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  1. #1
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    Large Kearney & Trecker HMC conversion.

    This started here a while ago.
    http://cnczone.com/forums/showthread.php?t=25929

    It got off course and things have changed. As of now the conversion is picking up speed and things are starting to move. I am starting fresh here as the old thread was more about making my own servo drives. (I ended up making a successfull one - but then ebay blessed us with some high powered AMC drives that have all the bells and whistles )

    This is a general retrofit thread (using emc2)

    So - lets get up to speed.

    This is a 60's vintage NC that used hydraulic servos. we are converting it to EMC2 using not quite as old Inland servos. (80's vintage) they are 8 brush low rpm high torque. (with the amc drives we are using - it will be 40ft-lbs peak.) We are using 2 mesa 5i20 boards as we are needing a good 70+ i/o + atleast 7 encoder counters and 5 ±10v outputs. We are at the point where the machine is waking up. the mesa hardware is awesome (thank to peter and seb for their work).

    Be sure to watch the 2 videos at the end of this post.

    lets see if I can create a linear picture show...
    this is what the machine looked like in the 60s
    http://electronicsam.com/images/KandT/oldkandt.JPG

    this is what the machine looks like now
    http://electronicsam.com/images/KandT/DSCCurrent.JPG

    getting rid of the old control
    http://www.electronicsam.com/images/control.jpg

    this is the old electrical box
    http://electronicsam.com/images/Kand...ctricalbox.JPG

    we welded 2 of the same boxes together for new electronics.
    http://electronicsam.com/images/Kand...n/moreelec.jpg

    here is it mostly hooked up
    http://electronicsam.com/images/Kand...ion/mostio.JPG

    Here is the computer with the 2 mesa cards in it.
    http://electronicsam.com/images/Kand...mputermesa.JPG

    This is the x,z,b gearbox - the old control used 1 hydraulic servo to run all 3 axis
    http://electronicsam.com/images/Kand...axis/start.JPG

    open
    http://electronicsam.com/images/Kand...axis/start.JPG

    stripped
    http://electronicsam.com/images/Kand...s/stripped.JPG

    shafts extended out so we can hook the servos up.
    http://electronicsam.com/images/Kand...is/3shafts.JPG

    servo plate mounted
    http://electronicsam.com/images/Kand...ervo_mount.jpg

    belts (B axis still needs a solution)
    http://electronicsam.com/images/Kand...rvo/belts.jpeg

    Because we are still using the z axis drive train that goes up though the saddle - we needed to get the backlash out of it. It uses split gears to do that. Grinding 1 washer thinner takes the backlash out of 5 sets of gears. the washer is the spacer between the 2 lower small gears.
    http://electronicsam.com/images/Kand...axis/gears.JPG

    we still have to mount the y axis servo. - The plan is to direct couple into this shaft.
    http://electronicsam.com/images/Kand...yaxisshaft.JPG

    here is the tool chain logic working...
    [nomedia="http://www.youtube.com/watch?v=4nuRea6615s"]YouTube- Kearney and Trecker tool chain logic working in EMC2. Mechanically barcoded tools[/nomedia]


    here is the first closed loop movement with the x axis (yes that is a .0001/div indicator )
    [nomedia="http://www.youtube.com/watch?v=FgOqEz5Tk-Y"]YouTube- Kearney and Trecker first closed loop movement with EMC2.[/nomedia]

    Getting there Very happy with the progress. (I only work on it about once a week.)

    sam

  2. #2
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    the servos we are using are inland kollomorgan. They have a tachs and we fitted 2540 line encoders on the back. (originally they had resolvers)
    http://electronicsam.com/images/KandT/DSC_0242.JPG
    (that is a 6 inch micrometer for scale)

    When we scored the AMC drives - we decided to do a velocity inner loop (tach back to the amp) so emc only had to worry about the position loop. (initally we where going to just use the encoder with the amps in voltage mode). I have to say - I am very impresses with dual loop systems. very easy to tune and stable (as you can see from the above video). With the amps tuned correctly - so that lets say 1v = 20ipm - setting the scales correctly in emc2 - There is very little PID effect - when FF1 is 1.

    it is a conventional control loop

       
    <- <- <- Tach
    \/ /\
    Emc2 -> Mesa +/-10v -> Amc drive -> Servo -> encoder -> Mesa encoder interface -> Emc2


    The encoders we are using are single ended. We figured we might have issues with the distances we are running - we did. Anything over about 50ipm and we start to lose position. We purchased line drivers from digikey. n so far so good (the mesa card will do both single ended and differential encoders)

    The tool chain was all done in ladder.

