detaINTERNATIONAL - TOPWELL · deta international process part list. d4-02-08 2001/12 page model...

detaI N T E R N A T I O N A L

#40 CHAIN TYPE TOOL CHANGER SYSTEM

MAINTENANCE MANUAL

This manual is applicable to model:

MC4BQ

BT40/CAT40/DIN40/HSK63A

1

Contents Page

1、Tool Changer System Mechanical Specification & Drawings··········02 2、Tool Changing Motion Flowchart·······················································04 3、Power Supply Specification for Electronic Control··························05 4、Electrical Control·················································································06 5、Electrical Control Protection Programming······································07 6、Installation Procedure·········································································08 7、Original Setting····················································································10 8、Trouble Shooting·················································································11 9、Maintenance·························································································17

2

1、Tool Changer System Machinery Specification & Drawing

1-1.Specification:

1-2.Maximum Tool Rotational Inertia Diagram:

Drawing:

Item MC4BQ

Tool Magazine Capacity 40 Tools

Maximum Tool Diameter 76mm / 127mm

Maximum Tool Weight 7 Kgf

Maximum Tool Rotational Inertia 216 Kgf – cm

Tool Total Weight 200 Kgf

Tool Changing Speed (Cambox only, not including Spindle Clamp/Unclamp)

1.86 sec (60Hz) (1:12)

Tool Chain Divisional Time 0.5 sec (60Hz)

Method of Tool Selection Two-Way Random Tool Selection

3

1-3.Drawings:

Assembly drawing and part list for chain type tool magazine, Tool changing mechanism and tool changing arm as per attached drawings and list.

D4-02-07

2001/12

PAGE MODEL DESIGN CHECK APPROVE

1/2 #40X40T CHAIN TYPE MC4BQ0000A01Candy

2006/01/10

NO. PART NAME PART NO. Q'TY NOTE

1 POT ASSEMBLY P40C-0000B01 40 OPTION

2 SPROCKET MC4A-0002A03 1

3 HOUSING MC4A-0003A02 1

4 MOTOR SEAT MC4A-0004A02 1

5 ADJUSTABLE RAIL MC4A-0005A03 1

6 SPACER MC4A-0006A01 6

7 CHAIN RAIL(I) MC4A-0007A02 1

8 SHAFT MC4A-0008A01 1

9 GEAR MC4A-0009A02 1

10 GEAR MC4A-0010A04 1

11 BRACKET MC4A-0011A01 1

12 SENSOR SEAT MC4A-0012A02 1

13 PNEUMATIC CYLINDER MC4A-0014A02 1

14 DOG MC4A-0015C04 12

15 COVER SEAT MC4A-0017A02 1

16 TOOL TILT BLOCK MC4A-0018A04 1

17 SHAFT MC4A-0019A01 1

18 COVER MC4A-0021A06 1

19 DOG MC4A-0022A01 1

20 RAIL SEAT(I) MC4A-0023A02 5

21 RAIL SEAT(II) MC4A-0024A02 1

22 ELECTRIC BOX MC4A-0027A01 1 OPTION

23 ELECTRIC BOX COVER MC4A-0028A01 1 OPTION

24 PENUMATIC CYLINDER MC4A-0043A01 1

25 PLATE MC4B-0002A02 2

26 FRONT COVER MC4B-0005A03 1 OPTION

27 RAIL(I) MC4B-0008A02 2

28 RAIL(II) MC4B-0009A02 2

29 POT BRACKET(LEFT) MC4B-0010A01 1

FC30

UNIT NO.

SPECIFICATION

φ63X75L FA

SS41

S45C

SCM4

SS41

SS41

SS41

SS41

23X23

SS41

SCM4

FC30

FC30

SS41

SS41

deta INTERNATIONAL PROCESS PART LIST

FCD45

FC30

FC30

SS41

SS41

φ63X25L FA

SS41

S45C

SS41

SCM4

SS41

SS41

D4-02-07

2001/12


2/2 #40X40T CHAIN TYPE MC4BQ0000A01Candy

2006/01/10


30 POT BRACKET(RIGHT) MC4B-0011A01 1

31 MAIN BODY MC4BQ-001A04 1

32 TOOL POSITION BRACKET MR4A-0012A08 1

33 TOOL TILT BLOCK RAIL MR4A-0014A01 2

34 POT CHAIN ASSEMBLY P40CC000VA0A 4

35 POT CHAIN ASSEMBLY(HOME P40CC000VA0B 1

36 ABOVE

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

FC30

UNIT NO.

