Mach4 Integration


SmartSwap ATC Software Description

The SmartSwap ATC system is powered by custom software built for CNC routers with ER-collet spindles. Instead of requiring an expensive ATC spindle and holders, SmartSwap combines cassette-based storage with intelligent Mach4 modules to deliver automated tool changes at a fraction of the cost.

Key Features

  1. Direct Mach4 Integration

    • Built on Lua scripting within Mach4 Hobby.

    • Persistent user settings stored in Mach4 profile registers for repeatable, consistent performance.

     

  2. Cassette Management

    • Supports up to 10 cassettes, each assigned through the Mach4 screen.

    • Cassettes accurately hold the collet nut, collet, and tool—a completely wireless solution.

    • Tool locations are tracked entirely within Mach4, ensuring full control from the Mach4 screen.

    • Oversized tool protection prevents unsafe cassette assignments.

     

  3. Robust Safety Checks

    • Tool Diameter Validation: Large tools above set limits cannot be stored in cassettes and will automatically  be handled with user instructions during tool change.

    • Probe Verification: Each tool change includes a probing routine to confirm tool presence and accurate length offsets.

    • Drop-off Confirmation: An optional secondary probe cycle verifies that a tool has actually been released before a pickup routine begins. This feature trades time for machine safety.

    • Location Validation: Cassette locations are checked against existing mach4 soft limits to prevent motion outside the safe working envelope.

    • Air-Blast Routine: This optional feature uses airflow from your air-cooled spindle to perform a cleaning sweep that clears sawdust and debris from the SmartSwap cassettes before tool pickup, ensuring reliable seating.

     

  4. Automated Tool Change Logic

    • Configurable drop-off and pick-up spindle RPM values.

    • Two-stage probing: fast initial probe followed by a slow, accurate probe.

    • Safe rapid moves based on known machine coordinates with built-in clearance margins.

    • Manual tool change fallback if no cassette assignment is available.

     

  5. Expandable Framework

    • Modular Lua design allows future enhancements.

    • Easily adapted for new routines such as custom probing cycles or alternate storage methods.

    • Designed for compatibility with add-on modules or plugin upgrades.