Monthly Archives: June 2024

CNC Tools

Tool Grinding Machine Saacke UW II NC: getting the axis drives turning

Leave a comment

Now with the tool grinder placed at its final location, time to have some more study of the electronics. Objective is, to get the drivers turning in the XYZA directions again, and then to determine the path forward. Surely overall intention is to replace the existing PEP control computer by a LinuxCNC-based motion control system, so I can control the machine with ordinary G code and use macros and such to easily do any kinds of grinding cycles without relying on computing technology of the 80s. Also, the affordable technology at the time has been limited to one axis or two axis simultaneous movement, but we are targeting 4 axis (at least 3 axis simultaneous movement. For the Saacke machine, the Y and Z axis were controlled by an independent, TTL logic based “infeed control”, with parameters set by a number of BCD switches at the front panel. Pretty useful for recurring tasks, but hard to program special features just by BCD switches, and, of course, each grinding cycle needs to be set again by hand – you can keep the settings in a notebook but there is no way to just load a program by clicking a button. If you make one mistake on the BCD switch, rotary switch, etc., the machine will likely crash in the old days…

First of all, we need to get power to the electronics, and there is some unreliable start-up condition to the circuits controlling the mains power to the axis drivers and control section. That power is switched through contacts of the K38 contactor, which is turned on if the voltage monitoring contactor K123 is actuated, and the K124 safety contactor is actuated. K124 state depends on the limit switches of the axis, if any of these normally-closed switches opens, power to the drives is immediately cut off, so even in case of some control system malfunction, the power will be interrupted safety. There are nice slide rails, except for the Y axis, where the limits can be set by an Allen key, so that you can limit, say, the X travel to within reasonably safe limits if there are any particular fixtures mounted on the table.

The K123 contactor is actuated if all current signals (closed contacts of the X and A axis drive controls, K400 and K401 relais) and the control voltage (nominal 24 V) is good, but it also has a feature that it will not re-actuate if tripped, by the 3-4 contact pair. So, if there is any fault with motor current or control voltage, even once, the machine will stay in that state until it is power-cycled by the operator (after correcting the error, hopefully).

However, at initial switch-on of the main switch, surely there won’t be any good control voltage, and with the trip function, K123 needs a current path to switch-on at initial power-up, which is done by the K10 time relais. This device closes a contact and actuates K123 for just one second, when powered on, then, opens and stays open until the next power cycle.

It is a little dated version of still available devices from Dold Mechatronics, AI983N.7100. The inner circuit is some simple monoflop circuit, some capacitor, a relais – and, a transformer.

Turns out, there is no voltage on the transformer secondary – the primary winding is open circuit. Heavy glued to the circuit board – these devices are made to be in a vibrating factory environment, but the circuit board is of pretty ordinary quality, not through-plated.

After a quick repair – fortunately had a similar print transformer in stock – and replacement of the electrolytic capacitor, K10 is working fine, and the drives are now powering-on normally each time the mains switch is set to “ON”.

With power now established firmly, to the axis motors. The Y and Z axis (Y is moving the spindle up and down, Z is moving the spindle forth and back – similar logic to a horizontal milling machine) is driven by two independent stepper motors.

These are pretty sizeable Berger Lahr RDM51117/50 frame size 110×110 (NEMA size 42) motors, pretty expensive back in their days, and some of the strongest stepper motor available in the market.

Current rating is about 5 Amp per coil, 500 steps full step, 1000 steps half step.

Because of the lack of computing power and also lack of immediate need, there are two motors, but only one drive! The drive used for infeed automatic control is selected by some switches, including rapid functions. The current is turned off during switch events, surely, never unplug or cut the current of a stepper motor while energized – it will likely damage the driver transistor.

The drives are “Quintronic” NI series drives, very solid built.

Made in Western Germany – probably all hand assembled, and with one dedicated logic control board, and 5 D190 current control boards (one per coil) – powered by a 90 Volts DC supply, rated at 750 VA.

However, before being able to tests these, need to get control signals (TTL level) from the LinuxCNC PC to the old control system (running on 24 V HV-TL, respectively, open collector inputs).

