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37 Automatic Tool Changer for X11 – 24T (Clone)

DISK TYPE 40#-24T(20T)

MAGAZINE 

AUTO TOOL CHANGE SYSTEM 

INSTRUCTION MANUAL

37.1 Machine Specification

  1. Machine Reference:
    This ATC has to compose by cam, magazine body and arm.
    (Reference figure)
  2. Machine Specification
  3. 2-1       Spindle Nose

Type of Tool: BT40 (CAT)

2-2       Quantity of Tool

24 Tools

2-3       Tool Sleeve Width Between Centers

80 mm

2-4      The Max. Tool Diameter

All Pocket Full: Ø80 mm

Alternate Pocket Empty: Ø125 mm (Full guard)
Ø150 mm (Half guard)

2-5       The Max. Tool Length 300 ʠ

2-6       Tool Weight

Max. Tool Weight: 7 Kg

Average Weight: 5 Kg

2-7       Max. Tool Partial Weight 84kg

2-8       Magazine Drive Source

Forward Electric Tension: AC220V, 3 Ø, 60HZ / 380V, 3 Ø, 50HZ

Min. Air Pressure: 5-6 kg/cm2

CHEN SOUND INDUSTRIAL CO., LTD.

Customer

 

Machine model

 

Magazine Spec.

40#-24T Disk

ATC Spec.

DEX (65o)

Type of tool

40#-BT/CAT/DIN

Arm Length

530

Type of Tool sleeve

40#-BT/CAT/DIN

Revolve Angle

65o

Type of Arm

40#-BT/CAT/DIN

Partial of Angle

0

Customer Confirm:

 ________________

 

Designer:

 _______________

Customer Date:

 ________________

 

Draw Date:

 _______________

 

 

 

TEL: 04-25624338     FAX: 04-25629520

No.

Part No.

Part Name

Material /Spec.

Q’TY

Remarks

01

MBX420200

New case

FC-25

1

24T

02

MBX420080

24T Disk plate

FC-25

1

 

03

MBX410010

Disk rotate shaft

S45C

1

 

04

MBX410030

Fixed cover of rotate shaft

S45C

1

 

05

MBX410070

Sleeve of rocker shaft

S45C

1

 

06

MBX410090

Lock plate right slide seat

S45C

1

 

07

MBX410100

Fixed plate of left side

S45C

1

 

08

MBX410150

Gear

S45C

2

 

09

MBX410220

24 divide up turntable of cam

SCM435

1

 

10.    

MBX410250

Single reaction block (On)

Powder metallurgy

1

 

11.    

MBX411000

Single reaction block (Off)

Powder metallurgy

1

Option

12.    

MBX410290

Rotor of tool upside down

S45C

1

 

13.    

MBX410740

A rocker arm of tool upside

FCD55

1

 

14.    

MBX410750

A rocker arm’s arbor

S45C

1

 

15.    

MBX410760

A cam seat

FCD50

1

 

16.    

MBX410770

24T Tool upside down paw

FCD55

1

 

17.    

MBX410780

An axle center of cam

S45C

1

 

18.    

MBX410790

Bearing cover

S45C

1

 

19.    

MBX410800

Collar

S45C

1

 

20.    

MBX410810

Sleeve of bearing

S45C

1

 

21.    

MBX410850

Fixed shaft of cylinder

S45C

1

 

22.    

MBX410870

Eccentric shaft of cylinder

S45C

1

 

23.    

MBX410880

Connect shaft of piston rod

S45C

1

 

24.    

MBX411010

Fixed block of flying rings

S45C

1

 

25.    

MBX450630

Interface board

AL-6061-T6

4

Ref (DEX65o x 530 L)

26.    

MBX460010

Tool pot (60o)

POM

24

 

27.    

MBX460020

Roate shaft of tool pot

S45C

24

 

28.    

MBX460030

Lock shaft of tool pot

S45C

24

 

29.    

MBX460040

Pull block of pull stud

Powder metallurgy

24

 

30.    

MBX460240

Fixed block of pull stud

POM

24

 

31.    

