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Summary of Contents for Walther prazision 91489
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Working Instruction english Revision Datum 17.03.2006 Ersteller This operating instruction is not subject to the updating Tool changer for industrial robot typ 91489 carrying force 25 KN 1-91489-2-FT524-AAAB-Y10-LI 1-91489-0-LT524-AAAB-Y10-LI...
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Working instruction english typ 91489 This coupling is a high-quality product with particular focus on high functionality, simple handling, safety and reliability. As a technical component the coupling is designed for the use in the industrial field and for operators who were trained by specialists with the handling of technical systems / tools.
Working instruction english typ 91489 List of Contents List of contents LIST OF CONTENTS ........................3 GENERAL ............................7 SAFETY INSTRUCTIONS........................8 PROOF DOCUMENTATION ACCORDING TO EC MACHINERY GUIDELINES ....9 ........................9 YSTEM DESCRIPTION .......................10 ENERAL DESCRIPTION ..........................10 ULY USAGE ......................11 BVIOUS IMPROPER USE TECHNICAL DATA ........................12...
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Working instruction english typ 91489 List of Contents COMMENTS TO APPLICATION PREPARATION FEHLER! TEXTMARKE NICHT DEFINIERT...............................29 .......29 ENERAL SAFETY INSTRUCTIONS EHLER EXTMARKE NICHT DEFINIERT ...........29 UNCTIONAL SEQUENCES EHLER EXTMARKE NICHT DEFINIERT 8.2.1 Push-pull technique Fehler! Textmarke nicht definiert............29 8.2.2...
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List of Contents 11.1.1 1-91489-2-FT524-AAAB-LI-Y10 tool changer – robot side LWL welding 1-91489-0-LT524-AAAB-LI-Y10 tool changer – tool side LWL welding ........44 1-91489-B-FT001-AAAB-LI elements equipment (robot side) welding........44 1-91489-B-LT001-AAAB-LI elements equipment – (tool side) welding........44 11.1.2 1-91489-B-FT500-AAAA-Y10 basic module (robot side) ....52...
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............161 ONNECTION AND FLOW SCHEDULES LOAD DIAGRAM 11.2.1 1-91489-D-00004-..-Y10 Mechanical interfaces to 91489-Y10 ..162 11.2.2 1-91489-D-00002 Mechanical interfaces / flanges of tool changer 91489 11.2.3 1-91489-D-00008-Y10 adjustment plan limit switch ......166 11.2.4 1-91489-F-00007-..-Y10 security module 2 / park station with cover 11.3...
Working instruction english typ 91489 General General This manual contains all regulations for operation, commissioning and maintenance of the Tool changer 91489. All information and references in this operating instruction were compiled under consideration of the valid regulations, the current engineering development stage as well as our years of knowledge and experiences.
Working instruction english typ 91489 Safety instructions Safety instructions The usage of this coupling requires from the operator to observe all relevant industrial safety regulations. It is up to the duty of care of the user of the coupling to plan protective measures which guarantee an orderly operation and to control their realization.
Working instruction english typ 91489 Proof documentation Proof documentation according to EC machinery guidelines System description The tool quick change system is a mechanic, electric, pneumatic and hydraulic interface between industrial robots and working-, assembling- or handling tools. Scope of delivery: The tool quick change system consists of: - tool changer part –...
While the tool changer type Z03 can be operated in pull-in and push-pull technique type 91489-Y10 is provided for force neutral push-pull technique. Duly usage The tool change system is no independent machine within the meaning of the EC machinary guidelines and is only allowed to put into operation in case that the total facility corresponds to the instructions of the machinary guidelines.
Working instruction english typ 91489 Proof documentation The provided kind of operation is push-pull-technique, i.e. robot carries out couple movement and tool changer locks the connected changer halves. Besides the valve spring forces of the fluidic elements and the frictional forces the robot must take up no further reaction forces (force neutral push-pull technique) in the process.
Working instruction english typ 91489 Technical data Technical data Overall height 96 mm; main dimensions according to drawing. Weights: • robot side = 9.2 kg at max. population in standard version • tool side = 6.2 kg at max. population in standard version.
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Working instruction english typ 91489 Technical data...
Working instruction english typ 91489 Description of equipment Description of equipment Max. 8 pressure or cooling water elements can be mounted in any combination (sideways assembly): Medium Type Nominal Max. Connection Housing Valve Valve tool bore pressure material (robot side...
