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The Automatic Tool Changer of DMU 60 / 80 P with TNC 426 Control

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List of necessary Key Numbers

Key Number Function

95148 Opening of Memory for Machine Parameters

807667 PLC-Mode selection for display of In and Output points
80766769 PLC-Mode selection for Edit in PLC-Range
72697680 Selection of Help-Funktions
531210 Resetting all Merker -bits used

Steps to open Memory for Machine Parameters

MANUAL
1. Manual
Manueller Programm-Einspeichern/Editieren
Betrieb

2. Process “Programm-Store/Edit“

3. MODE Mode Input Key number “95148 “

4. ENT Enter

5. The Maschine Parameters will be displayed

6. Select the required Parameter either with

GOTO
the Cursor or with “GOTO”-key.

END
7. Quit parameter memory with
this key.

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Adjustments of Tool Changer during asssembly on DMU 80P Machine
Introduction
The Tool Changer is assembled as a Functional Module initially .This ap-
proach limits the ammount of adjustment work during final machine assembly,
as listed below.

They are: - Determining Tool Changing Position for X-Axis (MP 4210.10)
and the Z-Axis (MP 4210.6)
- The position of Tool Magazine in Y-Direction for a tool change.
- M19-Position of Spindle (see Page 90-91)

Note: A maximum deviation of 1/10 mm only from the exact position is per-
missible .

Maschine Parameters

MP 4310.4 103 Selection of type of Tool Changer

MP 7261 30 oder 60 Number of Tool Pockets on the Magazine
MP 7260 254 Number of Tools in Tool Table
MP 7480.0 3 Display of Tool Pocket Number at Tool call-
block
MP 7480.1 3 Display of Tool Pocket Number at Tool Def-
block

Note: For determining the Tool Changing positions the sceen display must
be switched over to “REF“ .

For adjustments, tools(Id.No.63.019599 & 61.112660), as shown below,are ne-

cessary.

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General Information
A movenent control of the tool changer for required adjustments , are to
be executed in the operating mode “ Help“.It is necessary during the in-
stallation work, to set a Commisioning Marker “898 “ at Control.The Marker
prevents Error displays during Work (Exeeding the Time Limit caused by the
Refill Unit).Refer Page 88 for method of setting this Marker.

Steps for activating “ HELP-Function“

The “Help-Function” has been integrated in the control to support instal-

lation and service activities.The use of the Help-Function needs however,
a clear understanding of system sequences in advance.
It can be activated only in the Operating Modes ” Refp.-Search“, “Manual“
and „Jog“ .

MANUAL
1. Manual
Manueller Programm-Einspeichern/Editieren
Betrieb

2. Process “Programm-Store/Edit“

3. MODE Mode Input Key Nubmer “72697680 “

4. ENT Enter

Manueller Betrieb Programm

Einspeichern

5. Process „Manual Mode“

6. MODE Mode

7. HELP Help Selection of Language

Programm-Store/Edit
File-Name =

Englisch
German

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8.

GOTO

9. Change to Left Window (Languages)

10. Selection of Language “English“

11. Change to Right Window

12. ENT A list of Resetting functions will be displayed

on screen.

HELP-Funktionens for the ATC

- ATC -Movents to be executed with Cursor Section and pressing NC-START

# 0010 ATC Carriage TO MAGAZINE

# 0011 ATC Carriage IN BASIC POSITION
# 0012 ATC Carriage TO SPINDLE
# 0013 TOOL GRIPPER 1 (Gripper 1 (Collector) turns towards Spindle)
# 0014 TOOL GRIPPER 2 (Gripper 2 (Fetcher) turns towards Spindle
# 0015 ATC SHUTTER open
# 0016 ATC SHUTTER close
# 0017 SPINDLE IN TOOL CHANGING POSITION
# 0018 TOOL CLAMPING OPEN/CLOSE

MOVING AXIS TO TOOL CHANGING POSITIONS

# 0019 CROSS-AXIS DRAW-BACK POSITION

# 0020 VERTICAL-AXIS CHANGING POSITION
# 0021 VERTICAL-AXIS AUSFAHRPOSITION
# 0022 VERTICAL -AXIS FREIFAHRPOSITION
# 0023 LONGITUDINAL -AXIS CHANGING POSITION