Copying some circuitry I found in the Saacke old interface, using 7406 and 7407 open collector, some resistors, and a high-voltage tolerant LM311 comparator, soldered together a small interface board providing two step and two direction signal conversion. These also connect to some counters for the A and X axis at the front panel that I may use later as an auxiliary display.

In order to select the Y or Z axis controls, I also re-wired some of the feed selector circuitry to two small Finder relais, driven by a small control board.

The control boards – no schematic even needed, just a TTL relais driver, so there is double isolation – the PC TTL level with its own ground and 5/24V rail driving a small relais, which in turn uses the 24 V control voltage of the Saacke machine to actuate the Finder relais. With such industrial controls, contactors, motors, chopper-based drives, etc., it is very critical to use low impedance noise-insensitive circuits, rather than just the thinnest unshielded wire, common power supplies, etc.

The Y and Z motors are switched to the driver by Siemens contactors K200 and K201, which need to carry the 5 Amps DC at a very low resistance, say, 0.1 Ohms, to not upset the current regulator. Coil resistance of the steppers is barely 0.5 Ohms. Generally, I would consider this a problematic setup, firstly, because the contactor resistance may not be held to these very low resistances over time, also, there is no precise timing of the current-off signal to the drives, and the switching (happens at the same time, but may be milliseconds or 10s of milliseconds misaligned). So, there may be some arcing in the contactors, etc., and eventually the contactors or the drives may fail. Upon closer examination, indeed, a different, newer Berger Lahr drive is in the cabinet, compared to the X and A drives. Likely, it had failed, and then been replaced by a unit from a different machine (still has a label corresponding to the “X” axis – the table traverse).

Next, the control circuit – the drives are controlled by common step and direction pulse signals, originating from a rather large card with some TTL logic on it.

For convenience, I added the new small control/level converter boards to one of the old control cards, with a temporary DB15 connector to cable it to the PC.

Next up, confirmation of the phase currents. The cables of the stepper motor DC supply are fortunately routed such that a simple clamp-on current meter can be used to probe the current of each motor phase without any need to disconnect cables.

The X driver had one phase at only 3 Amps of current, rather than 5 Amps, strange – the motor was still working normally. Fortunately, I have the manual and schematics (at least the schematics without values and part numbers of the circuit elements) of the D190 current regulator boards of Berger Lahr company, so it was easy to find the culprit. A tantalum cap, not shorted, but soldered with incorrect polarity. Very likely this problem existed since manufacture, and slipped through Berger Lahr’s quality control system. Maybe the tests for quality were done at a lower current, say 3 Amps, because the reversed tantalum acted like a voltage limiter at about 3.5 Volts.

Easy fix, replaced by a multilayer cap.

The current input is normally operated at 5 Volts, and a trimpot is used to adjust the phase current of each coil.

Unfortunately, the Y/Z driver has some problems, keeping unstable current regulation on two phases, and after a short time and trying to adjust it, blew the fuse on two of the phases.

The D190 current control cards apparently used several types of transistors, I tried to collect what I can about these, some are very rare PT1132 transistors, other expensive NTE386, some use BUX41 and PT1132 in mixed (PT1132 for the upper transistor of the H-bridges, BUX41 for the lower). Nowadays, we would design that with MOSFETs and some high side drivers, easy enough.

The PT1132 seem to be related to BD245 or similar, or BUxxx series transistors, like, BU426.

Surely, we need NPN transistors with reasonably high gain, to avoid overloading the high-side drive circuit, and rather high voltage resistance (because of the 90 VDC), and fast switching – because the transistors won’t be able to sustain the linear load region to the 0.5 Ohms coil resistance for any length of time.

Later, it seems, Berger Lahr used BUX41 a lot, 200 V, 15 Amp NPN.

Yet, another type of BUX41…

NTE386 devices, very solid devices, but expensive, more than 20 EUR a piece!!

Finally, I would like independent motors and controls for both Y and Z, to avoid complicated switching and programming, and surely no full-current switching between driver and motor – surely retire the K200 and K201 contactors.

The are some options,

(1) Repair the Berger Lahr D190 cards – will surely repair these after sourcing some BUX41, but this will need to wait for some winter days and less busy times. Even consider to modify the H bridge on the card, by using MOSFETs and modern drivers. The drivers I have have combinations of PT1132 with BUX41, and PT1132 with RCA 41013 (equivalent to BDY58, NPN 125 V – 10 Amp, current gain of at least 20).