U.H.M.W.PE

SS41

SS41

SPECIFICATION

S45C

SS41


EDITION:01


1/2 #40X40T CHAIN TYPE MC4BQ0000A01Maggie

2005/05/20


101 BOLT BT0000000020 2

102 TAPER ROLLER BEARING BE0000032010 2

103 BEARING LOCKING NUT RN0000000050 1

104 AW WASHER RW0000000050 1

105 SKT. HD. CAP. SCR. CP0000005010 2

106 SKT. HD. CAP. SCR. CP0000006016 20

107 SKT. HD. CAP. SCR. CP0000006020 8

108 SKT. HD. CAP. SCR. CP0000006050 4

109 SKT. HD. CAP. SCR. CP0000006055 6

110 SKT. HD. CAP. SCR. CP0000008025 7

111 SKT. HD. CAP. SCR. CP0000008030 6

112 SKT. HD. CAP. SCR. CP0000008035 4

113 SKT. HD. CAP. SCR. CP0000006030 12

114 SKT. HD. CAP. SCR. CP0000010035 8

115 SKT. HD. CAP. SCR. CP0000010045 2

116 SKT. HD. CAP. SCR. CP0000010050 4

117 SKT. HD. CAP. SCR. CP0000012050 4

118 SKT. HD. SET. CP0000004010 2

119 SKT. HD. SET. BH0000005010 2

120 SKT. HD. SET. BH0000006010 32

121 BUT. HD. CAP. SCR CP0000006008 1

122 BUT. HD. CAP. SCR HH0000012080 1

123 BUT. HD. CAP. SCR CS0000012045 1

124 SKT. HD. SET. SCR NT0000000010 1

125 SKT. HD. SET. SCR NT0000000012 1

126 SKT. HD. SET. SCR NT0000000016 1

127 SKT. HD. SET. SCR NT0000000016 1

128 WASHER WA0000000010 2

129 WASHER WA0000000012 4

130 SPRING WASHER SW0000000005 1

M5XP0.8X10L

M5

M12

M12XP1.75

M16XP1.5

M16XP2.0

M10

M6XP1.0X8L

M12XP1.5X80L

M12XP1.75X30L

M10XP1.5

M12XP1.75X50L

M4XP0.7X10L

M5XP0.8X10L

M6XP1.0X10L

M20

32010

AN10

AW10

M6XP1.0X16L

M6XP1.0X20L

M6XP1.0X50L

M6XP1.0X55L

M8XP1.25X25L


UNIT NO.

SPECIFICATION

M8XP1.25X30L

M8XP1.25X35L

M6XP1.0X30L

M10XP1.5X35L

M10XP1.5X45L

M10XP1.5X50L

EDITION:01


2/2 #40X40T CHAIN TYPE MC4BQ0000A01Maggie

2005/05/20







136 FLAT HD. SCR FM0000006020 25

137 PNEUMATIC VALVE EV00222D2400 1

138 PNEUMATIC VALVE EV00212D2400 1

139 PILOT CHECK VALVE LV0000000002 1

140 VALVE FV0000000802 1

141 QUICK COUPLER QC000JPL0802 5

142 MUFFLER NE0000000002 2

143 BLOCK AB0000020200 1

144 REED SWITCH RS00000LSAD1 4

145 MALE STUD EQUAL TEE UC0000030313 1

146 RETARD SPEED MOTOR MT2022022260 1

147 PROXIMITY SWITCH SR0000000012 3

148 AIR HOSE WP0000006020 1

149 AIR HOSE WP0000008025 1

150 AIR HOSE WP0000008027 1

151 AIR HOSE WP0000008060 2

152 AIR HOSE WP0000008080 1

153 VALVE FV0000000803 2

154 QUICK COUPLER QC0000010802 1


156 DIRECT COUPLER TC0000001302 1


158 SET SCREW IC0000000002 1

159 POT RAIL UP0022052060 2

160 ABOVE

JPL-06-M5

3/8(OUT)X1/4(IN)

1/4PT"

1/4 DC24V

PC-02

φ8x80cm

JPL-802

φ8x60cm

JSC-803

3/8PT3/8PTX3/8

φ8x25cm

φ8x27cm

1/2HP 1:60 220V

3RG4012-OAB00

φ8x20cm

S-G1/4"

1/4x2 BF520202

LSAD-1

M6X1.0X20L

1/4 DC24V

JSC-802

JPL 08-02

M8

M10

M12

M16

M6


UNIT NO.

