In the era when automation is everywhere, automatic tool changers are now a vital component for many robotic and CNC machining applications.
Manual tool changing remains a bottleneck for some machining processes. Relying on a human operator causes the productivity of a machining operation to plateau. This is because your robotic cell always needs to wait for someone to change the tool between tasks.
With an automatic tool changer, you can optimize your machining operation.
The question is… how can you tell if your application would benefit from an automatic tool changer?
Let’s look at the considerations you can make when deciding whether to use a tool changer for your robotic setup.
The Definition of an Automatic Tool Changer
An automatic tool changer is a mechanical device that facilitates the seamless exchange of robot and CNC tools without manual intervention.
Through a combination of mechanical, pneumatic, and electrical components, the tool changer can quickly swap robotic end effectors.
This capability helps to reduce downtime of a robotic cell and to enhance operational flexibility. It also means you can use the same robot for a variety of distinct steps in a single manufacturing process.
Automatic tool changers usually comprise two parts: the master and the tool. The master attaches the wrist of the robot and the tool attaches to the end effector.
When the tool needs to be changed, the robot moves to the tool changer, releases the current tool, and attaches to the new tool.
How to Tell if Your Application Needs an Automatic Tool Changer
If you are reading this article, it’s likely that you already think you need an automatic tool changer for your robot application… and therefore, you’re probably correct.
Automatic tool changers are required when you need the robot to quickly switch between tools. This could mean switching between different types tools or switching between variants of the same type of tool to support maintenance.
According to Jean-Christophe Prioux from Stäubli, “In certain industrial fields, components are subject to a significant amount of stress. This results in premature aging and breakdown. For several manufacturing processes, a tool changer is the only means to ensure the optimal productivity of a robot.”
Here are some questions you can ask yourself to determine if you need an automatic tool changer:
- Are you experiencing frequent tool changeovers that disrupt production?
- Does your manufacturing process require multiple tools or configurations?
- Is tool wear and maintenance holding causing a recurrent disruption to production or quality issues?
- Do you have limited workforce resources to perform manual tool changes?
- Are you currently operating multiple machines that could benefit from tool interchangeability?
Of course, not all robotic setups need a tool changer. Sometimes, it makes more sense to invest in an entirely different robot instead — such as when one particular operation already needs to run continuously to meet demand.
5 Key Considerations When Comparing Automatic Tool Changers
Once you have decided that you need an automatic tool changer, the question becomes which model is the right one for you.
How can you assess the different models?
Here are 5 key considerations when comparing automatic tool changers:
- Compatibility — First, it is important that you pick an automatic tool changer that is compatible both with your robot and the tools that you will be using.
- Load Capacity — Like many robotic components, automatic tool changers have a load capacity. They should be able to handle the weight of any tools and, if using a gripper, the weight of workpieces.
- Speed and Precision — A fast changeover is important as it can become a point of bottleneck for your productivity. Find a tool changer that meets your requirements.
- Maintenance Needs — Repeatedly connecting and disconnecting tools can become a point of failure of some tool changers. Find a model that minimizes the need for maintenance.
- Control and Programming Integration — Finally, your chosen tool changer should be as easy as possible for you to control using the robot’s control hardware.
One way to streamline the control of using your tool changer is to use the right programming software. RoboDK natively supports some tool changer models and can be configured to support many more.
3 Automatic Tool Changer Models from the RoboDK Library
The RoboDK Robot Library includes models for easy integration of various tool changers.
Each tool changer requires you to load two models into RoboDK:
- Master Element — This connects to the end of the robot arm. You will need one of these per robot.
- Tool Element — This connects to the tool or end effector of the robot. You will need one of these per tool.
Here are 3 tool changers from leading robot equipment manufacturers:
1. ATI QC-11
The QC-11 from ATI is a lightweight and compact tool changer with a high-strength, fail-safe locking mechanism. It has a suggested payload limit of 35 lb (15.9 kg).
Here are the links to the the master model and the tool model in the RoboDK Library.
2. Zimmer FWR50F
The FWR50F from Zimmer has an integrated air feed for hoseless air and vacuum transfer. It also supports both automated and manual tool change options. It has a handling weight of 16 kg.
Here are the links to the the master model and the tool model in the RoboDK Library.
2. 3 OnRobot Dual Quick Changer
The Dual Quick Changer from OnRobot is interesting as it supports the connection of two tools simultaneously. This improves productivity by 50% or more. It supports payloads up to 20 kg.
Here are the links to the the entire tool model in the RoboDK Library.
How to Quickly Integrate Your Automatic Tool Changer Using RoboDK
If you want to get the most from your automatic tool changer, programming is an important step.
By using RoboDK, you can quickly and easily program your tool changer. Just load the associated model into the software and add it to your program. We have included
For a practical introduction, check out our article How to Use Tool Changers With RoboDK.
What automatic tool changer would you like to use with RoboDK? Tell us in the comments below or join the discussion on LinkedIn, Twitter, Facebook, Instagram, or in the RoboDK Forum.. Also, check out our extensive video collection and subscribe to the RoboDK YouTube Channel