INITIALIZING PLC FOR AUTO TOOL CHANGING

# 0024 INITIALISING TOOL CHANGING SOFT WARE

# 0025 T0 IN SPINDLE PLC-SOFTWARE
CHECK TOOL MEMORY OF CNC SYSTEM !!
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RELEASING AXES FOR MOVEMENT

# 0026 MOVEMENT OF AXES

# 0027 INIT SOFTWARE FOR TOOL BREAKAGE MONITORING

HELP-Funktions for Univesal Swivell Milling Head

EXECUTE FUNCTIONS OF UNIVERSAL SWIVELL MILLING HEAD WITHT NC-START

# 0001 SMH CLAMPING OPEN

# 0002 SMH CLAMPING CLOSE
# 0003 SMH TURNED FOR HORIZONTAL MILLING
# 0004 SMH TURNED FOR VERTICAL MILLING

AXIS MOVEMENTS TO TOOL CHANGING POSITION

# 0005 SMH HORIZONTAL POSITION

# 0006 SMH VERTICAL POSITION
# 0007 SMH X-AXIS LEFT SIDE RANGE
# 0008 SMH X-AXIS RIGHT SIDE RANGE

RELEASING AXES FOR MOVEMENTS

# 0009 ALL AXIS CAN BE MOVED

[END]

12. End
Exit Help -Function with Block-End key.

General Remarks :
If a Help Function is selected with the Cursor,its Execution needs a con-
tinued pressing of the “NC-Start” Key.

Note: In case, the NC-Start Key is realeased before arriving the destina-
tion point,the movement will be stopped immediately. This is ap-
plicable also for the Axis movements.For an Optical Confirmation
,the controller blinks “Stip“ (*) sign ,when the destination point
is arrived and the NC-Start Key is pressed further.

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Informations relating to the individual Help Funktions

# 0010 ATC-Carriage to Magazine

The movement of the ATC-Carriage to Magazine will be executed only,

when the Tool Magazine is not in motion, or when the Tool Grippers
are at defined positions,or the Commisioning Marker (see Page 88)
shows Status 1

# 0011 ATC-Carriage in Basic Position

For execution of this function, the Tool Grippers must be at defined

positions,or the Commisioning Marker has been set.

# 0012 ATC-Carriage in Basic Position

The Preconditions for executing this Function are :

1. ATC -Shutter is OPEN oder mechanische Klappe (MP 4310.3)
2. The Tool Grippers are at defined positions or the Commisioning
Marker has been set.

# 0013 Tool Gripper 1

A Turn About of Tool Grippers is possible only when the ATC-Carriage

stands at the Basic Position or at the Spindle Position or the Com-
misioning Marker for Tool Changing is active. The Tool Gripper 1
turns towards spindle.

# 0014 Tool Gripper 2

A Turn About of Tool Grippers is possible only when the ATC-Carriage

stands at the Basic Position or at the Spindle Position or the Com-
misioning Marker for Tool Changing is active. The Tool Gripper 2
turns towards spindle.

# 0016 Closing ATC Shutter

For executing this function the ATC -Carriage must stand atthe Basic
Position or at Magazine Position or alternatively the Commisioning
Marker has been set.

# 0017 SPINDLE IN TOOL CHANGING POSITION

The Spindle will be positioned at the value of Maschine parameter

MP 4210.30
# 0018 TOOL CLAMPING OPEN/CLOSE

By using key NC-START, the tool clamping can be opened or closed.

The Function will be blocked ,in case a Spindle Functionis presently
aktive.

Note : In case Jumpers have been used for Cabine Doors and the Machine
Parameter MP 4210.31 is set to value 30 000,the Tool Clamping
needs following handling :

A Tool in the Spindle must be at first firmly held by hand before

pressing NC-Start key to open clamping.This is because, the Clam-
ping will open immediately without time lag.

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The clamping will close with the next pressing of the key.
If the Machine Parameter is not set , it is additionally required
to use the Rotary Switch at panel after pressing NC-Start.
# 0019 - # 0023 AXES AT TOOL CHANGING POSITION

The precondition for this execution is the Reference Points of the

Axes have been arrived previously.

Note : To move axis to the Tool Changing Position speed will be reduced .
The Speed Setting is according to Machine Parameter MP 4231.16 for
1000 .The Feed Override is active .