SPECIFICATION

2M

JPC-6-03

D4-02-07

2001/12

PAGE MODEL UNIT NO. DESIGN CHECK APPROVE

1/1 #4OARM (R=265) A40C-0000B03Maggie

2005/04/28

NO. PARTS NAME PART NO. Q'TY MATERIAL NOTE

1 MAIN BODY A40C-0001B07 1 S50C

2 GRIPPER(BT) A40C-0002A02 2 S50C OPTION

3 GRIPPER(CAT,DIN) A40C-0002B02 2 S50C OPTION

4 GRIPPER(HSK63A) A40C-0002C03 2 S50C OPTION

5 FINGER A40C-0003B04 2 S50C

6 KEY(BT,CAT,DIN) A40C-0004A01 2 S45C OPTION

7 KEY(HSK63A) A40C-0004B01 2 S45C OPTION

8 SAFETY PIN A40C-0005A03 2 S45C

9 SPRING COVER A40C-0006A04 2 S45C

10 FINGER SPRING A40C-0007A02 2 φ17.1x61.4L

11 PIN SPRING A40C-0008A02 2 φ14.2x52L

12 SNAP RING PRESS PLATE A40C-0009A02 1 SCM4

13 PRESS BRACKET A40C-0010A01 1 S45C

14 ARM SPACER A40C-0011C01 1 SS41

15 ARM SPACER WASHER A40C-0012A01 SS41(0.8t)

16 SKT,HD,CAP SCR A40C-0013A03 2 M8XP1.25X11L

17 COPPER COVER A40C-0020A06 2 Cu

18 ABOVE

19

20

21

22

23

24

25

26

27

28

29

30

deta International

PROCESS PART LIST

D4-02-08

2001/12

PAGE MODEL UNIT NO. DESIGN CHECK APPROVE

1/1 #4O ARM (R=265) A40C-0000B03Maggie

2005/04/28

NO. PARTS NAME PART NO. Q'TY MATERIAL NOTE

101 TAPER SNAP RING CX0000d40D45 2 dφ40, Dφ45

102 O-RING OR0000000P18 2 P18

103 SEAL OT00000SER18 2 SER-18(φ22Xφ18X3.9H)

104 SKT. HD. CAP SCR. 6 M5X0.8PX35L



107 SKT. HD. CAP SCR. 4 M6XP1.0X55L



110 BUT. HD. SCR. 2 M5X0.8PX8L

111 SPRING WASHER 10 M8

112 SPRING WASHER 1 M12

113 SPRING PIN PN0000108025 2 φ8

114 ABOVE.

115

116

117

118

119

120

121

122

123

124

125

126

127

128

129

130

deta International

STAND PART LIST

６

Inpu

t sha

ft

86

5062

03

4802

3865

33

64

0427

8566

01

33

1383

84

8772

7250

6203

3802

48

８

Roc

ker

９

Sig

nal

5822

59

19

2588

57

8960

6937

2482

1817

7337

2145

58

2374

3381

20

４

Part

list

NO

. Pa

rts N

o.

Spec

ifica

tion

Q’T

YN

O.

Parts

No.

Sp

ecifi

catio

n Q

’TY

NO

.Pa

rts N

o.

Spec

ifica

tion

Q’T

Y

01

A40

2A10

1DEX

001

Cam

shaf

t 1

19A

402E

200D

EX00

1 Si

gnal

fixt

ure

1 43

7110

2640

H

K35

16/N

eedl

e ro

ller b

earin

gs

1

02

A40

2A20

9DEX

001

Tune

-up

cap

2 20

A40

2E30

9DEX

001

Sign

al w

heel

shaf

t 1

4471

1053

10

PFG

-502

9/O

il bu

sh

1

03

A40

2A30

9DEX

001

Tune

-up

scre

w

2 21

A40

2E40

9DEX

005

Sign

al c

ap

1 45

7120

0100

15

*24*

5/TC

type

oil

seal

s 1

04

A40

2A40

3DEX

001

Cha

in w

heel

1

22A

402E

409D

EX00

6 Si

gnal

cap

1

4671

2005

51

40*5

2*8/

TC ty

pe o

il se

als

1

05

A40

2B10

1DEX

001

Splin

e sh

aft

1 23

A40

2E50

9DEX

001

Sign

al c

hain

whe

el

1 47

7120

1380

U

HS5

0/U

HS

pack

ings

1

06

A40

2B20

3DEX

001

Bea

rings

tube

1

24A

402E

60Y

DEX

001

Sign

al a

djus

t slic

e 1

4871

2031

17

55*2

/O ri

ng

2

07

A40

2B30

3DEX

001

Tran

smit

whe

el

1 25

A40

2E70

ZDEX

001

Dus

tpro

of c

ap

1 49

7120

4070

G

50/O

ring

1

08

A40

2B40

9DEX

001

Fron

t fix

cap

1

26A

402F

10C

DEX

002

Mot

or fi

xtur

e 1

5071

2041

50

G75

/O ri

ng

2

09

A40

2B50

CD

EX00

1 B

earin

gs tu

be fi

xtur

e 1

27A

402F

2031

3A11

5 B

evel

gea

r (bi

g)

