2 Tool Magazine

2.1 Description of tool magazine

The tool can be loaded in and unloaded from the magazine not only manually through hand-operated door at the top of the magazine, but also through the spindle.

The magazine is connected to machining space through automatic door of magazine. When the door closes, the space between them is isolated. Automatic loading tool movement between spindle and tool is achieved by tool changing-manipulator.

The passage to magazine is monitored by photoelectric switch.

Magazine can be manually operated only in a state of JOG.

Machine program can be operated only when the magazine door closes. Please confirm that no one is within the tool magazine when machine tool is operated and after maintenance.

2.2 Technical parameters

1.1.1 Tool path of magazine

	Unit	Value
Tool path	pcs.	40
Maximum tool diameter without idle tool path	mm	80
Maximum tool diameter with idle tool path	mm	130
Maximum tool length, starting from spindle nose	mm	300
Max tool weight of tools to be replaced during automatic tool changing	kg	6
Max tool weight in magazine	kg	120

2.3 Prerequisites

Check and confirm：

Alarm free for the operation panel
Air pressure value is normal.

2.4 Basic operation

2.4.1 General notes

It must be noted first that no employee is in the magazine when the magazine is moved manually.

For security reasons, after the safety door of machine tool is opened, manual loading & unloading tool key can be pressed to operate only after the unloading tool preparation key is pressed.

After automatic tool changing, wrong tool installing on the magazine or wrong record on tool management table can lead to processing errors or collision, and may cause interruption of the tool changing process.

The allocation of the present magazine shall always be noted when loading &unloding tools.
Every loading in & unloading from the tool case for tools shall be updated in the tool management table. Tools can be identified by the numerical control system only through tool names registered on the tool management table.
Special tool with major diameter (refer to Technical Data).
Additional requirements for the oversized tool shall be registered on the tool management table (encode in a fixed position).
Make sure that the actual tool conditions shall be strictly in accordance with records in the tool table.

2.4.2 Magazine operation

Magazine shall be operated in the mode of JOG.

Manual mode (MAG JOG) of magazine shall be activated only in the following situations:

Exception handling of tool magazine
Check magazine by manual operation

All operations can be finished in the tool magazine management interface at normal using.

The blade is sharp, so there is a risk of injury if toughing the blade.

Please wear safety gloves.

Don’t clamp the tool within the range of synchro flange.

2.4.2.1 Enter the tool management interface

Procedures:

Press <MENU SELECT> key.
Press[Parameter]soft key.
Press[Tool List]soft key，magazine can be operated here.

2.4.2.2 Rotate the tool manually

Procedures:

Press machine tool panel <JOG> key (manual).
Press machine tool panel <MAG JOG> key （magazine manual mode）.
Close the magazine door.
Press key 2: Magazine rotates clockwise.
Press key 3: Magazine rotates counterclockwise.

Key 1: unlock key of the magazine door;

The magazine can be rotated manually only when magazine door is closed.

2.4.3 Tool list

Tool list shows the present use condition of tool paths, that is to say, a tool is placed on the spindle, manipulator or other positions in the magazine.

The specification on tool management in numerical control system materials

shall also be valued.

2.4.2 Created a new tool

Plug the tool in the present cursor position (spindle, magazine vacancy or buffer vacancy).

Before operation, make sure that the magazine door at the loading point 2 is closed.

When creating a new tool in the spindle, you shall plug the tool in the spindle manually, and respond from the prompts.

When creating a new tool in idle magazine, the magazine will rotate a selected tool path to the position of loading point 2 automatically, after it is in place, the corresponding tool shall be plugged from the prompts, and the magazine door will be closed.

Tools newly created apart from the magazine and spindle shall be manual tools, when they are called, the spindle will move to the tool installing position firstly, then they will be plugged in the spindle manually.

Create a new tool in the spindle

Procedures:

Select the spindle in the tool list through moving cursor.

In [Parameter] interface, click soft key [New Tool]
Select required tools in the pop-up list.
Click [OK]
Number, letter or Chinese can be entered when setting the tool name. If the entered tool name has the same name with the original tool name, this tool is the sister tool of the original tool. For specification on the sister tool, please refer to the Chapter “Tool management” of
《SINUMERIK ONE Universal Operating
Manual》.
Move the cursor to set other parameters of tool.
Plug the tool on the spindle manually, then press loading & unloading tool key <OK> on the machine tool panel to finish loading.

