

The illustration shows the QMT 6600/175 faceplate.

Fig. 4: QMT 6600, Faceplate

QMT 6600/175 Tool plate

The illustration shows the QMT 6600/175 tool plate.

Fig. 5: QMT 6600, Tool plate

QMT_004

QMT_005

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QMT 6600/225Faceplate

The illustration shows the QMT 6600/225 faceplate.

Fig. 6: QMT 6600/225, Faceplate

QMT 6600/225 Tool plate

The illustration shows the QMT 6600/225 tool plate.

Fig. 7: QMT 6600/225, Tool plate

QMT_006

QMT_007


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QMT 7600 Faceplate

The illustration shows the QMT 7600 faceplate.

Fig. 8: QMT 7600, Faceplate

QMT 7600Tool plate

The illustration shows the QMT 7600 tool plate.

Fig. 9: QMT 7600, Tool plate

QMT_008

37

QMT_009

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Variants (and options)

3HXC 7412-1 Rev.0, Sep 2002 1-11

Chapter 4: Variants (and options)

Variants (and options) for QMT 6600, QMT 7600

Ordering list The tables describe the variants (and options) that can be order for QMT 6600, QMT 7600.

QMT 6600/175 Name Part. no.

Faceplate, assembly 3HXC 0100-384

Clamping ring, assembly 3HXC 0100-386

Tool plate, assembly 3HXC 0000-153

QMT 6600/225 Name Part. no.




QMT 7600 Name Part. no.




Variants (and options)

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3HXC 7412-1 Rev.0, Sep 2002 Installation and operation i

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Flap 2: Installation and operationChapter 1: Unpacking and handling 1

Safety 1General 1Acceptance inspection 1Cleaning 1

Chapter 2: Mechanical installation 3

Dismantle the faceplate from the robot 3IRB 6600 3IRB 7600 3

Assembling the QMT-Faceplate, 3IRB 6600 3 IRB 7600 3

Assembling the QMT-tool plate 3QMT 6600 3QMT 7600 4

Docking the tool 4IRB 6600 4IRB 7600 5

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Unpacking and handling

3HXC 7412-1 Rev.0, Sep 2002 2-1

Chapter 1: Unpacking and handling

Safety

GeneralRead through this chapter before using QMT.

Wear protective footwear with all handling of heavy objects.

Always lift heavy equipment according to the stipulated codes of practice.

Always attempt to find the most comfortable working height/working position.

Acceptance inspection

Check using the list of items that all components parts have been included in the delivery.

Check that no visible damage has occurred during transport.

Test assemble to ensure no damage has occurred during transport.

CleaningClean all components using a cloth and white spirit before assembly.

Unpacking and handling

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Mechanical installation

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Chapter 2: Mechanical installation

Dismantle the faceplate from the robot

IRB 6600 To dismantle the faceplate from the robot, refer to the Maintenance Manual for IRB 6600.

IRB 7600 To dismantle the faceplate from the robot, refer to the Maintenance Manual for IRB 7600.

Assembling the QMT-Faceplate,

IRB 6600 Assemble the QMT-Faceplate according to the instruction, refer to the Maintenance Manual for

IRB 6600.

IRB 7600 Assemble the QMT-Faceplate according to the instruction, refer to the Maintenance Manual for

IRB 7600.

Assembling the QMT-tool plate

Tools • Torque wrench:

• Hexagonal insert M12:

QMT 6600 Assembling the tool plate on the tool

WARNING! Ensure the faceplate is tightened on the robot to the specified torque. See the robot's Installation Manual for the faceplate torque.

Step Procedure name Instruction

1 Tools and tool plate Carefully clean the contact surfaces

2 Assemble QMT 6600 Assemble the stated number of screws/washers in the joint. NOTE! assemble the plate so that the holes for the guide pins are perpendicular, this makes docking easier.

NOTE! The screw length must not be longer than the thickness of the tool + 15 mm.

3 Tightening Tighten the joint to the applicable torque

4 Visual inspection Ensure the joint is secure. The guide pin must be located, see page 1-2


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QMT 7600 Assembling the tool plate on the tool

Docking the tool

Tools • Plastic mallet:

• Torque wrench:


IRB 6600


1 Tools and tool plate Carefully clean the contact surfaces

2 Assemble QMT 7600 Assemble the stated number of screws/washers in the joint. NOTE! assemble the plate so that the holes for the guide pins are perpendicular, this makes docking easier.