1 51

7120

4160

G

80/O

ring

1

10

A40

2B60

0DEX

001

Bac

k fix

cap

1

28A

402F

303D

EX00

2 B

evel

gea

r (sm

all)

1 52

7120

4190

G

95/O

ring

1

11

A40

2B80

9DEX

001

Bea

rings

tube

gas

ket

1 29

A40

2F70

9DEX

002

Mot

or tu

ne-u

p lo

op

1 53

7130

0090

A

N08

/Loc

knut

2

12

A40

2B80

9DEX

002

Gas

ket

1 30

A40

2J10

9DEX

001

Idle

r pul

ley

1 54

7130

0091

AW

08/L

ock

was

her

2

13

A40

2C10

2-60

L3-A

60∘

Cam

1

31A

402J

201D

EX00

2 Id

ler p

ulle

y sh

aft

1 55

7130

0120

A

N11

/Loc

knut

1

A

402C

102-

65L3

-A

65∘

Cam

32A

402J

409D

EX00

1 Id

ler p

ulle

y ca

p 1

5671

3001

21

AW11

/Loc

k w

ashe

r 1

A

402C

102-

70L3

-A

70∘

Cam

33A

402Z

00C

DEX

001

Cam

box

1

5771

3010

50

M4*

8L/H

ex so

cket

cap

scre

w

2

A

402C

102-

75L3

-A

75∘

Cam

34Y

0A20

0X28

4X13

0 ∮

20 C

am fo

llow

ers

6 58

7130

1060

M

4*10

L/H

ex so

cket

cap

scre

w

8

A

402C

102-

80L3

-A

80∘

Cam

35Y

0A22

0X34

5X11

5 ∮

22 C

am fo

llow

ers

1 59

7130

1070

M

4*12

L/H

ex so

cket

cap

scre

w

10

A

402C

102-

85L3

-A

85∘

Cam

36Y

0B24

0X45

2X13

0 ∮

24 C

am fo

llow

ers

1 60

7130

1160

M

5*16

L/H

ex so

cket

cap

scre

w

2

A

402C

102-

90L3

-A

90∘

Cam

3771

1001

30

6202

zz/B

all b

earin

gs

2 61

7130

1290

M

6*14

L/H

ex so

cket

cap

scre

w

4

14

A40

2D10

9DEX

001

Roc

ker

1 38

7110

1070

H

R30

206/

Tape

red

rolle

r bea

rings

2 62

7130

1300

M

6*16

L/H

ex so

cket

cap

scre

w

17

15

A40

2D20

9DEX

001

Roc

ker s

haft

1 39

7110

1290

H

R32

008/

Tape

red

rolle

r bea

rings

2 63

7130

1320

M

6*25

L/H

ex so

cket

cap

scre

w

6

16

A40

2D30

1DEX

001

Roc

ker f

ixtu

re

1 40

7110

1320

H

R32

011/

Tape

red

rolle

r bea

rings

2 64

7130

1460

M

8*20

L/H

ex so

cket

cap

scre

w

7

17

A40

2E11

CD

EX00

1 B

rake

sign

al w

heel

1

4171

1022

10

NTB

4060

/Thr

ust b

earin

gs

2 65

7130

1470

M

8*25

L/H

ex so

cket

cap

scre

w

13

18

A40

2E12

CD

EX00

1 C

am si

gnal

whe

el

1 42

7110

2211

A

S406

0/Th

rust

bea

rings

par

cel

4 66

7130

1490

M

8*35

L/H

ex so

cket

cap

scre

w

2

５

Part

list

NO

. Pa

rts N

o.

Spec

ifica

tion

Q’T

YN

O.

Parts

No.

Sp

ecifi

catio

n Q

’TY

NO

.Pa

rts N

o.

