Connectors for Docking and Robot Systems

ODU DOCK Connectors for Docking and Robot Systems www.odu.de

Connectors for Docking and Robot Systems Robust Circular Connectors ODU DOCK Applications Features – Industrial robots – Good safeguarding against failure – Tool change and depot systems – Best guidance features – Cable connections for robot systems – Robust design – Test equipment – High quality standards – Easy handling during servicing – Easy to use – High number of mating cycles / long lifetime – Flexible insert configuration – Best electrical features All shown connectors are according to DIN EN 61984:2009 connectors without breaking capacity (COC). All dimensions in mm. Most of the pictures are illustrations. All data and specifications subject to change without notice. Page 2 www.odu.de

Connectors for Docking and Robot Systems Table of Contents (Part I) Chapter From Page 1 Product description ODU DOCK 7 Main fields of application 8 Advantages 9 Housing versions 10 Contact inserts 11 ODU SPRINGTAC 12 Inserts with quick-change head technology 13 Order information 14 2 ODU DOCK size 1 17 Housing 18 Pin and socket inserts with crimp termination 20 Pin and socket inserts with solder termination 23 Quick-change head system with crimp termination 26 Current carrying capacity for fully equipped inserts 27 3 ODU DOCK size 2 31 Housing 32 Pin and socket inserts with crimp termination 34 Pin and socket inserts with solder termination 37 Quick-change head system with crimp termination 40 Current carrying capacity for fully equipped inserts 41 4 ODU DOCK Größe 3 43 Housing 44 Pin and socket inserts with crimp termination 46 Pin and socket inserts with solder termination 51 Quick-change head system with crimp termination 57 Insert with modular construction 58 Modules from the ODU-MAC program 59 Current carrying capacity for fully equipped inserts 65 5 ODU DOCK accessories 69 Accessories 70 ODU DOCK assembly instruction and crimp information 71 Assembly instruction 72 Crimping tools and contact preparation 73 Removal tools for crimp contacts 77 www.odu.de Page 3

Connectors for Docking and Robot Systems Table of Contents (Part II) Chapter From Page 6 Application specific connectors for Docking and Robot Systems 79 Additional docking connectors 80 Application specific docking systems 81 7 Technical information 83 International Protection (IP) Classes in accordance with DIN EN 60 529 84 Explanations and information according to VDE 85 Conversions AWG – sross section 88 Principles of current carrying capacity 89 Current load 90 Line current load 91 Technical information / definitions / terms 92 8 Company information 95 Quality management 96 Your partner in many application areas 97 The complete ODU product range 98 Everything from one source 99 Application specific connectors 100 Page 4 www.odu.de

Connectors for Docking and Robot Systems ODU DOCK Connectors for Docking and Robot Systems – a Special Kind of Connector Connectors for Docking and Robot Systems are connec- tors that have restricted guidance and that can be insert- ed automatically. The force can be applied manually, electrically or pneumatically. Connectors for Docking and Robot Systems require sim- ple constructed connectors with very different contacts. Often a large number of mating cycles are called for. The docking system stands or falls on the guide and the contact system that are selected. Following are some of the features that are critical when connectors for Docking and Robot Systems are used: – Good safeguarding against failure – Best guidance features – Robust design – High quality standards – Easy handling during servicing – Easy to use – High number of mating cycles / long lifetime – Flexible insert configuration – Best electrical features. Connectors for Docking and Robot Systems are ideally suited for such use and satisfy these requirements. From simple standard connectors for Docking and Robot Systems to the complex docking unit – ODU supplies the complete range. www.odu.de Page 5

Connectors for Docking and Robot Systems ODU DOCK Application of Connectors for Docking and Robot Systems Connectors for Docking and Robot Systems have become indispensable in automation engineering. Industrial robots, tool change and depot systems, cable connections and test equipment are just a few examples of the applications for these systems. ODU docking systems are built into combined quick coupling systems (electrical/pneumatic) where they enable the greatest possible flexibility. Page 6 www.odu.de

Connectors for Docking and Robot Systems Product Description ODU DOCK www.odu.de Page 7 Product Descr. ODU DOCK

Connectors for Docking and Robot Systems Product Description ODU DOCK Main Fields of Application ODU DOCK systems are mostly used for the following applications: – Tool change and depot systems – Test equipment – Industrial robot systems. Page 8 www.odu.de Product Description ODU DOCK

