I've started construction of a 10-tool carousel ATC for my mill, and today I had a few hours free, so I got the first few parts made. It is currently configured for TTS tooling, but can be trivially re-configured to work with CAT/ISO-30, as I intend to switch my spindle to 30-taper at some point.
It uses a simple DC gearmotor and a Geneva mechanism for carousel rotation, allowing rapid, accurate positioning using a single digital output and relay, rather than a stepper motor and driver. Hall effect pickups are used to provide both "tool in position" and "home position" sensing on the carousel.
Rather than moving the spindle up and down to grab/release tools, the carousel itself moves up and down under control of a short-throw air cylinder. A second long-throw cylinder swings the carousel into position under the spindle, then retracts it back completely out of the way for machine operation.
Operational sequencing will be provided by a DSP program running on my KFlop, but could just as easily be provided by a Mach3 VB macro if I were using Mach3. The overall mechanism is designed to be simple, and robust, with just enough controlled compliance to enable smooth operation without requiring high precision in either fabrication or operation, and enough feedback for the controlling software to be able to detect nearly all failure mechanisms, and a build-in, inexpensive failure point to protect the bulk of the mechanism from un-detected crashes.
I'm now stalled for a few days, waiting for the rest of the parts to arrive, but hope to have it finished up in the next two weeks or so.
Regards,
Ray L.