Spec

ifica

tion

Q’T

Y

67

7130

1620

M

10*2

0/H

ex so

cket

cap

scre

w

4

FM22

409A

A1A

M

otor

_3/4

HP_

1:9_

AC

220V

68

7130

1640

M

10*3

0/H

ex so

cket

cap

scre

w

4

FM22

410A

A1A

M

otor

_3/

4HP_

1:10

_AC

220V

69

7130

2800

M

4*8L

/Cou

nter

sink

scre

w

1

FM22

412A

A1A

M

otor

_3/

4HP_

1:12

_AC

220V

70

7130

2820

M

5*8L

/Cou

nter

sink

scre

w

4

FM22

408D

A1A

M

otor

_3/

4HP_

1:8_

DC

90/2

20V

71

7130

3010

PT

1/8”

*8/O

il pl

ug

1

FM22

409D

A1A

M

otor

_3/

4HP_

1:9_

DC

90/2

20V

72

7130

3050

PT

1/2”

*12/

Oil

plug

4

FM

2241

0DA

1A

Mot

or _

3/4H

P_1:

10_D

C90

/220

V

73

7130

3140

M

5*5L

/Soc

ket s

et sc

rew

2

FM

2241

2DA

1A

Mot

or _

3/4H

P_1:

12_D

C90

/220

V

74

7130

3150

M

5*10

L/So

cket

set s

crew

4

91

75

7130

3170

M

6*8L

/Soc

ket s

et sc

rew

8

92

76

7130

3485

∮

6/Sp

ring

was

her

4 93

77

7130

3525

∮

10/S

prin

g w

ashe

r 4

94

78

7130

5052

M

10*P

1.25

/Loc

knut

1

95

79

7130

5060

M

12/N

ut

1 96

80

7130

5805

ST

W12

/Bas

ic e

xter

nal S

TW

1 97

81

7130

8512

25

H*9

2L C

hain

1

98

82

7140

1060

4*

4*10

/Dou

ble

roun

d ke

y 1

99

83

7140

1120

5*

5*20

/Dou

ble

roun

d ke

y 1

84

7140

1540

10

*8*5

5/D

oubl

e ro

und

key

1

85

7140

2110

8*

30L/

Stra

ight

pin

2

86

7140

3210

8*

40L(

1/50

)/Tap

er p

in

3

87

7140

5070

28

mm

Oil

eyeg

lass

1

88

7170

0030

Si

gnal

-PN

P-3/

E2E-

CR

8B1

1

89

7170

4050

M

G16

A-1

0B/W

ire st

uds

1

90

FM22

408A

A1A

M

otor

_3/

4HP_

1:8_

AC

220V

1

4

2、 Tool Changing Motion Flowchart:

#40 Chain Type Tool Magazine Tool Changing Motion Flowchart – 1 ················································································ DMC4AQ001A01

#40 Chain Type Tool Magazine Tool Changing Motion Flowchart – 2 ················································································ DMC4AQ002A01 #40 Chain Type Tool Magazine Tool Changing Motion Flowchart – 3 ················································································ DMC4AQ003A01 #40 Chain Type Tool Magazine Tool Changing Motion Flowchart – 4 ················································································ DMC4AQ004A01 #40 Chain Type Tool Magazine Tool Changing Motion Flowchart – 5 ················································································ DMC4AQ005A01 #40 Chain Type Tool Magazine Tool Changing Motion Flowchart – 6 ················································································ DMC4AQ006A01 #40 Chain Type Tool Magazine Tool Changing Motion Flowchart – 7 ················································································ DMC4AQ007A01 #40 Chain Type Tool Magazine Tool Changing Motion Flowchart – 8 ················································································ DMC4AQ008A01 #40 Chain Type Tool Magazine Tool Changing Motion Flowchart – 9 ················································································ DMC4AQ009A01

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3、Power Supply Specification For Electronic Control

3-1.Follow The Table Listed Below if Chain Type Tool-Changing System’s Power Supply is not specified:

Power Supply

Category Electrical Pneumatic

Specification

Electrical Power Supply: 3 Phase

220V (50/60Hz) Signal Power Supply: DC

24V

5 BAR (Filtered Through Three- Points Assembly)

3-2.Specification Of Sensor Used In Chain Type Tool Changer System are as Followed:

Sensor Tool Magazine Positioning and Counting

Tool-Changing Mechanism

Specification

M12 PNP 24V Normal Open

Shielded Distance = 2mm

ψ4 PNP DC24V Normal Open

Shielded Distance = 0.8mm

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4、Electrical Control:

＃40x40T Chain Type Configuration Drawing for Electrical Control Components ···································································DMC4BQ011A01

