How does a CNC tool changer work?

Part of a CNC machine which changes and stores the tool bits

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In machining, an automatic tool changer (ATC) is used in computerized numerical control (CNC) machine tools to improve the production and tool carrying capacity of the machine. ATCs change tools rapidly, reducing non-productive time. They are generally used to improve the capacity of the machines to work with a number of tools. They are also used to change worn out or broken tools. They are one more step towards complete automation.[1]

Description

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Simple CNC machines work with a single tool. Turrets can work with a large number of tools. But if even more tools are required, then an ATC is needed. The tools are stored in a magazine. This allows the machine to work with a large number of tools without operator intervention.

The main parts of an automatic tool changer are the base, the gripper arm, the tool holder, the support arm, and the tool magazines.[2]

Although the ATC increases the reliability, speed, and accuracy of a machine, it creates more challenges compared to manual tool change. For example, the tooling used must be easy to center, be easy for the changer to grab, and there should be a simple way to provide the tool's self-disengagement. Tools used in ATC are secured in tool holders specially designed for this purpose.[3]

A chain-type automatic tool changer with swiveling arm and two grippers, installed on a mill

Types of tool changers

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Depending on the shape of the magazine, an ATC can be of two types: 1) Drum Type changers are used when the number of tools is lower than 30. The tools are stored on the periphery of the drum. 2) Chain type changers are used when the number of tools is higher than 30 (The number is different depending on the design and manufacturer. It is important to note that the number of tools for the drum type is fewer than the chain type). But the tool search speed will be lower in this case.[4]

Automatic tool changer mechanism

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After receiving the tool change command, the tool to be changed will assume a fixed position known as the "tool change position". The ATC arm comes to this position and picks up the tool. The arm swivels between the machine turret and the magazine. It will have one gripper on each of the two sides. Each gripper can rotate 90°, to deliver tools to the front face of the turret. One will pick up the old tool from the turret and the other will pick up the new tool from the magazine. It then rotates 180° and places the tools into their needed position.

Tool changers on sheet metal working machinery

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ATCs were first used on chip-removal machines, such as mills and lathes. Systems for automatic rearrangement of tools have also been used on sheet metal working machinery. Panel benders have an integrated CNC-controlled device that allows punches to be moved according to the size of the part. Automated tool changes on press brakes were limited to machines integrated on a robotic bending cell. Typically a 6-axis robot used for handling sheet metal blanks is also in charge of changing punches and dies between different batches.

Since the s automatic tool changers have appeared on non-robotic press brakes. The most common configuration is a tool rack on the side of the press brakes, with a shuttle picking up tools and positioning them where needed. This reduces physical strain on the operator and increases overall productivity.

An Automatic Tool Changer for press brakes, used to set up, rearrange, and remove punches and dies. Tooling is stored in a motorized tool rack (right) and is placed in the desired position by the shuttle (blue/grey/white on center).

Functions of a tool changer

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The use of automatic changers increases the productive time and reduces unproductive time. It provides the storage of the tools which are returned automatically to the machine tool after carrying out the required operations, increases the flexibility of the machine tool, makes it easier to change heavy and large tools, and permits the automatic renewal of cutting edges.[5]

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Automating CNC tasks wherever possible in the shop is one of the best ways to reduce your overall production timelines without sacrificing precision or quality.

Manually performing multiple tool processes is one of the especially time-consuming tasks that can slow you down significantly if you have to stay nearby and babysit your CNC router. Not only does the need to be present slow production, but having to pause jobs to manually change tools also wastes time that could be better spent elsewhere.

This is where an automatic tool changer can have a serious impact. An automatic tool changer or ATC is one of the most beneficial forms of automation you can implement within your CNC operation, helping you seamlessly change tools in seconds without having to pause operation.

Here is a closer look at what an automatic tool changer is, how it works, and the advantages of adding it to your CNC process.

What is an automatic tool changer?

An automatic tool changer improves the production and tool-carrying capacity of a CNC machine by changing tools very quickly without the help of a manual operator. In doing so, the ATC dramatically reduces downtime on a given project.

ATCs are generally used to improve the capacity of a machine to work with several tools at one time, but they can also be used to change out worn or broken tools. There are generally two types of automatic tool changers rotary-style and linear-style which vary in the number of tools present within the changer.

An automatic tool changer typically consists of:

• Base
• Gripper arm
• Tool holder
• Support arm
• Tool magazines (where the tools are stored)

How does an automatic tool changer work?

Once set up on your CNC machine, an automatic tool changer follows a quick set of steps to swap tools in and out. Heres how it works.

1. The tool change command is given to the machine via the computer.
2. The tool to be changed assumes a fixed position known as the tool change position.
3. The ATC spindle moves to that position to pick up the tool.
4. The z-axis moves between the machine tool rack/rotary to pick up/drop off tooling.
5. Internally, the spindle opens or closes the chuck to exchange tooling before returning back to work.

In a matter of seconds, an ATC enables you to switch tools automatically without any need for human involvement (apart from programming the change).

What are the benefits of an automatic tool changer?

An automatic CNC tool changer has numerous significant benefits in the shop, including:

• Ability to switch between a large number of tools without requiring a human operator
• Increased accuracy
• Increased efficiency
• Reduced labor cost
• Reduced downtime and total production time
• Increased tool storage capacity
• Increased machine versatility
• Increased safety for employees and equipment
• Ability to change larger and heavier tools with ease
• Increased edge finish due to more appropriate tooling per process

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At ShopSabre, our in-house engineering talent has extensive expertise in motion control and always aims to provide hobbyists and shop owners alike with unmatched precision, efficiency, and versatility.

We offer a variety of CNC machine automatic tool changers as well as many accessories that are compatible with ATCs, including dust docks, containment skirts, aggregate and c-axis attachments, and more. Our tool changers are available in both linear and rotary solutions with 5 or 10 positions on most models, with the option to start with 5 and update to 10 at a later date if needed.

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