Working instruction english typ 91489 Description of equipment Application: control current Type Number Rated Rated Connection Connection Cable- Housing Contact of poles voltage current cross Ø material material contacts section assembly group III 95285 36 + PE 250 V 16 A 1.5 mm...
Working instruction english typ 91489 Description of equipment Signal transmitter Marking Type Inquiry condition Mounting position Equipment SE1.1 Limit switch Docking control: plate robot side Standard docked (left) SE1.2 Limit switch Docking control: plate robot side Standard docked (right) SE1R...
Working instruction english typ 91489 Description of installation Description of installation (standard version) Fehler! Textmarke nicht defi- niert. Assembly Before assembly the tool changer as well as all moving parts and the subassembly elements have to be checked for damages and contaminations and these must be eliminated.
Working instruction english typ 91489 Description of installation 7.1.4 Disassembly CAUTION!! Disassembly only when tool is parked and secured! Prior to the disassembly the subassembly elements are to be taken off or hose and cable connections are to be loosened.
Working instruction english typ 91489 Description of installation Hydraulic installation 7.3.1 Installation of locking cylinder Not planned. 7.3.2 Installation of cooling water elements Caution! - Do not use any sealing materials whose particles can come into the elements and lead to functional impairment!
Working instruction english typ 91489 Description of installation Caution Carefully mount threaded pin to avoid damage of the plastic socket in the cylinder. Before the assembly of a proximity switch one of the both nuts of the proximity switch has to be removed.
Working instruction english typ 91489 Description of installation 7. If the electronic testing device shows in every case the changing in the position of the locking piston it is well adjusted. If not the proximity switch has to be screwed out by several turns and the procedure has to be restarted from (item D).
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Working instruction english typ 91489 Description of installation 10. Crimp (4 point crimping) single conductor to contact socket/contact pin. Strands must be visible in window after crimping. 11. Absolutely avoid solder beads at the outside of the contacts when soldering 12.
Working instruction english typ 91489 Description of installation Signal plug with Aluminium housing (screwed cable gland Pg 21)Fehler! Textmarke nicht de- finiert. Shielded version Fehler! Textmarke nicht definiert. 1-95285-1-XX001-..-Z10 1-95285-4-XX001-..-Z10 (Cable-Ø 11,5 ... 15,5) Unshielded version 1-95285-1-XX001-..-Z11 1-95285-4-XX001-..-Z11 (Cable-Ø 13 ... 18) Installation sequence 1.
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Working instruction english typ 91489 Description of installation Caution! Please observe position of the earth contact! 13. Linearly slide in contact sockets/ contact pins with a WALTHER assembly tool (inserting tool) until they snap in – row for row. 14. Check the perfect snap in by a slight pulling at the single conductors.
2. A version which is not wired. In case of this version the procedure is as follows: A) To install the signal plug both plug carriers 1-91489-B-00023-..-Y10 need neither to be released from the robot nor the tool side. B) The signal plugs are dismantled by removing the pilot screws (item 6) and the signal plugs out of the guide.
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Working instruction english typ 91489 Description of installation L) Absolutely avoid solder beads at the outside of the contacts when soldering. M) Pre-plug contact sockets into the rear of the socket insert ( contact pins in pin insert), row for row. Blind bores must be sealed with blanking plugs.
Working instruction english typ 91489 Description of installation Installation of welding current plug (screwed cable gland Pg 29) Caution! The insert sealing of the screwed cable gland must be suited to the cable diameter! If necessary the insert sealing must be exchanged.
Working instruction english typ 91489 Description of installation 14-16) Deleted. 17. Insert socket/pin insert into the housing part according to the colour marking. In doing so hold on contacts and push back cable so far through the screwed cable gland that a small overlength remains in the plug housing and/or no sideways tension comes on contacts.
- description of optional feature. 8.2.2 Pull-in technique This technique exclusively refers to tool changers of type 91489-Z02/Z03. In function mode pull-in technique connection process will be done by the tool changer. No re- action forces occur for the robot. However, in case of same compressed air connection the tool...
Working instruction english typ 91489 Comments to application preparation Adjusting and programming of the robot 8.3.1 Safety instructions to adjust The recommended functional sequence is specified in the flow charts (see 8.2). Caution! It is forbidden for any person to be right next or below the tool changer during adjusting (e.g.
It is necessary to observe this adjustment procedure to be able to park and/or dock the tools in a force neutral way ( force neutral means without any force) into parking stations (tool parking stations) with the WALTHER tool changer 91489-Y10 in push-pull technique. Locking procedure 1.