Timing Sequence Drawing for Tool Changing System·····DMC4BQ012A01 Standard Wiring Diagram·················································DMC4BQ013A01 Motor Wiring Diagram for Tool Magazine·························DMC4BQ014A01 Motor Wiring Diagram for Cambox···································DMC4BQ015A01 Configuration Drawing for Pneumatic Control Components····································································DMC4BQ016A01 Sensor Wiring Diagram····················································DMC4BQ017A01 Pneumatic Circuit Diagram··············································DMC4BQ018A01

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5、Electrical Control Protection Programming

(1) As Cambox and the tool magazine move extremely fast, the control program for all motor relays, sensors, and the I/O port of electromagnetic valves should be written on PLC Level 1 of the controller (where scan time reacts faster). This is to prevent the electrical control from having slow reactions and causing mechanical wrong movements.

(2) In the proceeding of tool changing, each movement has to be confirmed for its completion signal before continuing with the next movement. (Refer to the tool-changing flowchart diagram)

(3) Do not start the motor of the tool magazine or rotate the tool chain prior to confirmation by tool magazine tool returning sensor (LS104 is ON) and orientation pneumatic cylinder sensor (LS103 is ON).

(4) Do not tilt the tool prior to confirmation by the tool magazine orientation sensor (LS101 is ON), orientation cylinder sensor (LS102 is ON) and Cambox origin sensor (LS112 is ON).

(5) Do not start the Cambox motor or rotate the tool chain prior to confirmation by tool tilt pneumatic cylinder (LS104 is ON) (LS105 is ON) during the course of tool tilt.

(6) Do not change the tool if the spindle of the machine has not returned to the tool changing position.

(7) Do not change the tool if the spindle orientation has not been completed.

(8) Do not move the spindle head if the tool arm has not return to its home position (LS112 is OFF).

(9) Overload protection relay should be activated when overloading occur, so that the motor will not be burn off.

(10) The amperage of the motor’s current has to be below the motor’s full load current. 1/4 Hp: 1.2 A; 1/2 Hp: 2 A; 1 Hp: 3A (at 60Hz)

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6、 Installation Procedure

Before installing our chain type tool-changing system, one should read this section carefully and understand this manual completely before proceeding with the installation procedure.

The adjustment of the aliment between arm and the pot within magazine has been done before the product left our factory, users do not have to spend time working on it. Hence, users could treat the tool magazine, the tool-changing mechanism and the tool arm as a complete unit without having to do any adjustment when installing our Chain Type Tool Changing System. But the tool-changing point of the spindle and the tool-changing point of the arm have to be accurately adjusted. The tool-changing point of the spindle and the tool-changing point of the arm have to be accurately overlapped, so that tool-changing movements will be smoothly carried out under normal usage without any collision noise. If the adjustment is inaccurate, not only tool-changing movements will not be smooth but it will also produce collision noises, which will have harmful effect on the life span of the tool. Hence, the only important point for installing our Chain Type Tool Changing System is “to overlap the tool-changing point of the spindle and the tool-changing point of the arm accurately”. We recommend users to follow the installation procedures below:

(1) Make a bracket as we have suggested, and tight it onto the vertical

column after confirming the bilateral perpendicularity geometrical tolerance between the vertical column interface and the tool magazine interface.

(2) Make a three-stages tool-calibration fixture as we have suggested.

(As per attached drawing)

(3) Lock the chain type tool-changing system onto the interfacing bracket. Put the two rest blocks closely on the top of the interfacing bracket and ensure the horizontal accuracy is kept.

(4) Move the Z-direction of the spindle to the highest point.

(5) Put adjustment fixture A into the spindle for the spindle to grip and let

the tool-changing arm grip adjustment fixture B. Press and release the brake, which is on top of the tool-changing mechanism motor. Then use a hexagonal spanner to turn the screw, which is located at the top

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center of the motor, until the tool-changing mechanism reaches the tool-clipping position. (Keep turning the screw on top of the tool-changing mechanism motor, and the tool-changing arm will remain fixed for a period of time. This will ensure that the tool-clipping position has been reached.)

(6) Use a level to adjust the interfacing bracket so that the tool-changing

arm is perpendicular to the spindle. (7) Move the Z-direction of the spindle to about 2mm from the top of the

predicted tool-changing point. (8) Adjust the X- and Y-direction of the tool-changing system so that the

X- and Y-coordinate of the tool changing points for the tool-changing arm and the spindle overlap. If adjusting the Fixture C allow it to pass through the Fixture B and entering the internal hole of the Fixture A that means the X and Y direction adjustment is completed.

