There are (2) types of mill tool changers: the umbrella style (UTC), and the side-mount tool changer (SMTC). You command both tool changers in the same way, but you set them up differently.

Make sure the machine is zero returned. If it is not, press POWER UP.

Use TOOL RELEASE, ATC FWD, and ATC REV to manually command the tool changer. There are (2) tool release buttons; one on the spindle head cover and another on the keyboard.

CAUTION: Do not exceed the maximum tool changer specifications. Extremely heavy tool weights should be distributed evenly. This means heavy tools should be located across from one another, not next to each other. Ensure there is adequate clearance between tools in the tool changer; this distance is 3.6" for a 20-pocket and 3” for a 24+1 pocket. Check your tool changer specifications for the correct minimal clearance between tools.

NOTE: Low air pressure or insufficient volume reduces the pressure applied to the tool release piston and will slow down tool change time or will not release the tool.

WARNING: Stay away from the tool changer during power up, power down, and during tool changer operations.

Always load tools into the tool changer from the spindle. Never load a tool directly into the tool changer carousel. Some mills have remote tool changer controls to let you inspect and replace tools at the carousel. This station is not for initial loading and tool assignment.

CAUTION: Tools that make a loud noise when released indicate a problem and should be checked before serious damage occurs to the tool changer or spindle.

This section tells you how to use the tool table to give the control information about your tools.

NOTE: If your machine has an umbrella-style tool changer, you will not use the tool pocket table.

7) Clear category [Space] - Highlight the desired tool and press SPACE to clear the flag.

8) Set tool [###] + [Enter]- Highlight the desired pocket and type in the tool number + Enter to set the desired tool number.

NOTE: You cannot assign a tool number to more than one pocket. If you enter a tool number that is already defined in the tool pocket table, you see an Invalid tool error.

9) Clear tool [0] + [Enter]- Highlight the desired pocket and press 0 + Enter to clear out the tool number.

10) Reset table [Origin] - Press ORIGIN with the cursor in the center column to use the ORIGIN menu. This menu lets you:

• Sequence All Pockets - Makes all of the tool numbers sequential based on their pocket location, starting with 1.
• Zero All Pockets - Removes all of the tool numbers from all of the pocket numbers.
• Clear Category Flags - Removes the category designations from all of the tools.

11) * Indicates current tool changer pocket.

Insert tool 1 (pull stud first) into the spindle.

Inserting a Tool Into the Spindle: [1] Tool release button.

Turn the tool so that the two cutouts in the tool holder line up with the tabs of the spindle.

Push the tool upward and press the tool release button.

When the tool is fitted into the spindle, release the tool release button.

The high-speed side-mount tool changer has an additional tool assignment, which is “Heavy”. Tools that weigh more than 4 pounds are considered heavy. You must designate heavy tools with H (Note: All large tools are considered heavy). During operation, an “h” in the tool table denotes a heavy tool in a large pocket.

As a safety precaution, the tool changer will run at a maximum of 25% of the normal speed when it changes a heavy tool. The pocket up/down speed is not slowed down. The control restores the speed to the current rapid when the tool change is complete. Contact your HFO for assistance if you have problems with unusual or extreme tooling.

H - Heavy, but not necessarily large (large tools require empty pockets on either side).

h - Heavy small diameter tool in a pocket designated for a large tool (must have empty pocket on both sides). The lower case “h” and “l” is placed by the control; never enter a lower case “h” or “l” into the tool table.

l - Small diameter tool in a pocket reserved for a large tool in the spindle.

Large tools are assumed to be heavy.

Heavy tools are not assumed to be large.

On non-high speed tool changers, “H” and “h” have no effect.

In the tool table, enter 0 (zero) for the tool number to label a tool pocket "always empty". The tool changer does not "see" this pocket, and it never tries to install or retrieve a tool from pockets with a ‘0’ designation.

You cannot use a zero to designate the tool in the spindle. The spindle must always have a tool number designation.

If you need to move tools in the carousel, follow this procedure.