# 0024 INITIALISING ATC-SOFTWARE

When the ATC-Carriage is brought to the Basic Position,the Marker

has to be executed by selecting function “Tool Changer-Software IN-
IT“ and pressing the “NC-Start”-key . The Register for Tool Grippes
as well as the Status of the Tool Changer ,which was aktive before
will be set back .The Locking of “ M77“-function is cancelled.
Otherwise the Error message “ATC not in Basic Position” is shown.
No movement of the ATC takes place .

# 0025 T0 IN SPINDLE PLC-SOFTWARE TOOL MEMORY OF NC CHECK !

If a Tool is removed from the Spindle returned to the Tool Magazine

using the Help Function,it is imperative to activate the Function
# 0025 .
The IPLC-Marker for the Spindle status will be set back .

Note : The Tool memory marked “ Pocket Table“ needs correction.

# 0026 AXIS MOVEMENT

Note : The Speed of movement will be considerably reduced . The speed value
set with the Machine Parameter MP 4231.16 to 1000 .The Feed Over-
ride Potentiometer remains active . The Axis can now be moved by
manual jogging by using the Directional Jog Keys.

# 0027 TOOL BREAKAGE MONITOR SOFTWARE INIT

Through the disruption of a Tool Changing (of a Tool ,with Breakage

Monitoring activated ) and moving back the ATC-Carriage to the Ba-
sic Position using Help Function,it is necessary to reactivate the
Tool Breakage Monitoring once again.
This necessity arises due to reason, that the Monitoring is not-
functional during a tool exchange.

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Determining the X-Axis Tool Changing Position (Longitudinal Axis MP 4210.6)

The Position Display will be switched over first to “REF“ , which will
enable a direct reading of the respective Position Values.The Special
Tool with the stationary Dowel is to be introduced now in the Milling
Spindle with the SMH in verticl position.
The machine Axis should be now for reasons of safety,be moved to
adequately safe positions( about half way of travel) before any attempt
is made to bring the ATC-Carriage inside the working area.Using the Help
Functions the ATC-Carriage can then be moved to following final
positions.

- Opn ATC Shutter

- Turn Gripper 2 (Holer) towards Spindle (A rotation is possible only
with carriage in the basic position or under the spindle.)
- Bring ATC-Carriage to spindle
- Push down the lever of Gripper locking mechanism and set the tool holder
with supplimentary tool in gripper .

In order to move the Axes ,the Help Function “# 0026 - Axis Travel“should
be selected. The Axis X and Z are now positionrd in such a way, that both
the tools are approximately concentric. The deviatiation in concentricity
in the X-Axis can be observed by turning the rotable dowel .To find the
exact axis position for tool changing,both the tools should be now brought
on the same center line exactly, by fine adjustment of positions using
Jog - Step or Continuous jogging . The Help-Function “# 0026 Axis Travel“
permits such movements. Once the position is arrived, the actual position
value of X-Axis is noted down from display, to be used later as the input
value for MP 4210.6.

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Determining Tool Changing Position of X-Axis (MP4210.5)

stationaary dowel

rotable half Cylinder

supplimentary tool

Position Adjustment Of ATC- Carriage in Y-Axis (Cross Axis)

The tool changing position of the ATC carriage does not include any movement
of the Y-Axis. This implies ,that if a positioning inaccuracy in Y-Axis,is
observed during automatic tool changing, the complete ATC-Module has to be
shifted parallel to Y-Axis (Table Movenent Axis)for correct setting.

The Tool Changer Module is screwed on to the machine bed as a complete unit
and is provided with two Accurate key- ways for guidance during Y-Axis
shift(parallel to Table).The position shift of the complete module can be
carried out with a screw rod provided.Refer drawing next page.
The ATC-Module has a tendency to tilt, when the 4 fixing bolts are unscrewed
and theby cause tightness in the key-ways for any shifting.To prevent this,
first support the module with Wood underneath at top of the Floor Plate.
In case a crane is available , it can also provide support by a slight
lifting of the ATC-Module. By rotating the Adjustment Nuts of Screw Rod,the
complete ATC- module is to be set in Y-axis ,concentric to spindle. After
tightening the fixing bolts , it is necessary to repeat the position check
for the X and the Y-axis.Eventually, a final adjustment of the axes are to
be carried out for accuracy.