Working instruction english typ 91489 Comments to application preparation Unlocking procedure 1. Move the tool into the parking station by the robot in such a way that the center lines of the parking areas (tool side) are in line with the center lines of the pick-up areas of the tool parking station.
Working instruction english typ 91489 Comments to application preparation Tool parking station The parking of the tools is carried out vertically into WALTHER standard tool parking stations (welding guns) according to the gravity principle. 8.4.1 Gravity parking station with guiding bolt and supporting roll Fehler! Textmarke nicht definiert.
Working instruction english typ 91489 Commissioning, operation and maintenance Commissioning, operation and maintenance General safety instructions Caution! It is forbidden for any person to be right next or below the tool changer during operation! In case of wrong control the tool changer can unintentionally...
Working instruction english typ 91489 Commissioning, operation and maintenance Preventive checks WALTHER tool changers are to be operated in such a way that external damages especially all moving parts, fluidic elements and electro plugs are excluded. According to our practical experience multicouplings will give long-term, trouble free service if care is taken to recognize and repair any possible damages in good time.
Working instruction english typ 91489 Commissioning, operation and maintenance 9.2.3 Check of fluidic elements - Check of plug elements, moving parts, sealing surfaces and seals for damages, contamina- tion and tightness. - Plug surfaces and seals are to be slightly greased according to the existing internal instruc- tions.
Working instruction english typ 91489 Works on malfunction and damages 10 Works on malfunction and damages 10.1 General safety instructions In case of malfunction and damages (e.g. after a crash) the tool changer is to be returned into starting position (tool to tool parking station) and stopped.
Working instruction english typ 91489 Works on malfunction and damages 10.4 Emergency separation facility The tool changer is to be moved with the mounted tool and the robot towards the tool parking station. In doing so the tool changer must be lowered up to 0 mm distance.
Working instruction english typ 91489 Works on malfunction and damages 10.5 Disassembly of fluidic elements The fluidic elements 4 of which can be installed in one plane are hold with a common fastening ridge. After the 3 fillister head screws are released with a hexagon socket screw key SW5 and the fastening ridge is removed all fluidic elements of this plane can sideways be pulled out of the plate.
Working instruction english typ 91489 Works on malfunction and damages 10.5.2 Repair of cooling water elements Adaptor element 1-EC-010-2-XX...-..-Y13 (robot side) housing and valve seal 1. Unscrew fillister head screw item 29 with hexagon socket screw key SW4 and then take it off.
Working instruction english typ 91489 Works on malfunction and damages Coupling element 1-EC-010-0-XX...-..-Y13 (tool side) – valve seal 1. Spirally take off Smalley retaining ring with suitable tool out of the groove. 2. Completely remove valve with valve butment to the back; in doing so press from the adaptor side against the valve.
Working instruction english typ 91489 Works on malfunction and damages 10.6 Disassembly of electro plugs 1. Disassembly of parallel pins item 28/67 by means of a hammer or mandrel Ø 7. Pins with female thread can be removed with a suitable pull off device.
Working instruction english typ 91489 Appendix: Drawings and parts lists 1-91489-2-FT524-AAAB-LI-Y10 11.1.1 tool changer – robot side LWL welding 1-91489-0-LT524-AAAB-LI-Y10 tool changer – tool side LWL welding 1-91489-B-FT001-AAAB-LI elements equipment (robot side) welding 1-91489-B-LT001-AAAB-LI elements equipment – (tool side) welding...
Working instruction english typ 91489 Appendix: Drawings and parts lists 11.1.4 1-91489-B-00059-..-Y10 Spreizbefestigung für SZ-System 1-91489-D-00012-Y10 Spannstiftbefestigung SZ-System...
Working instruction english typ 91489 Appendix: Drawings and parts lists 11.1.12 1-91489-E-00039-AAAA-Y10 electrical equipment (robot side) with secutity module) 1-91489-E-00046-..-Y10 Wiring plan...
Working instruction english typ 91489 Appendix: Drawings and parts lists 11.1.16 1-91489-P-00013-AAAA-Y10 pneumatic (VW-safety 2) 1-91489-B-00003-AAAA-Y10 mounting...
Working instruction english typ 91489 Appendix: Drawings and parts lists 11.1.17 1-EC-010-0-XX003-02-2-Y13-P015 Clean-Break-Coupling element n.b. 10 1-EC-010-2-XX004-02-2-Y13-P015 Clean-Break-adaptor element n.b. 10...
