4.1 Overview

Umbrella Tool Changer - Shuttle - Overview

SHUTTLE OVERVIEW

The standard mill tool changer has the name "umbrella tool changer" because its shape is almost the same as an umbrella. The umbrella tool changer has these primary systems:

  • shuttle assembly [1]
  • carousel assembly [2]

During tool changes, the shuttle assembly [1] moves the carousel assembly [2] to the spindle [3].

SHUTTLE MECHANISM

The shuttle assembly has four wheels [2] on tracks that connect to a plate. The I/O PCB (input/output PCB) sends 160 V dc to supply power to the shuttle-assembly motor [1]. This motor [1] turns the clutch-arm assembly [3] that pushes the shuttle in or out. The clutch-arm assembly [3] has a "slip-clutch" [4] on the motor shaft.

The slip-clutch [4] lets the motor continue to turn when these incidents occur:

  • The arm goes farther than its travel limit.
  • The shuttle assembly hits something that prevents its movement.

SHUTTLE SENSORS

The shuttle assembly has two proximity sensors [1]. These sensors tell the control the position of the tool changer.

Note: The location of the proximity sensors [1] is different on a 10-pocket tool changer.

To see the status of the tool changer, push DIAGNOSTIC to go to the diagnostics page. Go to the I/O tab.

Umbrella Tool Changer - Carousel - Overview

CAROUSEL OVERVIEW

The tool carousel [1] turns on a vertical axle [2]. The I/O PCB supplies 160 V dc to the motor [3]. The motor turns a Geneva mechanism [4,5]. The Geneva mechanism turns the carousel from pocket to pocket.

The Geneva mechanism has these two parts:

  • The Geneva driver [4] which connects to the motor shaft.
  • The motor turns the Geneva gear ("star") [5] to turn tool carousel [1].

CAROUSEL MECHANISM

As shown in the illustration that follows, one revolution of the Geneva driver [1] moves the Geneva gear [2] (and the carousel) to the next pocket.

CAROUSEL SENSORS

The carousel assembly has these sensors for status input:

  • Tool One In Position sensor [1]
  • Tool In Position sensor [2]

When tool 1 is in position, the dowel pin [5] on the Geneva star [4] energizes the Tool One In Position sensor [1]. When a tool is in position, the Geneva driver [3] energizes the Tool In Position sensor [2] and counts each pocket.

4.2 Service Replacements

Umbrella Tool Changer - Shuttle Service Replacement Procedures

Procedure Description
Umbrella Tool Changer - Shuttle Roller Replacement This procedure show you how to replace the top and bottom shuttle rollers on an umbrella tool changer.
Umbrella Tool Changer - Removable Geneva Drive Carousel Motor - Replacement This procedure shows you how to replace the geneva drive carousel motor on an umbrella tool changer.
Umbrella Tool Changer - Pocket - Replacement This procedure shows you how to replace the pocket assembly on an umbrella tool changer.
Umbrella Tool Changer - Carousel Plate - Replacement This procedure shows you how to replace the carousel plate on an umbrella tool changer.
Umbrella Tool Changer - Guide Pin and Trap Door - Replacement This procedure shows you how to replace the guide pin and trap door on an umbrella tool changer.

4.3 Tool Change Offsets

Umbrella - Tool Changer Offsets Procedures

Procedure Description
Umbrella Tool Changer - Z-Axis - Tool Change Offset This procedure is used to set the Z-axis tool change position.
Umbrella Tool Changer - Spindle Orientation Offset This procedure is used for setting the spindle orientation for a tool change.

4.4 Alignments

Umbrella Tool Changer - Alingment Procedures

Procedure Description
Umbrella Tool Changer to Spindle - Alignment This procedure will show you how to aling the umbrella tool changer to the spindle.

4.5 Troubleshooting

Introduction

EXPLODED VIEW:

  1. SHUTTLE MOTOR
  2. V-TRACK COVER
  3. WIPER
  4. WIPER RETAINER
  5. SHCS 10-32 X 3/8
  6. SLIP CLUTCH ARM
  7. MOUNTING BLOCK
  8. PROXIMITY SENSOR
  9. SHUTTLE ROLLER
  10. NUT 3/4-10 NYLON LOCK
  11. WASHER 3/4 FLAT
  12. TOOL CARRIAGE
  13. NUT 3/8-24 HEX
  14. GASKET TOOL CARRIAGE
  15. CONNECTOR BRACKET
  16. TURRET MOTOR
  17. TOOL CARRIAGE COVER
  18. MOTOR MOUNTING PLATE
  19. SHCS M3 X 5
  20. DRIVER GENEVA 2 PIN
  21. CAM FOLLOWER 3/4 HEX
  22. SPACER RING
  23. BHCS 10-32 X 1
  24. TOOL #1 STANDOFF
  25. GENEVA STAR
  26. VERTICAL AXLE
  27. BEARING
  28. BEARING LOCKNUT
  29. BEARING HOUSING
  30. DOOR SPRING
  31. NUMBER RING
  32. TOOL CHANGER CAP
  33. SHCS 5/16-18 X 1
  34. FHCS 10-32 X 3/8
  35. SLIDING PANEL COVER
  36. SLIDING PANEL DOOR
  37. RIVET 3/32 X .200 X .160 HEAD DIA
  38. EXTRACTOR BUSHING
  39. ROLL PIN 3/16 X 7/8
  40. EXTRACTOR COMPRESSION SPRING
  41. EXTRACTOR
  42. ALIGNMENT KEY
  43. SHCS 1/4-20 X 7/8
  44. SHCS 5/16-18 X 3/4
  45. TOOL CHANGER COVER
  46. TRAP DOOR
  47. SWITCH COVER
  48. SHCS 8-32 X 7/8
  49. HOLDING PLATE
  50. LOCATING PIN
  51. DOOR OPENER BRACKET LOWER
  52. DOOR OPENER BRACKET UPPER