MBX460180

Spring

Piano wire

96

 

32.    

MBX410230

Orientation seat of left pot

SPHC

1

 

33.    

MBX410240

Orientation seat of right

SPHC

1

 

34.    

MBX480140

Decelerator of gear motor

Hardware

1

 

35.    

MBX480150

Cylinder of tool pot up and

Hardware

1

 

36.    

MBX480190

Wiring connect box

Hardware

1

 

37.    

MBX411200

Limit switch fixed seat 1

SPHC

1

 

38.    

MBX411210

Limit switch fixed seat 2

SPHC

1

 

39.    

MBX411220

Limit switch fixed seat 3

SPHC

1

 

40.    

MBX470130

Arm- 530L

FCD-50

1

 

41.    

MBX470340

Fixed plate

SPHC

2

 

42.    

MBX470420

Slide block of stop tip

S45C

2

 

43.    

MBX470460

Sleeve of stop tip

S45C

2

 

44.    

MBX470480

Slide & fixed block

S45C

2

 

45.    

MBX470490

Lock key

SS41

2

 

46.    

MBX410280

Ø 8 Stop tip

S45C

2

 

47.    

MBX470690

Fixed collar

S45C

1

 

48.    

MBX470720

Stop tip

SCM415

2

 

49.    

MBX470740

Spring Ø 1.2 x 9 od x 14T x 41L

Piano wire

2

For stop tip

50.    

MBX470750

Spring Ø

Piano wire

2

For Slide block of stop

51.    

MBX410860

Cylinder fixed block

S45C

1

 

 

 

 

 

 

 

100.  

 

Hexagonal bolt

M4x0.7P-25L

4

For limit switch

101.  

 

Stop bolt

M5x0.8P-20L

4

 

102.  

 

Stop bolt

M5x0.8P-25L

2

 

103.  

 

Hex. Socket head screw

M5x0.8P-12L

4

Limit switch (OP)* 10 PCS

104.  

 

Spot bolt

M6x1P-8L

6

 

105.  

 

Hexagonal bolt

M6x1P-20L

10

 

106.  

 

Hexagonal bolt

M6x1P-25L

1

 

107.  

 

Hexagonal bolt

M6x1P-40L

24

Compose with 20T

108.  

 

External Hexagonal bolt

M6x1P-20L

1

Origin point reaction

109.  

 

Hexagonal bolt

M8x1.25P-16L

4

 

110.  

 

Hexagonal bolt

M8x1.25P-20L

1

 

111.  

 

Hexagonal bolt

M8x1.25P-25L

14

 

112.  

 

Hexagonal bolt

M8x1.25P-45L

1

 

113.  

 

Hexagonal bolt

M8x1.25P-65L

1

 

114.  

 

External Hexagonal bolt

M8x1.25P-30L

1

 

115.  

 

Hexagonal bolt

M10x1.5P-65L

1

 

116.  

 

Hexagonal bolt

M12x1.75P-20L

1

 

117.  

 

Stop bolt

M6x1P-6L

2

For arm

118.  

 

Shallow head screw

M6x1P-0L

14

For arm

119.  

 

Hexagonal bolt

M6x1P-16L

6

For arm

120.  

 

Hexagonal bolt

M8x1.25P-55L

4

For arm

121.  

 

Self-tap screw

3*16 x 1”

96

 

122.  

 

Any eye ring

M16

1

 

123.  

 

Spring washer

M5

4

 

124.  

 

Flat washer

M5

4

 

125.  

 

Spring washer

M6

34

Compose with 20T Disk* 30 PCS

126.  

 

Spring washer

M8

20

 

127.  

 

Flat washer

M8 x 2T

14

 

128.  

 

Flat washer

M8 x 5T

6

 

129.  

 

Nut

M5 x 0.8P

4

 

130.  

 

Nut

M6 x 1P

2

 

131.  

 

Nut

M8 x 1.25P

1

 

132.  

 

Nut

M16 x 1.5P

1

 

133.  

 

 

 

 

 

134.  

 

C Ring (External)

S-10

50

Compose with 20T Disk* 42 PCS

135.  