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Locking Nut

Screw Rod

Angle

4 Nos. Fixing Bolts

Carrier of ATC- Module for ATC- Module

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Determining the Tool Changing Position for the Z-Axis ( Vertical Axis , MP 4210.10 )

Procedure:
The special setting tool ,which is now in the tool gripper, is to be remo-
ved. With the tool changer in Basic Position, move the Z-axis to a position
where the tool gripper is exactly in the middle of V-groove at tool holder
collar (tool in spindle).There are two possible methods for determining the
position.

Determining the Z-Axis Tool Changing Position Z-Axis

Feeler Gauge
Tool in Spindle

First Method of Determining Position (Z-Axis)

Due to reasons of safety, it is necessary to disconnect the valve controls

(21Y2.1, 21Y2.2, 21Y3.1 und 21Y3.2) and move the ATC by hand.
As a first step, push the tool changer towards the tool in spindle to a
distance that the gripper jaws come very close to the tool holder collar.The
gap can now be measured with the feeler gauge.The Z-axis is now to be ad-
justed by incremental step jogging,till the gripper is concentric with the
V-groove.The position value is to be recorded from the Actual Position dis-
play, to be used as Input value for MP 4210.10 .

The ATC-Carriage is to be brought back again to the Basic Position and the
tool removed from the spindle.Now execute Help- Function “ INITIALIZE TOOL
CHANGING SOFTWARE “.Exit Mode with Key ” Block-End “. Input the previously
determined value in MP -Table.Prior to testing the functional accuracy of
the ATC in automatic cycle, a complete tool changing cycle should be simu-
lated step by step ,using the Help-Funktions.In this way , the individual
stations for a tool change can be arrived stepwise, enabling a counter check
for positional accuracy.

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Second Method of Determining Position ( Z-Axis )

The following precoditions are to be established :

- No tool in Grippers
- The Milling Spindle carries a tool and the spindle stands oriented at M19
-Position.
- The Longitudinal Axis (X) and the Vertical Axis (Z) are moved to positions
midway of their travel range to ensure safety.
- The ATC-Unit is moved to Spindle by using Help-Function “ # 0012 ATC-
Carrier to Spindle“.

The axis X and Z are now moved by manual jogging in such away that the V-
Groove of Tool Holder in spindle, stands close to the Tool Gripper.Using
incremental Step-Jogging , the Z-Axis Position can be finely adjusted to
bring the gripper exactly in the center of V-Groove.
Zur Überprüfung kann eine Meßuhr an die Greiferplatte angestellt werden,
welche beim Vorsichtigen Einfahren der X-Achse (X-Wechselposition) beob-
achtet wird.
The permissible deviation is 0.1mm max.
The Position value for Z-axis is read from Correspondind Axis -Display
(Ref) and to be noted down as Input value of MP 4210.10 .

Checking ATC-Functions and Input of Machine Parameters

The ATC Carriage is to be brought back again to the basic position.Remove

the Tool ,which is now in Spindle,and execute Help- Function “ TOOL CHANGE
SOFTWARE INITIALISE“ .Exit Help-Funktion with Block-End key.The Machine Pa-
rameter values determined and recorded ealier, are to be entered now in
memory. Before running the system in full Automatic Mode the motion se-
quence must be checked once with Help-Function for the complete tool chan-
ging cycle.This way ,the individual positioning movement of the involved
axis can reconstructed step by step.

As a possible alternative for checking ATC-Function, a “Tool call“ command

can be executed in Single Step Mode . For this purpose change the value
of Machine Parameter MP 4310.2 to a value = current value + 32 .

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Machine Parameters used for the ATC

Machine Parameter Description Input Example.

MP 4310.2 ATC general Funtions Bit- Coded
88
+0 Man. tool change : all axis free
+1 Man. tool change : all axis except X free
+2 Man. tool change: only tool axis free
+4 Man. tool change: no axis free
+8 Check tool in gripper during fetching from
magazine
+16 Function Stop for tool clamping in mode
Manuall/Jog
+32 Activate Single Step mode for ATC installation
+64 Activate Tool Breakage Monitoring
+ 128 Further processing with Replacement Tools in
case tool breakage is observed.