Connectors for Docking and Robot Systems Product Description ODU DOCK Advantages of the ODU DOCK Connectors – Easy assembly – High contact reliability due to the established – Temperature range: – 40° C up to +100° C ODU SPRINGTAC contacts – Robust housing made out of aluminium or plastic – High number of mating cycles – up to 100,000 – Housing with EMC protection available – Versions with quick-change head available for – 3 sizes mating cycles of more than 1 million – Contacts with crimp and solder termination available – Floating mounting on docking plates – Exchange of crimp contact within a few seconds – Easy assembly of the insulator – anti-rotation – Positions: 2 + PE up to 36 + PE, mixed inserts, power – High density with small contact diameter inserts (e.g. 31 x ∅ 0.76 mm in size 1) – Protection class: up to IP 65 available – High variety of contact inserts. – Straight and right-angled cable exit possible The ODU DOCK connection system consists of housing, insulator and contacts. These three components can be combined in a multitude of ways. In the crimp version, the contacts can be installed into and removed from the insulator in just a few seconds. The appropriate tools are available for this. In the solder version the contacts are permanently mounted in the insulator and cannot be removed. www.odu.de Page 9 Product Description ODU DOCK

Connectors for Docking and Robot Systems Product Description ODU DOCK Housing Versions for ODU DOCK There are three housing versions available: Plastic housing – Plastic housing – Aluminium housing, nickel-plated – Aluminium housing, black anodized. Plastic housing – Material: POM, black – Protection class: IP 65 in mated condition – Operating temperature: – 40° C up to +100° C – 3 housing sizes – Easy assembly from rear of panel – Straight and right-angled cable exit possible, sealing plug for unused cable exit is included in the delivery Aluminium housing – Two-part housing nickel-plated – More than 100,000 mating cycles¹) Aluminium housing, nickel-plated – Material: aluminium, nickel-plated – Protection class: IP 65 in mated condition (depends on version) – Operating temperature: – 40° C up to +100° C – 3 housing sizes – Easy assembly from rear of panel – Straight and right-angled cable exit possible, sealing plug for unused cable exit is included in the delivery – Two-part housing Aluminium housing black anodized – Available with and without EMC protection – More than 100,000 mating cycles¹) Aluminium housing, black anodized – Material: aluminium, black anodized – Protection class: IP 40 – Operating temperature: – 40° C up to +100 °C – 3 housing sizes – Mountable from front of panel – Straight and right-angled cable exit possible, sealing plug for unused cable exit is included in the delivery 1 Housing without shielding and without o-ring: min. 100,000 mating cycles. – Two-part housing Housing with shielding and without o-ring: min. 50,000 mating cycles. – More than 100,000 mating cycles¹) It is recommended to change the front parts of the housing after 50,000 mating cycles, both socket and pin side. Housing with o-ring: min. 25,000 mating cycles without maintenance and min. 100,000 mating cycles with maintenance. Page 10 www.odu.de Product Description ODU DOCK

Connectors for Docking and Robot Systems Product Description ODU DOCK Contact Inserts for ODU DOCK Pin and socket inserts with crimp termination The contact inserts consist of an insulator (contact carrier) and the associated number of pin or socket contacts. In the crimped model, the insulator and contacts must be ordered separately. This flexible design allows the contact insert to be equipped individually. Crimp contacts can be installed and removed very quickly. Material Insulator PBT-GF (UL 94V-0) Contacts Cu-alloy surface contact from ∅ 1.0 mm Au surface contact from ∅ 1.5 mm Ag Pin and Socket inserts with solder termination The contact inserts consist of an insulator (contact carrier) and the associated number of pin or socket contacts. Our solder inserts can cover a larger connection range. The contacts in the solder version are already mounted in the insulator, which means that the delivered contact insert is already completely equipped. Material Insulator fibre-glass reinforced polyester resin (UL 94V-0) Contacts surface Ag www.odu.de Page 11 Product Description ODU DOCK

Connectors for Docking and Robot Systems Product Description ODU DOCK ODU SPRINGTAC® (Contacts with Springwire Technology) The springwire contact is the inspired Unmated invention of Otto Dunkel. It offers the highest number of contact surfaces. The Socket Pin springwires are mounted individually and joined optimally to a turned carrier. The individual springwires contact and cushion independently of one another. Advantages – More than 100,000 mating cycles – Low contact resistances – Large number of independently cushioning contact springs Carrier Expansion ring Spring wires Spark protection – Low insertion forces – Extremely secure contacting – High resistance to vibrations and Mated impacts – Long life span due to premium Socket Pin materials and surfaces. Page 12 www.odu.de Product Description ODU DOCK

Connectors for Docking and Robot Systems Product Description ODU DOCK Inserts with Quick-Change Head Technology (QCH) for an extremely high number of mating cycles Die ODU SPRINGTAC contacts offer contact stability for up to 100,000 mating cycles. The ODU DOCK quick- change head is suitable for applica- tions that require even more mating cycles. Principle behind the quick-change head The connection system consists of an interchangeable front part (connector piece) and a back part (terminal piece). When the contacts suffer from wear, the front part is exchanged in a very short time without it being necessary to separate the connections that are made with the contacts of the back part. Material Insulator PBT-GF (UL 94V-0) Contacts Cu-alloy Crimp contact Crimp contact Part B Part A Part C Part D Terminal Connector Connector Terminal piece piece piece piece Socket side Pin side Terminal pieces stay wired. Connector pieces are exchanged in the Docking System. Contacts at the Terminal piece B and D are respectively crimp contacts. www.odu.de Page 13 Product Description ODU DOCK