 

C Ring (External)

S-18

2

 

136.  

 

Single side round key

5 x 5 x 28L

2

 

137.  

 

Double side round key

8 x 7 x 40L

1

 

201.  

GKW030205

Angular ball bearing

30205JR (HIC)

2

 

202.  

GKW006008

Deep groove ball bearing

6008 ZZ

2

 

203.  

GKWCF00100

Bearing for cam (with M10 nut)

CF-10

24

20T- 20 PCS

204.  

 

 

 

 

 

205.  

MBX460180

Spring

Ø 1.2x7.8odx10Tx25L

96

20T- 80 PCS

206.  

 

 

 

 

 

207.  

 

Steel ball

Ø8

96

 

208.  

 

 

 

 

 

209.  

EDWN00001

Air throttle

¼ x ? 8

2

 

210.  

FEWN10002

Oil filter joint

1/8 PT

2

 

211.  

MBX480450

Sensor fixed jig

PM-10

2

 

212.  

EAWC00001

Magnetism reed switch

LS-BD2

2

 

213.  

EAWA00001

Micro limit switch

YAMATAKA SLI-A

2

 

214.  

EAWB00001

Proximity switch

BALLUFF-PSC40B

3

Sensor + Nut + Washer

215.  

GLW040045

Taper cone Collar

40 x 45

2

 

Control Element Position Explanatory Drawing

Sequence diagram of electric action

Control circuit Reference Diagram

Voltage DC24V (please choose positive or negative output voltage by PNP or NPN)

 Voltage 220V 60 HZ DC 24V 

Motor & Limits Switch Wiring Diagram

Air Pressure Wiring Diagram

Wire Junction Box Continue Drawing

Wire Box

ATC GEAR OIL SPECIFICATION

BRAND NAME

SPEC (VISCOSITY GAGE ISO VG

SHELL

Omala EP 152-220

TOTAL

Garter EP 152-220

MOBLE

Mobil EP 152-220

ESSO

Spartan EP 152-220

CASTROL

Alpha SP (EP) 152-220

CPC

85w / 90
  1. INPUT OIL NOTE:
    Must be use new oil to POU the mechanical, avoid to use the recycle oil.
  2. TURN LIFE HOUR:
    Machine continue run 2400 hours must change new oil.
  3. MAINTAIN:
    1. Check the oil enough before run machine, if not enough, must be added.
    2. The lubricant oil must be used correct viscosity.
    3. Motor voltage must be correct to joint input power.

Dismantled Procedure:

  1. How to dismantle and reinstall the splined (output) shafts:
    1. Turn to original position, remove the taper pin (246) and M8 bolt (227) on the case cap.
    2. Remove the case cap (101B).
    3. Loose hexagonal screw (225), remove the front fix cap (111).
    4. Remove the spline (output shaft (106), and transmit wheel (107), sun’s nut (208), sun’s gasket (210), and take the new shaft.
    5. Assrmblt it, you can reverse in connection.
  2. Change the bearings on bearings tube:
    1. Turn to start position, remove the case cap of taper pin (246) and M8 bolt (227).
    2. Remove the case cap (101B).
    3. Rotate the bearings tube (108), to stand by position.
    4. Remove the side settled screw (233)
    5. Use special tool to remove the bearings ?20((134), reinstall the new bearings, use the no air rubber to fastener be settled screw (233)
    6. Assrmblt it, you can reverse in connection.
  3. Take rocker apart in many steps:
    1. Turn to start position, remove the case cap of taper pin (246) and M8 bolt (227).
    2. Remove the case cap (101B).
    3. Then remove the rocker to settled screw down (224).
    4. Use the teardown tool, removed the rocker shaft (116).
    5. Remove the thrust bearings AXK1108 (206), thrust bearing pad AD1108 (227) and needle bearing HK 3516 (205).
    6. The needle bearings ?22(135) and needle bearings ?24(136) taken apart the rocker is now replaced new product.
    7.  Assrmblt it, you can reverse in connection.  

