ORDERING INFORMATION QUANTITY
7.0 AUTOMATIC TOOL CHANGERS
VMC models 3020, 4525, 6535 come standard with the Dual Arm Tool Changer. VMC models 2216, 3016, 4020, 6030, 8030 (DATC optional) come standard with a 21 tool capacity (30 tool capacity optional for 4020, 6030, 8030) Geneva drive tool changer.
160 AUTOMATIC TOOL CHANGERS MAN-0121 R1
7.1 OPERATION
7.1.1PROGRAMMING To make an automatic tool change, an M6 code is used. This code can be used in a program or in Manual Data Input (MDI) mode.
In a Program
When another tool is needed, an M6 followed by a tool location. (T_) is entered and the tool changer will make the appropriate tool change and then continue on with the program.
In MDI
The operator can make a tool change with out running a program. If the operator is testing the tool changer or setting tool lengths, the M6 code followed by the tool location will command the tool changer to make the necessary tool change.
7.1.2 TOOL CHANGE
SEQUENCE The following is the order of operations for the CNC when making a tool change (Geneva driven ):
1. Move the Z axis to the machine home (Cold Start) position.
2. Turn the spindle slowly while looking for the Orientation Sensor signal.
3. When orientation signal is received, stop the spindle.
4. Activate the orientation arm.
5. Move the ATC turret to the tool position of the tool in the spindle.
6. Verify the orientation sensor.
7. Check the ATC Home sensor and verify that the ATC is at the home position.
8. Activate the ATC slide reverse circuit.
9. Activate the ATC slide motor circuit.
10. Watch for the ATC extended sensor signal.
11. Stop the slide motor when the extended position sensor is read.
12. Activate the draw bar.
13. Watch for the drawbar sensor detection (air feed parameter).
14. Check for the ATC fault switch.
15. Move the Z axis up to 3.8” above the cold start position.
16. Activate the turret motor and the turret reverse (if the reverse direction is required) circuit(s).
17. Count the turret sensor signals, with a dwell time for coasting as set by the turret factor, until the requested tool position is reached.
18. Stop the turret motor.
19. Move the Z axis downward to the machine home position.
20. Check for the ATC fault switch.
21. Release the drawbar circuit.
22. Activate the ATC slide motor.
23. Watch for the ATC Home sensor, to determine the ATC home position.
24. Stop the ATC slide motor.
25. Release the orientation arm.
NOTE
The hall effect sensors have three wires. One for 5vdc, one for ground, and one for the signal. The signal will be about 5vdc until a magnet is over it, then it will become active, and the signal will be about zero.
7.1.3 ATC FAULT
MESSAGES ATC FAILURE: The machine is receiving a signal from the ATC fault switch. This would indicate that the ATC spindle is out of position. Check the position of the ATC spindle. If it is in the proper position, check the switch, the switch wiring.
ATC TURRET FAILURE: The machine did not receive a signal from the ATC Turret Sensor, when the tool position change was commanded. If the turret moved to the next position, then the sensor is not operating. This could be caused by a bad sensor, wiring problem, sensor to magnet spacing, or chips on the sensor or magnet. If the turret does not move, then the turret motor circuit is not operating. This may be caused by a mechanical bind, turret motor, wiring problem.
ATC WILL NOT MOVE TO POSITION: When the ATC is commanded to move to either the extended or home positions and the appropriate sensor does not send a signal within the allotted time, this fault is displayed. The possible causes for this fault are mechanical problems including chips in the track area preventing the rollers from rolling, misalignment of the ATC or spindle position, bad sensor or gap setting on cylinder, wiring problem, motor.
ATC WILL NOT MOVE TO SPINDLE: Same as the ATC WILL NOT MOVE INTO
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162 AUTOMATIC TOOL CHANGERS MAN-0121 R1
7.2 ADJUSTMENTS There are four motions that influence the automatic tool changer alignment. These motions are:
• Z-axis up & down.
• Spindle orientation.
• Turret in & out.
• Turret rotation.
7.2.1 Z AXIS COLD
START ADJUSTMENT 1. Remove the ATC upper cover.
Figure 7-1 Remove ATC Upper Cover
2. Position the Z-axis head to the machine zero position (G28 G91 Z0.0).
3. Orientate Spindle (M190).
4. Manually move the ATC slide in toward the spindle following the next steps:
• Disconnect the air to the machine.
• Manually move the ATC slide towards the spindle.
• Re-connect the air to the machine for added pressure against the spindle.
NOTE
ATC will come back with a force. Make sure that nobody is inside of the machine.
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Figure 7-2: Move ATC Slide Toward Spindle
5. Measure the distance from the ATC carriage to the nose of the spindle with a thickness gauge. Adjust the Z axis until the nose of the spindle is .050” [1.27mm]
above the turret carriage for CAT taper, .250” [6.35mm] for BT tooling.
Figure 7-3: Measure Distance from ATC Carriage to Spindle
6. When the Z axis is in the correct position, tighten the screws. For AC machines, determine their offset by cold starting the machine then jogging the Z axis. Enter the value in G28 G91 Z0.0.
7. Cold Start the machine and recheck the position.
164 AUTOMATIC TOOL CHANGERS MAN-0121 R1
SLIDE ADJUSTMENT 1. Position the Z-axis to the machine zero.
2. Orient the spindle using M190 from MDI mode.
3. Insert a tool holder in the spindle.
4. Manually move the slide to the spindle until fully engaged. Loosen the 2 each 1/4’
hex bolts on the top of the Carriage Plate.
NOTE
The machine uses an air cylinder for the turret movement. To manually move the ATC as suggested in step (4) several steps must be taken:
• Disconnect the air to the machine.
• Switch the air lines connected to the air cylinder (see figure 7-5)
• Manually move the ATC slide towards the spindle.
• Re-connect the air to the machine for added pressure against the spindle.
8 each set
Figure 7-5: Loosen Hex Bolts / Move Slide to Spindle Until Engaged
Figure 7-6: ATC Cylinder
5. Give the slide a firm push toward the spindle. Retighten the 2 bolts.
6. If the slide does not fully engage, loosen each of the six 3/8" hex bolts holding the tool carrier. This will allow the slide to fully engage.
Figure 7-7: Loosen Hex Bolts Holding Tool Carrier
Air lines to switch for ATC adjustment Adjust the air flow
Adjust the cushion
Adjust the cushion
166 AUTOMATIC TOOL CHANGERS MAN-0121 R1
7. Tighten all bolts on tool carrier and upper Geneva slot. If the slide still does not engage, check the spindle orientation.
8. Disconnect the air to the machine.
9. Move the ATC slide back.
10. Switch the air lines connected to the air cylinder.
11. Re-connect the air to the machine.
12. Adjust the air flow. Make sure that the ATC doesn’t move too quickly or too slowly on a tool change.
13. Adjust the cushion. Make sure that during the tool change the ATC doesn’t “bang”
at either end of it’s travel.
7.2.4 TOOL TURRET ROTATIONAL ADJUSTMENT
1. Position the Z-axis to the machine zero.
2. Orient the spindle using M190 from MDI mode.
3. Loosen each of the six 3/8" hex bolts on the under side of the tool carrier.
Figure 7-8: Loosen Hex Bolts on Under Side of Tool Carrier
4. With the tool in the spindle, manually move the slide into the spindle, until fully engaged.
Figure 7-9: Manually Move Slide Into Spindle
5. Tighten the 6 each 3/8" hex bolts.
7.3 ATC MOTOR