Assembly Instructions for
MRT Automatic Tool Changer
These instructions assume that the machine 0,0 is at the lower left hand corner of the machine. If your machine is set up differently you may need to deviate from the instructions listed below. If unsure contact customer support at firstname.lastname@example.org
Mounting the Tool Changer to the Z Axis.
If you can drill through the Z axis cleanly, the template is located correctly. Look down the inside center of the Z axis and make sure you will not interfere with any internal components. If this position does not work, move the Z axis up till the top holes are clear to drill or till a ¼” bolt can pass through the Z axis. Clamp the template to the Z axis. Align the template as close as possible in the Z direction with the Z axis. Drill through one of the top holes through the Z axis. Install one of the ¼” bolts. It may be necessary to raise the Z axis in order to drill these top holes. Recheck the alignment of the template with the Z axis. Drill through the other top hole in the template and install another ¼” bolt. There are 4 sets of holes in the lower portion of the template. Drill through one of the holes in each of these 4 sets of lower holes. Use the template hole which either has a hole already there or where you can drill a complete hole. Do not try to drill through a hole which is partially covered by the template. It will not work and the hole will not be placed in the proper location.
Once the holes have all been drilled, remove the Tool Changer from the bracket and bolt the bracket to the Z axis. A 5/16 hex key and a 7/16 socket or box end wrench are required for this. Install one of the top bolts and lightly tighten. The air tubing might need to be removed to get access to the holes. To do this, push the tube into the connector, push in the locking ring on the connector and pull the air tube out of the connector.
Put a level across the top Tool Changer clamp on the bracket. Adjust the bracket (not the upper router clamp) till the level reads plumb. This is a good 1st pass at getting the Tool Changer level. A method of final alignment is shown later. Install and tighten the lower opposite bolt. Install and tighten the remaining bolts. Reinstall the Tool Changer making sure the lip of the Tool Changer is seated securely on the top of the upper rear bracket.
Reinstall the front bracket and tighten securely. Make sure the cap screws are tightened evenly so the gaps between the front and rear clamps are consistent on each side.
Once the Tool Changer is back in place adjust the air blow off nozzle on the bottom of the unit to blow air just below the center of the collet chuck on the Tool Changer.
Tool Changer Control Module Installation
Air and Electrical Hook Up
Caution: Make sure the power to the control box is disconnected before starting the next section.
Control Module Hook Up
TURN THE POWER TO THE BOX OFF ONCE YOU HAVE VERIFIED A 12 Volt SOURCE.
Tool Changer Alignment
DISCONNECT THE POWER TO THE Tool Changer TO DO THIS ALIGNMENT.
Make a measuring plate similar to the one shown in the pictures below using shaft with a diameter of an available collet. The longer the measuring plate, the more accurate the alignment will be. Mark one end of the plate. Perform the measurements described below using only this side of the plate to minimize the effect of any height difference between the two ends of the plate.
Insert the arbor into a Tool Holder using the collet and load the Tool Holder into the Tool Changer. Lower the Tool Changer till the marked end of the plate is within the range of the telescopic gage. Rotate the measure plate till it is in line with the Y-axis. Measure and record the distance between the marked end of the plate and the table. Rotate the measuring plate 180°. Measure and record the reading. Loosen the Tool Changer retaining screws and adjust the Tool Changer till the two values are as close as possible. The difference should be within .005" of each other. Repeat for the X axis direction. Recheck both Y and X axis to make sure they have not moved while adjusting the other axis.
Mounting the Tool Pallet
It is also recommended that the Tool Pallet be mounted as high as possible to allow the thickest material to be used. To do this, raise the Tool Changer as high as possible. Lower by 4.5 inches. The Tool Pallet should be mounted so the Zero Plate on the Tool Pallet is no higher than this point. This will give the Tool Changer room to raise the longest tool bit above the Zero Plate in order to zero the tool. The Tool Pallet may be mounted lower than this but may reduce the length of tool bit able to be used in automatic tool changes due to table clearance.
Once a height has been chosen, the Tool Pallet needs to be attached to the table. To maximize the table space available for routing, the Tool Pallet should be mounted as far from the table as possible. This will be determined by the reach of the Tool Changer. Move the Tool Changer as far in the –X direction as possible. Move back in the positive X direction 1-1/2”. The Tool Changer should be mounted so the center of the Tool Holder is no further in the –X direction than this point.
There are several methods of mounting the Fixed Tool Platform to the table. Since there are many different table configurations and materials, mounting hardware is not included. The following installation shows the Fixed Tool Platform being mounted to a wood table using lag screws. The Mounting Brackets are made of 1/4" phenolic to provide the flex needed when automatically changing tool holders.
Place the Fixed Tool Platform on the table at the required height with two spacers of equal size under each end of the Platform. This will make the hole marking and platform leveling much easier. Make sure the Mounting Brackets are in contact with the table edge.
Mark the locations for the clamping screw holes. Do not use the extreme bottom or top of any slot in the Mounting Bracket as you will need some adjustment to level the top of the Platform later.
It is very important that the Fixed Tool Platform be level in both the x and y directions otherwise the Tool Changer may not be able to pickup and replace the Tool Holders properly. 1/4x20 tapped holes have been provided in the Rear Support Plates for adjusting screws to make leveling in the X direction much easier. Lightly snug the bottom bolts. Put a level in the X direction and level the Fixed Tool Platform by tightening the adjustment screws. If this makes the condition worse, back out the adjustment screws, loosen the clamping screws, and put a spacer below the clamping screw on the bottom of the mounting bracket so the bracket leans slightly in toward the Tool Changer. Retighten the clamping screws and level with the adjustment screws. If the adjusting screws are resting against a non metal surface, it is recommended to put a piece of hardened shim stock between the adjusting screw and the material so the screw will not dig into the material over time.
To level the Fixed Tool Platform in the Y direction, use a zero plate with the Tool Changer and zero out the Tool Changer on tool bay 1. Move to tool bay 8 and adjust the height till there is as little difference as possible (no more than .010” difference). This may require several re-zeros at each end.
When finished with the Y axis go back and adjust the X axis level if necessary. Secure all mounting bolts and recheck for level in both directions. Adjust as necessary.