(9) Measure the Z-direction coordinate for the tool-changing point of the tool-changing arm. Use the electronic control system to move the spindle down to approximately 0.3~0.5mm above the Z-direction coordinate of the tool-changing point for the tool-changing arm (the ideal distance would be 1/2 of the spindle clamp distance). And set this point as the coordinate for the tool-changing point. Again, use the hexagonal spanner to turn the screw on the top center of the motor in the opposite direction, until the tool-changing mechanism returns to its home position.

(10) Change the tool manually first, to check that the movements of tool pot

toppling, the tool-changing mechanism performing the tool-change, the spindle catching and releasing tools, … etc coordinate well together without any error, then proceed with CNC automatic sequence program control. After trial tool-changing several times and making sure that no bad phenomena appear, the positioning pins can be fix into positions between the tool-changing system and the interfacing bracket, and between the interfacing bracket and the vertical column, respectively.

(11) Connect the circuit for electronic control, pneumatic valves, and

pneumatic source according to the wiring diagram. (12) Pour the hi-grade of circulation oil into the tool-changing mechanism

until the surface of the oil can be seen from the oil-viewing window.

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7、 Original Setting

(1) The gap between the tool magazine orientation and the counter sensor (M12) and the sensor block should be adjusted to between 0.8~1.0 mm.

(2) The gap of tool magazine motor’s brake pad should be adjusted to between 0.3~0.35 mm.

(3) The gap between the sensor (φ4) on Cambox tool-changing mechanism and the sensing block should be adjusted to between 0.4~0.5 mm.

(4) The gap of Cambox motor’s brake pad should be adjusted to between 0.3~0.35 mm.

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8、Trouble Shooting:

8-1.Unstable tool-toppling:

We have made the best adjustment to the chain type tool-changing system before our product left our factory, and we would suggest users not to do any random adjustment. If tool toppling is unstable due to the transportation or human error, please follow the procedures below to check and make adjustment: (1) Check whether the pneumatic source conform to the power

supplying specification (refer to the section on the electronic control’s power supply specification). Re-check the pneumatic piping to see whether there is any clogging or bending.

(2) Check whether the tool-toppling mechanism has any damage to it. If so, please contact us and we will send someone over to repair it.

(3) If there is no error from the above two points mentioned, then the

tool toppling pneumatic cylinder should be adjusted (it is situated below the back side of the tool magazine main structure, please refer to the attached drawing). Please use the heaviest 8 kef tool to test the tool toppling speed, adjust the speed adjustment valve on the pneumatic cylinder, so the tool toppling stroke and tool returning stroke takes approximately 1 second each to complete. ※Note: Be sure not to set the speed too fast, otherwise there is a possible danger of dropping the tool.

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8-2. Tool Calibration Procedure:

Please adjust the arm as following procedure when need:

(1) Use an overhead crane to lift the Cambox and inspect it externally for any flaw.

(2) Use M12×50L + spring washer + flat washer to fasten the Cambox onto the datum surface of the tool magazine’s main structure, and pull the Cambox to the elongated holes on the outside.

(3) Open the power distribution box of the Cambox and connect it to the power supply of the electronic control box. Check to see if there is any abnormal phenomenon in the operation of the Cambox.

(4) Insert two sets of packing rings inside the tool-changing arm. They should be in the same direction with the female on the inside and the male on the outside (as illustrated in Diagram 1).

(5) Use M6×35L bolt + spring washer to fasten the packing rings on the tool-changing arm, but do not tighten it temporarily.

(6) Sequentially insert the separation ring for the tool-changing arm and put the tool-changing arm into the Cambox axis, and fasten M12×35L bolt + spring washer onto the tool-changing arm with a bit tightness around the axis and without any gaps.

(7) Supply electrical power to Cambox to allow the Cambox axis to

rotate to the tool-clipping angle. (8) Topple the tool pot 90 degrees and install the three-point

calibration fixture (as per attached drawing). (9) Use the three-point tool calibration fixtures to adjust the position of

the tool-changing arm. The adjustment method is to insert Fixture A into the tool pot, and Fixture B is placed at the tool clipper and coupled with the protuberance, but the tool pusher clip has to be placed into the arm first. Then, re-adjust the Cambox position, so

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that Fixture C can go through Fixture A and Fixture B and reach the arm at the position of the tool-clipping point, and line up with the center of the tool pot.

(10) After correctly adjusting the angle of the arm, fasten Cambox onto

the tool magazine with four M12×50L bolts.