Installing backwards or plugging dislocation of tool may damage the magazine or

spindle during tool changing; be sure to check carefully after the tool is plugged.

Create a new tool in the buffer:

Tools in the magazine of the buffer are manual; tools put outside the magazine for daily use can be stored in this zone.

Procedures:

Select a vacancy in the buffer.
In the interface [Parameter], click the function key [New Tool].
Select required tools in the pop-up list.
Click [OK].
Enter tool name and related tool parameters.

2.4.5 Tool loading

Loading, used for plugging tool within the buffer in magazine or spindle manually.

Load program appears only when selected tool path or spindle is vacant.

Prerequisites

Be sure to align down the guide gib (German angle projection).

The blade is sharp, so there is a risk of injury if toughing the blade.

Please wear safety gloves.

Don’t clamp the tool within the range of synchro flange.

Installing backwards of plugging dislocation may damage the magazine or spindle during tool changing; be sure to check carefully after the tool is plugged.

When closing the tool magazine, the door lock will block automatically.
A mechanical drop-proof mechanism keeps tools in the tool cylinder.
Load the tool in the magazine

Tool-loading in the magazine can be operated in the mode of JOG.

Procedures:

Press function key [Parameter].
Select a vacant tool path.
Press function key [Load].
Open the list of caching tool zone, press any of letter keys to expand the list, press <INPUT> Enter key to confirm.
The magazine starts rotating to the selected tool path automatically, and locate the loading point.
Open the magazine door and load tools.
Press loading & unloading tool confirming key <OK>, then loading is completed.

Load the tool on the spindle

Procedures:

Select the first column in the tool list.
Press function key [Load].
Open the list of caching tool zone, select the tool to be loaded, press <INPUT> key to confirm.
Press <JOG> key.
Keep pressing spindle tool release preparation key<CHG Rdy> until the light is on, then prepare the spindle tool release.
Press spindle tool release key <TOOL Rel>, then the spindle broaching mechanism pops up.
Load the tool on the spindle correctly, please pay attention to the plugging direction to ensure that the shank is close to the spindle nose completely.
Press spindle tool release preparation key <TOOL Rel> again, then the broaching mechanism retracts, and the tool is locked.
Press loading & unloading tool confirming key <OK>.
Loading of the spindle tool is completed.

2.4.6 Unload the tool

Unload the tool from the magazine or spindle, and the corresponding tool information shall be placed in the buffer.

If a new tool is not be placed, it will be deleted from the tool path list.
When drawing the tool, make sure that edges shall not be collided.

Unload the tool in the magazine

Unloading of the tool manually shall be operated in the mode of JOG.

Procedures:

Press function key [Parameter].
Move the cursor in the tool list, and select the tool to be unloaded.
Press function key [Unload].
The magazine starts rotating to the selected tool path automatically, and locate the unloading point.
Unlock the magazine door, and take the corresponding tool away, then close the magazine door.
Press loading & unloading tool confirming key <OK>.
Unloading of the tool in the magazine is completed.

Unload the tool from the spindle

Procedures:

Select the first column in the tool list, spindle
Press function key [Unload].
Keep pressing spindle tool release preparation key <CHG Rdy> until the light is on, then prepare the spindle tool release.
Use hands to hold the shank.
Press spindle tool release key <TOOL Rel>, then the broaching mechanism pops up, and the tool is released.
Press loading & unloading tool confirming key <OK
Unloading of the spindle tool is completed.

2.4.7 Delete the tool

Delete the tool from the magazine, and the tool unloaded will not be put in the buffer. For operation procedures, see Chapter “Unload the tool in the magazine”.

2.4.8 Tool compensation

If a tool has many compensations, every compensation has separate compensation data, for this kind of tool, you must select or specify one of these compensations to conduct the processed tool compensation numbers.

9 compensations can be set at most for every tool.

During tool change, select different compensations through different D numbers.

There is risk of collision! On some tools, such as the boring tool with bearing boss or fractional drill, if wrong tool compensation number is specified, collision may occurs when axis moves, so make sure that the tool compensation number is correct.

