Re: Kearney and Trecker Milwaukeematic IIIb retrofit

Thanks It is really neat to see this thing come back together.

Some of the specs
servo drives are AMC 40a40 - 40 amp peak 20 amp continuous. The servos are about 1 amp/ft-lb. so with our 2:1 reductions we get about 80ft-lbs peak and 40ft-lbs cont. (ball screws are 3tpi)

The spindle was originally hydraulic but we converted it to a 5hp ac with a Toshiba vfd. This was done a few years ago with the original control. The mechanics of the spindle are pretty neat. It has a 16 speed transmission that is shifted by 4 hydraulic solenoids. that is 4 bit binary. so 0000 is first gear 0001 is second 0010 is 3rd and so on. It also has a dog that can be engage for locking the spindle for tool changing or retracting a boring head from a hole. I thought about doing the shifting in ladder but decided it would be eaiser for me to create a hal componant for it. (a C like language that makes it easy to create real time components in EMC2). The spindle componant does a ton of stuff like shifting, orienting, at-speed signal, override logic... I am happy with it. Here is a video of it shifting though the 16 gears - you can see on the right the ssr's that are controlling the shift rails. the very top of the black bunch is the hydraulic enable to the spindle - the next 4 down are the shift rails. so the first thing in the video is I turn the machine on which initallizes the shift componant in emc. This puts it into a known state. (shifts the transmission into the lowest gear). then I run a gcode program that commands a speed for each gear. (each gearshift requires a spindle creep so the gears can shift without grinding much)

http://www.youtube.com/watch?v=22dWg3GbywE

The pallet changing is working again also. It is limited by the hydraulic speed - but work well.

http://www.youtube.com/watch?v=CYA5uEwLSTA

sam

--- In CAD_CAM_EDM_DRO@yahoogroups.com, "imaginerring" <wwooley@...> wrote:
>
> WOW!!!!
>
> This was a great read to start the day!
>
> It is so nice to see a classic machine rebuilt rather than scraped.
>
> What fun you must be having.
>
> --- In CAD_CAM_EDM_DRO@yahoogroups.com, "samcoinc2001" <samcoinc2001@> wrote:
> >
> > I am coming to the end of this retrofit and thought I would post some info.
> >
> > This is a late 60's nc machine that originally came with a GE control. It was 2.5 axis + the table indexed to 5deg increments. (2.5 axis because x and z shared a servo). The servos where hydraulic. The old control worked well iirc repeatability was .0005.
> >
> > http://www.electronicsam.com/images/KandT/oldkandt.JPG
> >
> > We had been accumulating parts for the last few years. Large servos, drives and such.. The original control finally literally smoked so we thought it was time. :)
> >
> > The main thing we wanted was to make it full 3 axis and make everything else work as good or better than the original control. We had been playing with emc2 on a gantry router and found it to be very stable and flexible. We dove in figuring out how to replace the the hydraulic servos with dc ones. We removed all the hydraulics we didn't need. (servo lines, clutch packs and such).
> >
> > This is x,y and b servo
> > before
> > http://www.electronicsam.com/images/KandT/conversion/xaxis/start.JPG
> > after
> > http://www.electronicsam.com/images/KandT/conversion/servo/belts.jpeg
> >
> > Y axis
> > before
> > http://www.electronicsam.com/images/KandT/conversion/hyservo.JPG
> > after
> > http://www.electronicsam.com/images/KandT/conversion/yaxis/yassembly.JPG
> >
> > In the first picture above you see the original control on the right.. we fit the computer, drives, vfd and i/o all in the control pannel. (after we made it twice as big ;))
> >
> > before
> > http://www.electronicsam.com/images/KandT/conversion/mainelectricalbox.JPG
> > after
> > http://www.electronicsam.com/images/KandT/conversion/mostio.JPG
> > (^ that was taken a few months ago - there is a bit more in there now)
> >
> > we are using mesa hardware (they are an awesome company.) We are using 2 of their 5i20 cards for a total of 144i/o. I am using 2 servo interfaces (one is 4 axis analog the other is 6 axis analog - gives +/-10v and fast encoder interface) so I end up with a total of 10 axis and 96 i/o. (and I need it all) ;) we are using opto22's as input and output buffers and emc2's integrated ladder for tool changing, pallet swap and such.
> >
> > some videos
> > first closed loop movement (that is a .0001 indicator :))
> > http://www.youtube.com/watch?v=FgOqEz5Tk-Y
> >
> > First complete tool transfer (I love this video)
> > http://www.youtube.com/watch?v=KplU8hkI0AQ
> >
> > First cut (crappy video - sorry)
> > http://www.youtube.com/watch?v=RW6eXiMoFp8
> > (it is actually cutting the hex in the center of this timing gear http://www.electronicsam.com/images/KandT/conversion/testing/DSCF1231.JPG for an encoder mounted on the spindle for rigid tapping.)
> >
> > Rigid tapping
> > http://www.youtube.com/watch?v=2E3PMooch1k
> >
> > one more tool change - swapping out a 7/8" drill with a 1" tap
> > http://www.youtube.com/watch?v=q6S-QfmWcsI
> >
> > Now that things seem to be coming together I need to do some tweeking to the ladder and such. Take a look at the pictures here http://www.electronicsam.com/images/KandT/conversion/
> > (random crap :P) also look at the youtube channel - there are other videos. http://www.youtube.com/user/samcoinc
> >
> > I would do it all again and emc2 would be the control. I would like to thank all the developers - the have created an awesome control that just keeps getting better and better.
> >
> > sam
> >
>