NOTE! The screw length must not be longer than the thickness of the tool + 20 mm.

3 Tightening Tighten the joint to the applicable torque

4 Visual inspection Ensure the joint is secure. The guide pin must be located, see page 1-2

WARNING! The robot must not be run without the clamping ring

WARNING! Rotation of axes 4 and 6 before the clamping ring is fitted can cause the tool to release.

WARNING! Ensure the tool plate and tool are tightened to the specified torque.


1. Clean Contact surfaces The contact surface between the QMT- faceplate and QMT-tool plate should be cleaned using a cloth. Clean the T-slots and pins.

2. Locking plate Ensure the locking plate works.

NOTE! If the locking plate is missing the QMT must not be used.

3. Locking plate Move the locking plate to the open position.

4. Robot Run the robot to the docking position using the jog function. NOTE! axis 6 should be set so the guide pins are perpendicular.

5. Robot Dock the plates with each other and then lift so that the tool comes into position. NOTE! Use the Jog function

WARNING! Never rotate axes 4 and 6 without the clamping ring.

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IRB 7600

6. Locking plate Move the locking plate to the closed position. WARNING! Never rotate axes 4 and 6 without the clamping ring.

7. Clamping ring Check to ensure the clamping ring is not damaged.

8. Clamping ring Fit the clamping ring halves in the slot so that the QMT-faceplate and QMT-tool plate are locked together, use a plastic mallet to knock the ring halves into position.

9. Clamping ring Assemble the two M10 screws and washer which join the two ring halves. Screw grade 12.9

10. Tighten Tightening torque crosswise 75 Nm, the gap between the halves should equal on both sides.



1. Clean Contact surfaces The contact surface between the QMT- faceplate and QMT-tool plate should be cleaned using a cloth. Clean the T-slots and pins.

2. Locking plate Ensure the locking plate works.

NOTE! If the locking plate is missing the QMT must not be used.

3. Locking plate Move the locking plate to the open position.

4. Robot Run the robot to the docking position using the jog function. NOTE! Axis 6 should be set so the guide pins are perpendicular.

5. Robot Dock the plates with each other and then lift so that the tool comes into position. NOTE! Use the Jog function WARNING! Never rotate axes 4 and 6 without the clamping ring.

6. Locking plate Move the locking plate to the closed position. WARNING! Never rotate axes 4 and 6 without the clamping ring.






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Undocking the tool

Tools • Plastic mallet:

• Drawbar handle, ratchet handle:


• Screwdriver:

WARNING! The robot must not be run without the clamping ring.


WARNING! Ensure the tool plate and tool are tightened to the specified torque.


1 Robot Jog the robot to the unloading area.

2 Robot Jog axis 6 to the changing position (i.e. the locking plate in the UP position, see the marking on the changer).

3 Dismantle the clamping ring

Dismantle the screw joint on the clamping ring.


Use a screwdriver to split the clamping rings.


Use a plastic hammer to remove the ring halves.

6 Locking plate Move the locking plate to the open position.

7 Robot Release the tool by jogging the robot in the faceplate's perpendicular direction (pos. six o'clock) approx. 4 cm. with axis 5 clamped perpendicular.

8 Robot The faceplate can now be separated by using a dividing movement with the robot still in jogging mode.

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Flap 3: MaintenanceChapter 1: Maintenance intervals 1

Routine checks and preventive maintenance 1Maintenance chart 1

Chapter 2: Maintenance instructions 3

Mechanical maintenance 3Guide pin 3Locknig plate 3Clamping ring QMT 6600 3

Chapter 3: Spare parts 5

Spare parts for QMT 6600/175 5Faceplate 5Clamping ring 6Tool plate 7

Spare parts for QMT 6600/225 8Faceplate 8Clamping ring 9Tool plate 10

Spare parts for QMT 7600 11Faceplate 11Clamping ring 12Tool plate 13

Locking plate 14QMT 6600 14QMT 7600 14

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Maintenance intervals

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Chapter 1: Maintenance intervals

Routine checks and preventive maintenance

Maintenance chart

The changer is designed to need a minimum of maintenance. However, routine checks and

preventive maintenance always need to be carried out at regular intervals.

The maintenance chart describes the routine maintenance and routine checks in chronological

order.

.

Fig. 1: QMT 6600 and 7600, maintenance

Interval Part Maintenance More info.