2.4.9 Change the tool automatically

Users can achieve automatic tool change in the following two ways.

1. Operation procedures in the mode of JOG:

Press button <JOG>.
Press soft key [T, S, M].
Enter “tool name”, or select the tool in the tool list through function key
Start automatic tool change process by pressing <CYCLE START>.
Tool loading on the spindle is finished, two seconds later, other operations can be started.

“T0” shows that after tools on the spindle are put in the magazine, there is no tool on the spindle.

2. Operation procedures in the mode of MDA and AUTO:

Press key <MDA>.
Enter tool change command T and M6, and achieve tool change through NC programming. (Refer to Fundamental Part of SINUMERIK ONE Programming Handbook).

2.4.10 Tool magazine positioning

Position the present selected tool path to the loading point. This is often used to check tools.

Operation is allowable only in the mode of JOG.

All the tool paths in the magazine can be operated except the spindle and buffer.

The green double sided arrow in the tool list shows the present tool path position corresponding with the spindle.
The gray double sided arrow shows the present tool path position corresponding with the loading point 2.

Procedures:

Select a tool path to be positioned.
Press soft key [MG positioning].
The magazine rotates automatically and prompt window of magazine positioning pops up until a selected tool path locates to the loading point.
Meanwhile, gray double sided arrow mark appears in the left side of tool path, which shows that the present tool path is in loading point 2.
Magazine positioning is finished.

2.5 Tool management

For tool management operation, refer to《Fundamental Part of SINUMERIK ONE Programming Handbook》.

The difference of tools in different positions of tool management:

Tool in the buffer: also named manual tool, it is unloaded from the magazine temporarily, and shall be plugged in spindle or magazine manually when it is used.

Magazine tool: put in the tool path of the magazine, finish automatic tool change with the tool change command.

2.6 Exception interrupt handling

2.6.1 Press Stop or Rest button during tool change

During tool change, when the process is interrupted by pressing Stop or Rest button, it shall be handled manually.

If tool change loop has not been operated to finish, a piece of fault information will be presented.

Manual operation of the magazine shall be conducted in the mode of MAG JOG.

Prerequisites

The machine tool is connected to the power.
The control voltage is connected.

Procedures：

Release <Emergency Stop>.

Press button< RESET >.

Move the spindle to safety position.
Press key <CUSTOM>.
Press <MG ADJ>.
Keep pressing key <MAG JOG> until the light is on, then the magazine manual mode is activated.
Press function key [AutoDoor Open], then the auto door of the magazine
Press key <ATC FWD> to move the mechanism arm, then move the mechanism arm to the position where tool withdrawing is convenient with the help of key [ATC returning] and [ATC rotate].
Withdraw the tool on mechanism arm, if the tool is stuck by the clampingclaw, the ATC mechanism arm shall be returned or rotated.
After all the tools on the mechanism arm are withdrawn, press key [ATC return], make sure that the mechanism arm rotate to the initial position; the button blue shows the mechanism arm is in place currently.
Press 、、、 in sequence, then the mechanism arm moves
Press function key [Auto DOR CLO], then the auto door of the magazine closes.
Unload the tool on the manipulator in the tool list.
Press confirm key of loading & unloading tool <OK>.
The tool list, clamping claw occupancy and spindle occupation must be checked. Please check if the actual occupation and the content of memory is consistent.

2.7 Protection function

2.7.1 Interlocked operation function

This function mainly aims at manual operation of the magazine to prevent collisions inside the magazine caused by human error.

After <MAG JOG> is activated, there are the following protection functions:

When the magazine door opens, the magazine stops rotating;

When the automatic door closes, positive shift of the mechanism arm is limited;

When the stroke of negative shift manually of the mechanism arm is limited, the arm will not come into the range of the tool link;

When the mechanism arm is in the tool chain, the tool magazine will be forbidden to rotate.

2.8 Maintenance

2.8.1 Tool magazine cleanup

Iron dust on moving parts of tool magazine shall be cleaned after work every day.

2.8.2 Lubrication check

With displacement of axis X, Y and Z, guide lubrication pump starts automatically instead of starting manually.
Check the guide lubrication line every week, if there is blockage, it shall be dealt with promptly.
Check if there is enough grease on the moving parts of tool chain in magazine; take care of replenishing the grease in time.