    emc calls for a certain tool number
    unclamp tool chain
    Chain starts moving high speed.
    The tool reader wipes by the tool - all the 'bits' are latched
    The bits are converted to a number
    on the leading edge of the tool chain prox detector - the read number is compared to emc's number - if different - keep looking.
    if the read number matches emc - activate chain creep.
    Count 2 more leading edges of the prox detector
    stop chain
    clamp chain.
    Tell emc - tool is found.
    (that is from memory - so I might have missed something)

    The spindle has a 16 speed gearbox that is run by 4 spool valves. (4 bit logic 0 - 15 = 16 speeds)

    I am writing a comp for this (hal component) It is going pretty smooth and have something that I can test once we get the vfd hooked up agian.

    Getting there.

    sam

  3. #3
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    2 axis running

    [nomedia="http://www.youtube.com/watch?v=QU_O_Z7Vv8c"]YouTube- Kearney and Trecker X-Z 22" diameter Circle @ 190ipm Emc2[/nomedia]

    sam

  4. #4
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    It's a gear! It's a broach!

    we are working on getting a servo hooked to the y axis. It has been a bit harder than the rest as we need to direct couple the servo. It used to be run with a hydraulic servo with split gears to take up the backlash. We have access to the gear that the servo used to drive - so we are going to make that end of the 'flex coupler' by making a mate to the gear.

    we have a few of the same gear (2 machines and they are doubled because they took out the backlash on the old setup) we sharpened the back side of the gear and proceeded to push it though the aluminum ring. I think it turned out great. It is now a slight slip fit which should give us the little bit of flex we need with very little if none backlash. It took over 12 ton to press it through.


  5. #5

  6. #6
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    Looking good! It's fun to see someone converting a big beast like that

    I think going for the velocity loop in the drive is smart. The high update rate in the drive will make things easy for the PC and will ensure the highest performance for a given complexity. I think you'll appreciate your good decision (or won't know how much worse it could have been) in the future.

  7. #7
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    Thanks. It has been going very well - concidering that it was going from hydraulic to dc servos.

    Here is the y axis servo mount bolted to the machine. The copper tube coming out is to run the brake. The mill is horizontal - so the y axis is vertical and needs a way to keep it from moving when powered down.

    http://www.electronicsam.com/images/...aptmounted.jpg

    sam

  8. #8
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    Have the y axis servo mounted with the brake installed. So far so good - We just have to hook up a few wires and we can start testing and tuning

    http://www.electronicsam.com/images/.../yassembly.JPG

    http://www.electronicsam.com/images/...xis/ybrake.JPG

    sam

  9. #9
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    full 3 axis!

    [nomedia="http://www.youtube.com/watch?v=pOHL_KlUdqw"]YouTube - Kearney and Trecker IIIB full 3 axis helix[/nomedia]

    sam

  10. #10
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    Worked on the tool changer arm ladder logic last night. have it pretty close. I do not have it transfering the tool to the spindle yet because we don't have the hydraulic pump wired in that does the collet clamp/unclamp.

    [nomedia="http://www.youtube.com/watch?v=ovxW8TKBGWU"]YouTube - Kearney and Trecker tool changer arm[/nomedia]

    sam

  11. #11
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    Worked on the gear shifting yesterday. I created a component in emc to do it. (emc has a way to create realtime hal (hardware abstraction layer) components in a C like language.) I initially thought of doing it in ladder but decided that I would have more control creating a hal component. It takes the s word and decides what gear the transmission should shift into. (if it doesn't have to shift - it doesn't) there are a few things I need to add yet like spindle lock, 'at speed' and then maybe closed loop speed control.

    Here is a video showing it shift through all the gears. (about 10 seconds each gear cycle)
    [nomedia="http://www.youtube.com/watch?v=22dWg3GbywE"]YouTube - kearney and Trecker 16 speed spindle gearbox[/nomedia]

    the lower 4 of the top 5 black ssr's show the shift rails. They count up in binary for each gear.
    0000, 0001 ,0010, 0011 and so on.

    I am using an encoder on the spindle motor to know that the spindle is at the correct rpm to allow shifting. I am going to add an encoder on the actual spindle also so I can rigid tap. With both encoders installed - I can also make 100% sure the spindle is in the right gear by comparing the two encoders.

    http://www.electronicsam.com/images/...lemotorenc.JPG

    sam

  12. #12
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    spindle lock - tool change location. So far so good.

    [nomedia="http://www.youtube.com/watch?v=KplU8hkI0AQ"]YouTube - Kearney and Trecker full tool change with spinle orient[/nomedia]

    sam

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