With each change

Guide pin Visual inspection

Locking plate Cleaning, lubrication

Discs Visual inspection

Every six months Screw, clamping rings Check the torque See Chapter 2:Mechanical installation

Clamping ring

Tool plate

Clamping ring

Faceplate

QMT_010

Maintenance intervals

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Maintenance instructions

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Chapter 2: Maintenance instructions

Mechanical maintenance

Guide pin Do the following when replacing the guide pin:

1. Heat the guide pin

2. Carefully knock the guide pin at the same time as it is unscrewed.

3. Screw in the new guide pin until it bottoms. Apply Loctite 270.

Locking plate Do the following if the locking plate breaks:

1. Remove the remaining parts of the locking plate.

2. Fit a new locking plate.

Changing the oil axis 6, changer.

Clamping ring QMT 6600

WARNING! The robot must not be run without the clamping ring.


1. Clamping ring Dismantle the clamping ring from the QMT-changer.

2. Changing the oil Refer to the manual for IRB 6600 to change the oil.

3. AbsAcc-calibration If the robot needs to be AbsAcc-calibrated, see the manual for IRB 6600.





Maintenance instructions

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Clamping ring QMT 7600 1. Clamping ring Dismantle the clamping ring from the QMT-

changer.

2. Changing the oil Refer to the manual for IRB 7600 to change the oil.

3. AbsAcc-calibration If the robot needs to be AbsAcc-calibrated, see the manual for IRB 7600.


5. Clamping ring Check to ensure the clamping ring is not scored.



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Spare parts

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Chapter 3: Spare parts

Spare parts for QMT 6600/175

Faceplate Spare parts for QMT 6600/175, Faceplate

Fig. 2: 1QMT 6600/175 Faceplate

Quantity Description Art. no. Item

Faceplate assembly 3HXC 0100-384

1 Faceplate 3HXC 1000-170 1

1 Guide pin 3HXC 1000-171 2

1 Locking plate 3HXC 0100-385 3

1 Cylindrical pin 3ABA 107-7 4

1

2

3,4

QMT_011

Spare parts

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Clamping ring Spare parts for QMT 6600/175, Clamping ring

Fig. 3: QMT 6600/175 Clamping ring


Clamping ring assembly 3HXC 0100-386

2 Clamping ring 3HXC 1000-165 1

2 Screw M10 9ADA 183-55 2

2 Lock washer twisted tooth 3HXB 1154-3 3

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Tool plate Spare parts for QMT 6600/175, Tool plate:

Fig. 4: QMT 6600/175 Tool plate


QMT Tool plate assembly 3HXC 0000-153

1 QMT Tool plate 3HXC 1000-166 1


1 2

QMT_013

Spare parts

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Spare parts for QMT 6600/225

Faceplate Spare parts for QMT 6600/225, Faceplate

Fig. 5: QMT 6600/225 Faceplate







1

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3,4

QMT_014

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Clamping ring Spare parts for QMT 6600/225, Clamping ring

Fig. 6: QMT 6600/225 Clamping ring




2 Screw M10 9ADA 183-55 2

2 Washer 3HXB 1154-3 3

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QMT_015

Spare parts

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Tool plate Spare parts for QMT 6600/225, Tool plate

Fig. 7: QMT 6600/225 Tool plate





1 2

QMT_016

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Spare parts

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Spare parts for QMT 7600

Faceplate Spare parts for QMT 7600, Faceplate

Fig. 8: QMT 7600 Faceplate





1 Locking plate assembly 3HXC 0100-389 3


1

2

3,4

QMT_017

Spare parts

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Clamping ring Spare parts for QMT 7600, Clamping ring

Fig. 9: QMT 7600 Clamping ring




2 Screw M12 21212518-546 2

2 Washer 3HXB 1154-5 3

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Tool plate Spare parts for QMT 7600, Tool plate

Fig. 10: QMT 7600 Tool plate





1 2

QMT_019

Spare parts

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Locking plate

QMT 6600

Fig. 11: QMT 6600 Locking plate

QMT 7600

Fig. 12: QMT 7600 Locking plate


Locking plate assembly 3HXC 0100-385


1 Spring-loaded locking pin 3HXB 1000-619 2

1 2

QMT_020


Locking plate assembly 3HXC 0100-389


1 Spring-loaded locking pin 3HXB 1000-619 2

1 2

QMT_021

3HXC 7412-1 Rev.0, Sep 2002

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