Working instruction english typ 91489 Appendix: Drawings and parts lists 11.1.18 1-70-010-2-XX003-39-2-Z01-P015 Adaptor element n.b. 10 1-70-010-2-XX005-39-2-Z01-P015 Adaptor element n.b. 10 1-70-010-7-XX004-39-2-Z01-P015 Thru-type coupling element with Valve plunger n.b. 10...
Working instruction english typ 91489 Appendix: Drawings and parts lists 11.1.19 1-95285-1-XX008-46-2-Z05-M. pin housing for contact insert assembly III for sideways plate mounting 1-95285-E-00008-..-.-Z05 wiring plan (35 mm)
Working instruction english typ 91489 Appendix: Drawings and parts lists 11.1.20 1-95285-4-XX003-46-2-Z05-MA socket housing for 3x35 mm with primary circuit plug 1-95285-4-XX100-46-2-Z05-M. electro socket housing 3-way (without connection) for sideways plate mounting 1-C5285-4-ET350-2.-0-AB socket-contact set 3-way 1-C5285-4-ET350-2.-0-AA electro socket 1-way...
Working instruction english typ 91489 Appendix: Drawings and parts lists 11.1.21 1-95288-1-XX002-AAAB-Y02 pin housing in elements style 1-95288-E-00001-..-Y02 wiring plan...
Working instruction english typ 91489 Appendix: Drawings and parts lists 11.1.22 1-95288-4-XX003-AAAB-Y02 socket housing in elements style 1-95288-E-00001-..-Y02 cable plan...
Working instruction english typ 91489 Appendix: Drawings and parts lists 11.1.25 1-C5285-1-ET350-2.-0-AB plug contact set (3-way) 1-C5285-1-ET350-2.-0-AA electro plug 1-way...
Working instruction english typ 91489 Appendix: Connection and flow schedules, load diagram 11.2.1 1-91489-D-00004-..-Y10 Mechanical interfaces to 91489-Y10...
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Working instruction english typ 91489 Appendix: Connection and flow schedules, load diagram 11.2.2 1-91489-D-00002 Mechanical interfaces / flanges of tool changer 91489...
Working instruction english typ 91489 Appendix: Connection and flow schedules, load diagram 11.2.4 1-91489-F-00007-..-Y10 security module 2 / park station with cover...
Working instruction english typ 91489 Appendix: Description of extra equipment 11.3.2 Optical fibre for tool changer Technical data Type robot side 1-91489-E-00043-AAAA-Y10 Type tool side 1-91489-E-00042-AAAA-Y10 Cladding diameter 0.98/1 mm Single core diamete 2.2 mm Outer cladding diameter 8 mm...
Working instruction english typ 91489 Appendix: Description of extra equipment Installation of voltage supply plug Drawing 1-95288-4/1-XX001-Y02/3 Connection screwed cable gland M 16x1,5, Cable diameter 4,5 – 10 Installation sequence a) Disassembly/assembly see 7.4(disassembly of fluid elements). b) Slide electro plug/electro socket sideways out of the guide.
Working instruction english typ 91489 Appendix: Description of extra equipment Installation of signal plug Drawing 1-95288-4/1-XX002-Y02 Connection flanged male socket/pins Installation sequence a) Aus-/Einbau siehe 7.4 (Ausbau der Fluid-Elemente). b) Slide electro plug/electro socket sideways out of the guide c) Unscrew the 4 cover screws with screwdriver for hexagon socket SW 3.
Working instruction english typ 91489 Appendix: Description of extra equipment Check of optical fibre coupling Visual check for mechanical operation. Check fastening screws for firm seat. Check floating position of optical fibre plug for perfect movability (tool side). Regular check and removal of dirt in the transmission range of optical fibres.
Working instruction english typ 91489 Index 12 Index functional test.............8 further development ...........7 according .. 7, 8, 9, 10, 12, 18, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 33, 35, 36, 174 actual scope ............7 General ...............7 Appendix ............
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Working instruction english typ 91489 Index screw-type connections ........8 SE1.1............16, 19 parts lists............43 SE1.2............16, 19 plan protective measures ........8 SE1R..........16, 20, 21, 32 Position repeatability........12 SE1V............16, 20, 32 power current........... 15 separating protection units ......9, 10 pressurized............8 Signal transmitter ..........16...
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Questions and answers