 

  1. Shuttle motor: DC motor that drives the slip clutch arm assembly to move the shuttle in and out of the spindle.
  2. Carousel motor: DC motor that rotates the carousel.
  3. Tool Changer pocket assembly: Holds the tools in the carousel, it consits of two extractor fingers, spring, locating tool key.
  4. Slip clutch arm: Mechanism that couples the shuttle motor to the carriage casting, it will slip if there is a crash to prevent damage to tool changer.
  5. Carousel motor connector bracket: The motor and sensors will connect to this connector bracket.
  6. Shuttle in and out sensors: These sensors let the control know the shuttle position.
  7. Tool #1 and tool mark sensors: These sensors let the control know the carousel position.

Symptom Table

Symptom Possible Cause Corrective Action

Alarm 113 SHUTTLE IN FAULT

 

Alarm 114 SHUTTLE OUT FAULT

Alarm 125 SHUTTLE FAULT

Alarm 856 ATC SHUTTLE DRIVE TRAIN FAILURE

Alarm 859 ATC SHUTTLE MOTOR ELECTRICAL FAULT

Alarm 2066 TOOL CHANGER HOME POSITION FAULT

 

 Chips interfere with the umbrella tool changer proximity sensors or the movement of the shuttle. Check the system for chips. Refer to the Rail Guides and Proximity Sensors section.
The motor does not receive power. Check the voltage to the motor.  Refer to the Carousel and Shuttle Motor section.
Check resistance in the motor. Refer to the Carousel and Shuttle Motor section.
Check the motor brushes. Refer to the Carousel and Shuttle Motor section.
The slip clutch arm is loose or damaged. Inspect the slip clutch arm.  Refer to the Slip Clutch Arm section
The spindle orientation is incorrect. Set the correct spindle orientation.
The extractor fingers or springs are damaged or worn. Rebuild the tool pockets.
The carousel plate is bent. Find the cause of the bent carousel plate.
Damaged cable or loose cable connection. (Especially if problem is intermittent or during movement of shuttle)
 Inspect pins and cable for condition.
One of the tool changer relays is faulty. Test the tool changer relays.
Alarm 143 SPINDLE ROTATED DURING A TOOL CHANGE Incorrect alignment of the carousel plate to the spindle is causing the spindle to turn as it goes into the tool holder. Check the tool changer alignment to the spindle.
The spindle orientation is incorrect. Set the correct spindle orientation.
The orientation is weak due to low voltage or loose motor power wires. Check for loose wires at the spindle motor and amplifier terminals.  Check incoming voltage.

Alarm 115 CAROUSEL POSITION FAULT

 

Alarm 127 NO TURRET MARK

Alarm 854 ATC CAROUSEL DRIVE TRAIN FAILURE

Alarm 942 CAROUSEL POSITION TIME OUT

 

 Chips interfere with the umbrella tool changer proximity sensors or movement of the shuttle. Check the system for chips.
The proximity sensor is faulty or not recieveing power Check the operation of the proximity sensor
One of the tool changer relays is faulty. (non-servo motor tool changers only) Test the tool changer relays.
The motor does not receive power. Check resistance in the motor.
Check the motor brushes.
Alarm 115 CAROUSEL POSITION FAULT, during Power-up. There is a software error (NGC only). Set setting 81 TOOL AT POWER UP to 0, as a temporary work around. Check NGC software release notes for when the error was corrected.

 

Note: Only a Certified Service Technician can upgrade the machine software.
Tools fall or drop from the tool changer. The extractor fingers or springs are damaged or worn. Rebuild the tool pockets.
The pull studs are incorrect. Check the tool specifications.
The tool is too heavy or too long.
The Umbrella Tool Changer Carousel Plate is Loose. The lock nut on the shaft axle is loose. Check the lock nut on the shaft axle, bearing housing bolts and the 6 screws that hold the carousel plate.
The bolts at the bearing housing are loose.
Mounting hardware in the tool changer assembly is loose.
Tool changes are noisy. The plastic riders on the carousel trap door are damaged or missing. Inspect the carousel trap door.
The guide pin on the carousel trap door is damaged.
The Tool changer is not aligned to the spindle.