Condition

Reason

Trouble Shooting

Tool disk stops without positioning

1. Brake fail to work or overload

2. Sensor switch with far distance

1. Please check electronic brake wiring in correct connection or not? If part fail to work

2. Move sensor switch closer to sensor

Tool disk non-stop rotating

1. Sensor switch break down

2. Sensor switch with far distance

1. Replace sensor switch

2. Move sensor switch Closer to sensor

Pot break

Tool disk rotated while tool clamping

Replace new tool pot & adjust arm Clamping position again

Tool disk to get stuck in operating

Tool disk rotated while cylinder action

Check tool pot damaged or not and reinstall new pot

Shake during tool clamp & returning

1. Cam out lubrication

2. Cylinder speed out of balance

Fill lubricant oil 2. Adjust cylinder pressure & speed valve

Tool pot is not positioning(loosen)

Bolt of positioning bolt or pot bolt

are loosen

Adjust it to normal & tighten

Tool disk dose not work during tool selection

1. Induction switch dose not work

2. Induction switch break down

3.Motor break down

4.Electronic break bread down

1. Adjust reed switch to normal position

2. Replace reed switch

3. Repair motor

4. Check wiring & replace

5. Check sensor switch

Cylinder does not work During tool change

1. Proximity switch for tool counter positioning is break down

2. Tool disk is not positioning

3. Cylinder has no pneumatic air

4. ATC arm does not home

1. Replace proximity switch

2. Tool disk positioning

3. Check cylinder air, solenoid valve works or not?

4. Rotating motor bolt manually to let ATC arm back to original position

5. Check reed induction switch

ATC fail to work during Tool change

1. Tool clamp positioning reed switch fail to work

2. Induction switch break down

Adjust reed switch to proper position

2. Replace new reed induction switch

ATC motor over-heat

1. Break is not released

2. Break is break down

3.Commutator is break down

1. Check commutator to electrify or not?

2. Replace the brakes.

3. Replace the commutator.

ATC fail to work after tool clamping; ATC fail to work after 180° degrees tool change; ATC home stop & home Sensor switch does not work

1. Sensor is in wrong position

2. Sensor switch is break down

1. Adjust sensor to proper position

2. Replace sensor switch

ATC stop position out of

1. Sensor is in wrong position

2. Positioning ring of sensor switch is in wrong angle

1. Adjust 3 sensor at the same time to proper angle

2. Rotate set ring, adjust 3 sensor switch to proper angle

ATC tool clamping position out of accuracy

Arm & ATC spindle are not aligned

Loosen taper ring key & align it again

  1. Simple maintenance

    1. TOOL POT CHANGE PROCEDURE:

1. Take down the peripheral metal sheet and numeral acrylic cover.

 2. Unlock the hexangular screw bolt M8 and recede 10 mm on the shaft cover. (remark: do not move the 4 pieces fixing bolt)

3. Pull out the plate to the M10 screw bolt position.

4. Strip down the hexangular screw bolt M6 which be instead pot.

5. Take down the broken pot (push the pot forward inner side and take the pot upward, then extract it).

6.Confirm the fixing bolt and knob the correct position for the new pot.

TOOL POT CHANGE PROCEDURE

7. Stow down the new pot(the surface of knob recline the pot body and push forward into the plate.

8.  Lock the hexangular screw bolt M6 which the new pot.

9.Push the plate to the original position and lock it.