Connectors for Docking and Robot Systems Product Description ODU DOCK Order Information ODU DOCK Order example with crimp insert Housing, insulator and contacts must be ordered separately when crimp contacts are used. – ODU DOCK, size 2 – Housing: Aluminium, black anodized – 6 positions with earthing pin. Socket piece Pin piece Housing 1 × 656.162.051.000.000 1 × 656.162.052.000.000 Picture for example only. Cable clamp 1 × 027.825.090.170.007 1 × 027.825.090.170.007 Insulator 1 × 208.703.004.007.000 1 × 208.803.004.007.000 Contacts 7 × 170.382.000.201.000 6 × 180.334.000.301.000 Earthing contact 1 × 180.335.000.301.000 Order example with solder insert Housing and insert must be ordered separately when the solder version is used. The contacts are already fixed in the insulator and don’t need to be ordered separately. – ODU DOCK, size 1 – Housing: aluminium, black anodized – 4 positions. Socket part Pin part Picture for example only. Housing 1 × 656.164.051.000.000 1 × 656.164.052.000.000 Cable clamp 1 × 027.820.070.130.007 1 × 027.820.070.130.007 Insert 1 × 656.164.702.150.004 1 × 656.164.802.150.004 Page 14 www.odu.de Product Description ODU DOCK

Connectors for Docking and Robot Systems Product Description ODU DOCK Order example with flexible insert With the flexible inserts, the housing, insulator and the flexibly interchangeable modules must be ordered separately. The insulator must be completely filled with modules. – ODU DOCK, size 3 – Housing: aluminium, black anodized – 2 × power modules from the ODU-MAC program for AWG 14. Socket part Pin part Housing 1 × 656.163.051.000.000 1 × 656.163.052.000.000 Cable clamp 1 × 027.832.070.150.007 1 × 027.832.070.150.007 Flexible insert 1 × 209.610.000.000.000 1 × 209.611.000.000.000 ODU-MAC modules* 2 × 610.162.103.923.000 2 × 611.162.103.923.000 Contacts* 6 × 172.582.100.201.000 6 × 182.582.000.301.000 * Order information and technical data see from page 59, as well as the ODU-MAC product catalogue. Order example for the quick-change head The housing and inserts must be ordered separately for the quick-change head version. The contacts for the inserts are included in the delivery. – ODU DOCK QCH, size 3 – Housing: plastic – 36 positions with earthing pin. Socket part Pin part Part B Part A Part C Part D Housing 1 × 656.163.011.000.000 1 × 656.163.012.000.000 Terminal Connector Connector Terminal Cable clamp 1 × 027.832.070.150.007 1 × 027.832.070.150.007 piece piece piece piece A C 1 × 252.058.001.037.000 1 × 252.059.001.037.000 Insert QCH Socket side Pin side B D 1 × 252.061.001.037.000 1 × 252.061.002.037.000 www.odu.de Page 15 Product Description ODU DOCK

Connectors for Docking and Robot Systems For Your Notes Page 16 www.odu.de Product Description ODU DOCK

Connectors for Docking and Robot Systems ODU DOCK Size 1 www.odu.de Page 17 ODU DOCK Size 1

Connectors for Docking and Robot Systems ODU DOCK Size 1 Housing Plastic – Material: POM, black – Protection class: IP 65 in mated condition – Operating temperature: – 40° C up to +100° C – Easy assembly from rear of panel – Straight and right-angled cable exit possible, sealing plug for unused cable exit is included in the delivery – Two-part housing Description Part number Socket piece 656.164.011.000.000 Pin piece 656.164.012.000.000 Socket piece Pin piece M 20 × 1.5 M 20 × 1.5 36 50 31.5 44 50 Aluminium, nickel-plated – Material: aluminium, nickel-plated – Protection class: IP 65 in mated condition (depends on version) – Operating temperature: – 40° C up to +100° C – Easy assembly from rear of panel – Straight and right-angled cable exit possible, sealing plug for unused cable exit is included in the delivery – Two-part housing – Available with and without EMC protection Description Part number IP 40 IP 65 EMC protection 656.164.021.000.000 ● ● 656.164.023.000.000 ● Socket piece 656.164.024.000.000 ● ● 656.164.025.000.000 ● Pin piece 656.164.022.000.000 ● ● ● Socket piece Pin piece M 20 × 1.5 M 20 × 1.5 50 31.5 44 50 36 Page 18 www.odu.de ODU DOCK Size 1 ∅ 27.8 ∅ 27.8 ∅ 27.8 ∅ 27.8