Use this procedure to align the Umbrella Tool Changer to the Spindle.

Procedure: Umbrella Tool Changer to Spindle Alignment
The Geneva driver or the Geneva star is damaged. Examine the geneva driver and the geneva star for damage.  Use this procedure:

Carousel Plate Replacement - Umbrella Tool Changer
The shuttle roller bolts are not adjusted correctly.

Use this procedure to adjust or replace the shuttle rollers.

Procedure: Shuttle Roller Replacement and Adjustment
The sliding panels do not fully retract.

The sliding panels do not move smoothly. The tools make scores or scratches on the inner surface of the carousel. Clean the slider and spring assembly.

Use the correct procedure for slider and spring removal. Refer to Umbrella Tool Changer - Pocket - Replacement.
The Umbrella Tool Changer Trap Door Does Not Open The trap door pivot point is not greased. Grease the trap door pivot point.
There are chips between the trap door and the carousel. Inspect the carousel trap door.
The plastic trap door riders are worn.
CM-1 36 Pocket Tool Changer Only: Misloading of the tools. The tool changer's door spring is too strong.  Replace with weaker door spring P/N 93-3750. Refer to CM-1 36 Pocket Tool Changer - Door Spring Replacement - AD0678 for more information. 

For Umbrella Tool Changers built before 02/2022

Alarm 856 ATC Shuttle Drive Train Failure

Alarm 859 ATC Shuttle Motor Electrical Fault

Alarm 9809 Tool Changer Bus Short Circuit

 Coolant getting into the shuttle motor windings through the brush caps.

Clean out brush caps/brushes and attach vinyl caps with sealant, refer to the Shuttle Motor Coolant Intrusion section below for more info.

Note: Shuttle motors on umbrella tool changers built February 2022 and later are dipped and sealed at the factory and will not require the vinyl caps.

Shuttle Motor Coolant Intrusion

1. Remove the brush caps [1] from both sides of the motor

2. Inspect the brushes for coolant intrusion and clean and reinstall the brushes and their brush caps.

3. Order two (2) vinyl caps [2] for the shuttle motor

  • PN 59-2011 for 32-1875: MTR ASSY CAROUSEL/SHUTTLE/APC
  • PN 59-0297 for CM-1 tool changers

4. Fill the vinyl caps about a 1/4 of the way with RTV Silicone [3]

5. Push the vinyl caps onto the brush caps and rotate them clockwise and counterclockwise for an even seal [4]

6. A good seal could be seen in [5]

7. Put a rubber band around both caps as shown in [6] and leave them on for at least 4 hours to allow the vinyl caps seal to cure.

Note: Shuttle motors on umbrella tool changers built February 2022 and later are dipped and sealed at the factory and will not require the vinyl caps.

Rail Guides and Proximity Sensors

Corrective Action:

Check the top [1] and bottom [2] V-rails, and the wheels for chips. Check for damaged or worn wipers [3]. Some machines do not have a wiper bracket [4].

Remove any chips that prevent correct sensor operation. Remove the carousel motor from the carriage assembly. Remove the sensors [5] on both sides of the carousel motor plate to clean them.

Remove the cam follower assembly [6] and lower the slip clutch arm [8] to move the carriage assembly and access the sensors [7] behind the carriage assembly.

Older machine models use roller switches [5] in place of the proximity sensors. The plunger and roller must operate smoothly without sticking. If the switches or sensors are clean, but do not operate correctly, go to Mechanical Limit Switch - Troubleshooting Guide or Proximity Sensor - Troubleshooting Guide to troubleshoot them.

Slip Clutch Arm

Corrective Action:

Inspect the slip clutch arm: Remove and inspect the cam follower assembly [1] for damage and chips. Push the carousel motor housing in the direction of the spindle to get access to the slip clutch arm [2]. Manually turn the slip clutch arm [2] through 180° of movement. It should rotate smoothly, but with heavy resistance. If the arm does not move smoothly, the shuttle motor [3] is faulty.

Spindle Orientation

Corrective Action:

Find the cause of the spindle orientation error.

Make sure spindle drive and encoder belts have the correct tension. Make sure the spindle motor pulley and encoder pulley are not worn.

Refer to these procedures

Tool Changer Relays

Corrective Action:

Test the suspected relay: Exchange the relay with another relay. If the alarm changes to a different alarm, the relay is at fault.

For example: If the machine displays Alarm 113, change the K9 relay with the K10 relay. If the alarm changes to Alarm 114, the relay is faulty. If the alarm does not chage, proceed to other troubleshooting sections.

Tool Pocket

Corrective Action:

The extractor fingers and spring hold the tool in the tool pocket. Worn or damaged fingers or springs can let the tool fall.

Refer to:

Electrical Diagram