CAUTION: Plan the reorganization of the tools in the carousel ahead of time. To reduce the potential for tool changer crashes, keep tool movement to a minimum. If there are large or heavy tools currently in the tool changer, ensure that they are only moved between tool pockets designated as such.

If you need to move tools in the carousel, follow this procedure.

CAUTION: Plan the reorganization of the tools in the carousel ahead of time. To reduce the potential for tool changer crashes, keep tool movement to a minimum. If there are large or heavy tools currently in the tool changer, ensure that they are only moved between tool pockets designated as such.

The tool changer pictured has an assortment of normal-sized tools. For the purposes of this example, we need to move tool 12 to pocket 18 to make room for a large-sized tool in pocket 12.

Making Room for Large Tools: [1] Tool 12 to Pocket 18, [2] Large Tool in Pocket 12.

5) Enter the tool number into SPINDLE on the TOOL TABLE. Insert the tool into the spindle.

 NOTE: Extra-large tools can be programmed as well. An “extra-large” tool is one that takes up three pockets; the diameter of the tool covers the tool pocket on either side of the pocket it is installed in. Contact your HFO to provide a special configuration if a tool this size is needed. The tool table must be updated since two empty pockets are needed between extra large tools.

6) Enter P12 into the control and press ATC FWD. The tool is placed into pocket 12.

Tool Pre-Call

To save time, the control looks ahead as far as 80 lines into your program to process and prepare machine motion and tool changes. When look-ahead finds a tool change, the control puts the next tool in your program into position. This is called “tool pre-call.”

Some program commands stop look-ahead. If your program has these commands before the next tool change, the control does not pre-call the next tool. This can cause your program to run slower, because the machine must wait for the next tool to move into position before it can change tools.

Program commands that stop look-ahead:

• Work offset selections ( G54, G55, etc.)
• G103 Limit Block Buffering, when programmed without a P address or with a nonzero P address
• M01 Optional Stop
• M00 Stop Program
• Block Delete Slashes ( /)
• A large number of program blocks executed at high speed

To make sure that the control pre-calls the next tool without look-ahead, you can command the carousel to the next tool position immediately after a tool change command, as in this code snippet:

T01 M06 (TOOL CHANGE) ;
T02 (PRE-CALL THE NEXT TOOL) ;

Mills such as the MDC, EC-300 and EC-400 have a sub-panel to aid tool loading. The Manual/Automatic Tool Change switch must be set to “Automatic Operation” for automatic tool changer operation. If the switch is set to “Manual”, the two buttons, labeled with clockwise and counterclockwise symbols, are enabled and automatic tool changes are disabled. The door has a sensor switch which detects when the door is open.

If the cage door is opened while a tool change is in progress, the tool change stops and resumes when the cage door is closed. Any machining operations in progress remain uninterrupted.

If the switch is turned to manual while a tool carousel is in motion, the tool carousel stops and resumes when the switch is turned back to automatic. The next tool change will not execute until the switch is turned back. Any machining operations that are in progress remain uninterrupted.

The carousel rotates one position whenever a clockwise or counter-clockwise button is pressed once, while the switch is set to manual.

During tool changer recovery, if the cage door is open or the Tool Change switch is in the manual position and RECOVER is pressed, a message is displayed telling the operator the door is open or is in manual mode. The operator must close the door and set the switch to the automatic position in order to continue.

If a problem occurred during a tool change, a tool changer recovery needs to be performed. Enter the tool changer recovery mode by:

Press RECOVER and navigate to the TOOL CHANGER RECOVERY tab.

Press ENTER. If there is no Alarm, the control first attempts an automatic recovery. If there is an alarm press RESET to clear the alarms and repeat from step 1.

At the VMSTC TOOL RECOVERY screen, press A to begin automatic recovery or E to exit.

If the automatic recovery fails, press M to continue for a manual recovery.

In manual mode, follow the instructions and answer the questions to perform a proper tool changer recovery. The entire tool changer recovery process must be completed before exiting. Start the routine from the beginning if you exit the routine early.