10. Check the fixed clearance of the plate. ( can not have clearance).

11 Check the correct angled 90 degree which the replaced pot (test on the practically tool exchanged).

 
  1. Motor of magazine replacement
  1. Power off.
    1. To dismantle the wires of magazine motor in wiring connect box.
    2. Take off M8 bolts (4pcs) on motor seat, and then disassembly the motor.
    3. Disassembly the S18 ring & M6 bolt from damage motor & re-assembly those parts onto new motor.
    4. Please make sure the motor specification is correct before you replace it.
    5. Follow the steps to set up wires in wiring connect box.
  2. Motor of arm replacement
  3. Power off.
    1. To dismantle the wires of arm motor in wiring connect box.
    2. Take off M10 bolts (4pcs) on motor seat, and then disassembly the motor.
    3. Please make sure the motor specification correct before you replace it.
    4. Follow the steps to set up wires in wiring connect box.
  4. Cylinder replacement
    1. Turn off the power & cylinder air pressure source.
    2. Take off Ø8 air pipe.
    3. Take off induction switch & mark original position before remove it.
    4. To dismantle M8 bolt on cylinder and S12 ring on joint “I”.
    5. Please make sure to the cylinder specification correct before you fit it on, and then get back the induction switch to original position.
  5. Induction switch replacement
    1. Power off.
    2. Disassembly the wire of induction switches in the electric box.
    3. Please loosen the seat of reed switch & take it out.
    4. Replace new part & take care of the sensor position, push it to upward & downward until to end of both sides.
    5. Follow the steps to set up wires in electric box.
  6. Proximity switch of tool magazine replacement method
    1. Power off.
    2. Disassembly the wire of induction switches in the electric box.
    3. Take off the front cover & outer metal sheet cover.
    4. Take off the M12 bolt on proximity switch.
    5. Replace new part & make sure the sensitive distance is 4 mm.
    6. Follow the steps to set up wires in electric box.
  7. Proximity switch of arm replacement method
    1. Power off.
    2. Disassembly the wire of induction switches in the electric box.
    3. Take off the acrylic of ATC metal sheet.
    4. Replace new part & make sure the sensitive distance is 4 mm.
    5. Follow the steps to set up wires in electric box.
  8. Note
    1. Please use standard tool during maintenance & repair.
    2. We suggest you replace part which is bought from original supplier.
    3. Please take care of the part specification before replacement. You can get the specification from the part list.
    4. Please make sure the sensitive distance during replace proximity switch & reed switch.
    5. Please make sure the wires numbers & location in case you have to replace the wire connecting.
    6. In any case of abnormal or damage condition on the product, there should be someone checking the product. We strongly ask the service man has to be well trained & qualified engineer or expert come to check or repair the problem. This is to ensure safety of operator & engineer.
    7. Before disassembly the product, please make sure there are enough human beings to support the load. If there are not enough human beings, please use lifter, crank or any other carrier to support the weight.

Item

Description

Method

Tool

Routine

Remarks

1

Lubrication

A

Body fix board

Take off number cover, fill oil manually

Grease

Gun

Half year

Grease

B

Pot slide

Take off sheet metal, fill Lubrication oil manually

Grease

Gun

Grease

C

Arm slide block & position pin

Take off sheet metal cover, clean & fill oil manually

 

Grease

D

Cam Slide

Take off ATC cover, fill lubrication oil manually

Grease

Gun

Grease

E

Motor Gear

Take off front cover & outer sheet metal

Grease

Gun

Grease

2

Cleaning

A

Inner taper face of pot

Clean pot

 

Once a month

SHELL

TELLUS 32

B

Replace inner lubrication oil of ATC

Drain the old oil, and fill

New lubrication oil

 

3

Loosen Check

A

Sensor switch of magazine to loosen or not?

Check manually

 

Half year

 

B

Sensor switch of ATC to loosen or not?

Check manually

 

 

C

Sensor switch of cylinder to loosen or not?

Check manually

 

 

D

Limit switch to loosen or not?

Check manually & optically

 

 

E

Any bolt to loosen or not?

Check manually

 

 

F

Bolt on arm to loosen or not?

Check manually

 

 

G

Shake the arm to decide if backlashes too big

Check manually & inaccuracy can’t bigger than 0.2 mm

 

 

H

Check the disk body to shake or not?

Check manually

 

 

I

Check tool magazine to loosen or not?

Check manually

 

Before power on

 

4

Other Check

A

Pot ball is falling down or not?

Check manually

 

 

B

Noise or heat on motor?

Check manually

 

 

C

Solenoid valve of cylinder is out of air?

Check manually

 

 

D

Oil leak from ATC output shaft

Check manually

 

 

E

V shape flange of ATC arm to wear and tear

Check manually

 

 

F

The oil level lower of ATC oil tank

Check manually