MP 4310.4 Selection of ATC-Type 103

DMU80T = 101
DMU50V = 102
DMU80P = 103
DMC70V = 111
DMC50V = 112
MH 1x00 = 122

Description of Tool Changing Positions

MP 4210.6 Automatic tool changing position 1 + 3.9
X-Axis / Longitud. Axis (Tool changing position)

MP 4210.10 Automatic tool changing selposition 1 - 212.48

Z-axis /Vertical Axis (Tool changing lposition)

MP 4210.11 Automatic tool changing position 2 - 97.48

Z-Axis/Vertical Axis (Ausfahrposition)
MP 4210.11 = MP 4210.10 - 115 mm

MP 4210.12 Automatic tool changing position 3 - 10

Z-Axis/Vertical Axis Freifahrposition

MP 4210.14 Automatic tool changing position 1 - 10

Y-Axis/Cross Axis
Draw-Back position

MP 4210.0 Manual tool changing position 1 + 770

X-Axis (Wechselposition)

MP 4210.1 Manual tool changing position 2 0

X-Axis (frei)

MP 4210.2 Manual tool changing position 1 - 20

Z-Axis (Wechselposition)

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Machine Parameter Description Input Example

MP 4210.3 Manual tool changing position 2 0
Vertical Axis (frei)

MP 4210.4 Manual tool changing position 1

Cross Axis (Changing position) -20

MP 4210.5 Manual tool changing position 2

Cross Axis (frei) 0

MP 4210.30 Spindle Orientation position 1 for ATC

(vertical) 0

MP 4231.16 Maximum Feed value for HELP-Function

[mm/min] +1000

Timer Grid (21 ms) for Function Monitoring

MP 4110.26 Monitoring time Tool Clamping Open / Close 250

MP 4110.42 Monitoring time ATC Shutter Open / Close 500

MP 4110.43 Monitoring time ATC Gripper Turn Around 500

MP 4110.44 Monitoring time ATC Carriage Movement 500

MP 7260 Number of Tools in 254

Tool List

MP 7261 Number of Pockets in 30 oder 60

Tool Magazine

Elements of Tool List

MP 7266.0 Tool Description (Name) 1

1 to 99 = Position in Tool List

0 = No display

MP 7266.1 Tool Length (L) 2

MP 7266.2 Tool Radius (R) 3

MP 7266.3 Tool Radius 2 (R2) 4

MP 7266.4 Tool Length -Allowance (DL) 5

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Machine Parameter Description Input

MP 7266.5 Tool Radius-Allowance (DR) 6

MP 7266.6 Tool Radius-Allowance 2 (DR2) 7

MP 7266.7 Tool Locked ? (TL) 8

MP 7266.8 Replacement Tool (RT) 9

MP 7266.9 TIME 1 10

MP 7266.10 TIME 2 11

MP 7266.11 CURRENT TIME 12

MP 7266.12 Tool Remarks (DOC) 13

(LTOL)

MP 7266.13 Number of Cutting Edges for Tool (CUT) 14

MP 7266.14 Wear-Tolerance for Tool-Length 15

MP 7266.15 Wear-Tolerance for Tool-Radius 16

(RTOL)

MP 7266.16 Cutting Direction of Tool (DIRECT) 17

MP 7266.17 PLC-Status 18

MP 7266.18 Tool Length Offset (TT:L-OFFS) 19

(LBREAK)

MP 7266.19 Tool Radius Offset (TT:R-OFFS) 20

(RBREAK)

MP 7266.20 Breakage-Tolerance for Tool Length 21

(LBREAK)

MP 7266.21 Breakage-Tolerance for Tool Radius 22

(RBREAK)

MP 7266.22 Length of Cutting Edge (LCUTS) 23

MP 7266.23 Angle of Penetrationl (ANGLE) 24

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Machine Parameter Description Input