Connectors for Docking and Robot Systems ODU DOCK Size 1 Aluminium, black anodized – Material: aluminium, black-anodized – Protection class: IP 40 in mated condition – Operating temperature: – 40° C up to +100° C – Mountable from front of panel – Straight and right-angled cable exit possible, sealing plug for unused cable exit is included in the delivery – Two-part housing Description Part number Thread X 656.164.051.000.000 M 20 × 1.5 Socket piece 656.164.001.000.000 PG 16 656.164.052.000.000 M 20 × 1.5 Pin piece 656.164.002.000.000 PG 16 Socket piece Pin piece X X 50 31.5 44 50 36 Assembly drilling for all size 1 versions ±0.5° Board spacing 25° .11 +0 2 in mated position: A .0 ∅ 2 8 +0 61 ± 0.5 mm Board thickness “X” 20 mm: ± 0.1 ∅ 34 ±0.1 14 mm: ± 0.1 Hole A: ∅ 3 for pin ∅ 3 10 mm: ± 0.1B ±0.5° H9 m6 25° Hole B: ∅ 2H9 for pin ∅ 2m6 www.odu.de Page 19 ∅ 28 ∅ 28 6±0.5 X ODU DOCK Size 1

Connectors for Docking and Robot Systems ODU DOCK Size 1 Pin and Socket Inserts with Crimp Termination 2 positions with earthing Socket Pin Contact Description Part number configuration Socket View on the mating side Insulator socket 207.703.004.003.000 Insulator pin 207.803.004.003.000 1 2 Sealing plug 021.341.136.304.000 Socket contact 170.382.000.201.000 Pin contact 180.334.000.301.000 30 3.0 2.5 31 ± 10 Earthing pin contact 180.335.000.301.000 29 ± 10 Socket contact 170.499.100.201.000 Pin contact 180.374.000.301.000 25 3.0 1.5 31 ± 10 Earthing pin contact 180.375.000.301.000 Voltage information Metal housing Plastic housing Dimensions insulator (socket piece/pin piece) acc. DIN EN*) Rated voltage 500 V 200 V 630 V 250 V 11.1 2 Rated impulse voltage 3 kV 4 kV 6 1 3 1 Po2llution degree 2 3 2 3 5 4 Crimping tools from page 73. *DIN EN 60664-1 (VDE 0110-1) : 2008-01 5 15 16.5 3.5 29 13.1 29 1 2 6 positions with earthing Socket Pin C1oBntac3t Description Part number con4 figurati7on 2 8 12 13 Socket 16 6 1 3 17 19 5 4 View on the mating side Insulator socket 207.702.004.007.000 2 Insulator pin 207.802.004.007.000 6 1 3 Sealing plug 021.341.135.923.000 1 2 5 4 Socket contact 170.381.000.201.000 Pin contact 180.332.000.301.000 25 2.0 1.5 40 ± 13 Earthing pin contact 180.333.000.301.000 1 2 37 ± 13 3 5 Socket contact 170.827.100.201.000 B 8 10 1 3 11 14 18 Pin contact 180.827.000.301.000 20 2.0 1.0 40 4 7 2122 24 ± 13 8 12 27 29 Earthing pin contact 180.828.000.301.00030 31 13 16 17 19 Voltage information Metal housing Plastic housing Dimensions insulator (socket piece/pin piece) acc. DIN EN*) Rated voltage 500 V 116B0 V 3 500 V 200 V 12.6 Rated impulse voltage 3 kV 4 7 3 kV 2 8 12Pollution degree 2 13 3 16 2 3 6 1 3 17 19 5 Cr4imping tools from page 73. *DIN EN 60664-1 (VDE 0110-1) : 2008-01 76 8 5 15 10.6 16.5 3.5 5 1 9 1 2 4 2 3 5 29 293 8 10 11 14 11 10 18 21 B 22 24 27 29 30 31 Page 20 www.odu.de 1 2 3 5 B 8 10 1 3 11 14 4 7 18 2122 24 8 12 27 2930 31 13 16 17 19 7 6 8 5 1 9 4 2 3 11 10 B 7 6 8 5 1 9 1 2 4 2 3 5 3 8 10 11 14 11 10 18 21 B 22 24 27 29 30 31 7 6 8 5 1 9 4 2 3 11 10 B ODU DOCK Size 1 ∅17 ∅17 ∅17 ∅17 ∅21.5 ∅21.5 Current in A Current in A nominal single nominal single contact current load contact current load Contact diameter Contact diameter in mm in mm Termination cross- Termination cross- section in mm² section in mm² Mating force in N Mating force in N Demating force in N Demating force in N