(11) Check whether the protuberance of the tool clipper and the gap of the groove on the tool are consistent. The tool clipper’s clamping gap should be 0.8mm (BT shank, CAT & DIN is 0.2mm); the best position for the tool clipper protuberance is slightly above the middle, but leave some gaps above it and in arm, so that the height of the arm is as described above.

(12) After adjusting the position of the tool-changing arm and centering

the tool to make them concentric, fasten the M12×35L bolts. Then, fasten the eight M6×35L bolts one by one according to their diagonal sequence, and then re-fasten the M12×35L bolts again to tighten the tool-changing arm.

(13) In the process of tightening, use magnetic holder to hold the

leveler on the Cambox. The pointer of the leveler should touch the tool clipper near the outer rim. Repeat the height measurement for both ends of the tool clipper, where the height at both ends should be within 0.1mm of difference. The technique for adjusting the height at both ends is: to loosen the higher end of M6×35L bolt, then tighten the lower end of M6×35L bolt.

(14) Place the tool pusher clip spring onto the end of the tool pusher

clip, and after smearing some lubricating oil, fit it into the tool-changing arm. Fix M8 anti-revolving bolt + spring washer to the arm (as illustrated in Diagram 2).

(15) Turn the manual bolt behind the Cambox motor, so that the tool-

changing arm descends about 50mm. Apply lubricant on the safety pusher pin of the tool-changing arm and then insert it into the lubricated spring of safety pusher pin. Then, insert the safety pusher pin into the tool-changing arm and fasten it with M5×35L bolt + spring washer (as illustrated in Diagram 1).

(16) After fastening the parts for the tool-changing arm, try several

times to make sure that the safety pusher pin can spring upwards

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freely, and test to see if tool-changing movement is working properly by putting a tool into the tool pot.

8-3.When the tool chain does not run smoothly:

(1) Please check to see if there is any foreign object got stuck to the chain wheel or rotating axis (refer to the assembly drawing and part list). Please eliminate it.

(2) Check whether there is any foreign objects got stuck to the tool pot

track (refer to the assembly drawing and part list). Please eliminate it.

(3) Please dismantle the motor and then electrify the motor, so it

operates independently. Check to see if it rotates smoothly without any noise.

(4) If after going through above inspections without eliminating the

breakdown, please contact our company.

8-4.When the tool arm does not run smoothly:

(1) Please check to see if there is any damage to the tool-changing arm. If there is, please contact our company to have the parts replaced.

(2) Please check the tool-changing mechanism and main structure of

the tool magazine to see if there is any change to the locking position (Check to see whether there is any damage to the positioning pin or it has already been shear off. If there is, please contact our company to have the parts replaced.

(3) Please check whether there is any loose movement between the

tool-changing arm and axis of the tool-changing mechanism. If there is, please stop the machine and cut off the power supply and loosen the screw on top center of the motor with a hexagonal spanner until the tool-changing mechanism reach the tool clipping position. Push the tool-changing arm upward to the end and clip on the tool that has toppled down, then calibrate both end of the tool-changing arm so they are within (0.1mm) in height, fastening the tool-changing arm packing ring cover in between the tool-changing arm and axis of the tool-changing mechanism. (Refer to tool calibration procedure)

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(4) Be sure not to self dismantle the tool-changing mechanism, if there

is any breakdown, please contacts our company.

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8-5.When the tool-changing speed is too slow:

(1) Please check whether the motor produces any strange noise (2) Please check whether the power supply conform to the

specification.

(3) Please check whether the speed of spindle clamping and unclamping complies with the requirement.

(4) If there is any other breakdown, please contact us.

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9、 Maintenance

(1) The circulation oil inside the tool-changing mechanism should be changed after 2400 hours of continuous usage. And the oil level has to be checked non-periodically. A refill is in order if the oil falls below the required level.

(2) The cylindrical cam and the tool-toppling cam rotate inside the tool

palette should be checked approximately once a month to ensure that there is still some lubricating oil.

(3) Check and see if there is still some lubricating oil in the bearing

every three-month. (4) If the brake for the tool-changing mechanism’s motor and the tool

magazine’s motor reached the end of their useful life, please contact our company for adjustment or replacement.

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Thank you for using our products. Please inform us if there is any defect so that we can make improvements and offer you more stable and better quality products.

detaI N T E R N A T I O N A L No. 1069-10, Chung San Road, Shen Kan Village, Taichung, Taiwan.

Tel: (886-4) 2561-7722

Fax: (886-4) 2561-7177

Sales department e-mail [email protected]

Design department e-mail [email protected]

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