Elemente der Platz-Tabelle

MP 7267.0 Tool Nummer (T) 1

1 bis 99 = Position in der Pocket List
0 = No Display

MP 7267.1 Special-Tool (ST) 2

MP 7267.2 Fixed Pocket (F) 3

MP 7267.3 Locked Pocket (L) 4

MP 7267.4 PLC-Status (PLC) 5

MP 7480.0 Output of Tool or Pocket Number 3

at Tool Call- Block

3 = Output of Pocket Nummer (W262) and Tool-Num-

mer (W264) only at a change of Tool number

MP 7480.1 Output or PocketzNumber

3
at Tool DEF-Block

3 = Output of Pocket Nummer (W262) and Tool-Num-

mer (W264) only at a change of Tool number

Simulated Tool Changing Position for Tool Call with Look Ahead Function
MP 951.0 X-Axis [mm or Degree] 254

MP 951.1 Y-Axis [mm or Degree] 254

MP 951.2 Z-Axis [mm or Degree] 254

MP 951.3 4th.-Axis [mm or Degree] 254

MP 951.4 5th.-Axis [mm or Degree] 254

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Special Note for individual Machine Parameters
MP 4310.2
+8 Check Tool in Gripper during fetching from Tool Magazine
The Function of Switch ”22S3“,which has been explained earlier,for Tool
identification at Hand Over Pocket, are thereby extended with following
activities .
- If the Tool is removed from the Magazine,the switch will be monitored for
“Zero-Signal“. This means that the Tool is in the Gripper.
- During the Tool return to Magazine, it will be checked first,whether the
Pocket is free. After the deposition it is to be checked,whether the tool
is really in the pocket or not . With the Tool in the Pocket, the signal
will change to “1“.In case it does not happen, it indicates that the tool
is still in the ATC Gripper .The Control will repeat the Tool deposition
movement for a second attempt .After the failure of this only,the Error
Report will be displayed .

MP 4210.30
Spindle Orientation Position 1 for ATC (Vertical)

- The M 19-Position of ATC for a vertical Tool Change is the input.

Refer M 19 explanations , Page 90-91.

MP 4210.32
X-Axis position of SMH for Swivelling( position-Cabine Door)

- If the X-Axis position is very close to the Cabine Door, (caused by manual
jogging or by Tool Position from the Programm) and then the cycle for
Head Swivelling is activated, the Spindle Head will initially move to
this position,before executing the swivelling cycle.

MP 4210.35
X-Axis position of SMH for Swivelling( position-ATC)

-If the X-Axis position is very close to ATC -Shutter and wall and then the
cycle for Head Swivelling is activated, the Spindle Head will initially
move to this position, before executing the swivelling cycle.

MP 4231.16
Maximmum Feed value for Help-Function

- The Axis movements to reach the Tool Changing Position with Help-Function
and further movements will be executed with this Feed value.The Feed Over-
ride is active.

MP 4110.42-44
Monitoring time for ATC

- The prescribed time limits are also active during working with Help-
Function. They can be deativated using Marker 898 for Commissioning. See
Page 88.

MP 4231.31
Maximum Spindle RPM for SAFETY REGULATIONS.

- With an Input value of 30 000, the Monitoring for SAFETY will be deacti-
vated. This step is necessary for eample during a Auto Tool Change or
similar activity with a by-passed cabine door.All doors must be uniformm-

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ly by-passed.

MP 4310.4
Selection Type of Tool Changer

- In case it is required to cancel the tool changer Option,then set value

“0“ for this Parameter.

MP 7480.0
Output of Tool Nr. or Pocket Nr. at Tool DEF- Block

- If the Option for Tool Changer Type is cancelled, then set value “1“ for
this Parameter.

MP 7480.1
Output of Tool Nr. or Pocket Nr. at Tool DEF- Block
- If the Option for Tool Changer Type is cancelled, then set value “1“ for
this Parameter.

MP 951.0 to .4
Simulated Tool Changing Position during “ Tool call“ for Look Ahead

- In these Parameters the same values must be input as for the actual values
of tool changing position for ATC. This is Important , because during a
Block Entry every Tool Change is mapped in the background.

Machine Parameters to cancel ATC

MP 4310.2 ATC - General Functions

- Deduct 8 from Input value

MP 4310.4 Selection of ATC Type

- Set value to “ 0” to cancel selection.

MP 7480.0 Output of Tool nr. or Pocket NR. at Tool DEF-Block

- If the ATC slection is cancelled ,then this Parameter value must be set
to”2”

MP 7480.1 Output of Tool Nr. or Pocket Nr. at Tool DEF-Block

- If the ATC slection is cancelled ,then this Parameter value must be set
to”2”

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