(2) Replace the 5-phase steppers by some NEMA42 bipolar steppers, with conventional microstep drivers – easy to maintain and repair going forwards. Then I would have some spare control cards from the former YZ driver, should any cards of the X and A axis drivers fail.

(3) Consider using more modern drive topologies like AC servos with encoders for the Y and Z axis, even for all axis, one I have figured out necessary adaptions of drive geometry (shaft diameters, case diameters).

With all the troubles of the design and state of the Y and Z drives, the X and A axes are working very well, even with the dated drivers and motors. 1000 steps per revolution results in about 3 mikron per step, and the speed of the table can easily reach 500 mm/min and more (mostly limited by the maximum step speed of a LinuxCNC real time step generator over parallel port) – given that it has a ball screw and roller ways, the mechanics would certainly tolerate more without any problem. Also confirmed the very smooth action of the table, mechanically no problem at all with the machine. Also the Y and Z axis – mechanically – are very sound. Cleaned all the screws, guideways etc., from the black dust and grease (better not use grease on grinding machines, but some CLP or HLP 46 oil).

CNC Tools

Tool Grinding Machine Saacke UW II NC: a few basic repairs

Leave a comment

The next big task, moving the Saacke from the entrance area of my house, to the workshop building. Fortunately, there are no stairs and steps, essentially, flat ground, but moving a large 300 kg electric cabinet, and a 700 kg machine, it is no easy task if you don’t have the right tools

Eventually, with the help of a friend and a pallet jack, maneuvered it to the location, but getting the pallet our from underneath a the machine, difficult. In a large factory, you just lift it up by crane of forklift, pull out the pallet, and let it down slowly. Also, you could build a tripod or gantry, and use a hoist to lift it up, but it is all pretty dangerous and labor-intensive, because I don’t keep all kinds of structural steel here.

Eventually, I managed to tilt the machine enough with a small hydraulic car jack, put two heavy flat steel bars underneath (70×15 mm), and lifted it up on some wooden support alongside the pallet, just suspended about 5 mm above. This way, I could pull out the pallet, and then lower the machine done bit by bit, by tilting it, and lowering the support 1.5 cm at a time, to avoid undue tilting. Take care that the whole thing doesn’t shift, and keep you fingers and feet clear at all times!!!

Eventually, after about 2 hours, the machine is at its final place. I will probably screw it down with three bolts, so it won’t move after setting it exactly (I mean very exactly) level. It makes it much easier to work on an exactly level machine, because you can use an electronic level to adjust angles pretty accurately. The seller did take great care of packaging the cables and plugs, glad these were not damaged in transit, because fixing these plugs normally means to completely newly wiring them, and while they are still widely available, these industrial plugs don’t come cheap.

Now, to some basic repairs, to fix the damages inflicted on the machine during transport.

First thing, a wheel of the electric cabinet (which has 3 doors, so to open the doors, you need to move around the cabinet. One wheel completely broke, probably someone hit it onto some wall when loading the truck. Rather than buying 4 all new wheels for such old machine, I try to fix what I can from stock I have, rather than buying ready-made parts. After all, that’s one of the purposes to have a workshop rather than a warehouse full of spare parts.

I cut-off a piece of a 35 year old rod of polyamide that I had around since my childhood time, once found at a scrapyard… then some machining on the lathe, and, a very study wheel is ready and mounted!

The fan of the table (X axis) drive, it really got damaged severely, fortunately, except some wire damage, the motor cover prevented further damage to the drive system, coupling, and, the very expensive ball screw that drives the table.

Most of these fans have their connectors at the outside, but the original one had been cabled to the inside of the cover. At least, I found a good replacement fan 112 m3/h nominal air capacity, run directly from 230 VAC mains.

Some disassembly of the connector, to get the wires exposed, some drilling.

Some soldering, shrink tubing has glue inside.

Still some need to adjust the cooling covers, but finally, got all the cables mounted and fiddled through. Also removed a few spoons full of grinding dust, and other dust.

Both the X and A (rotary) axis drives have new coolers.

Looking good, but the drives don’t even get that hot.

Next thing up for repair, the cover of the table.

Really terribly bent, taking it off was no easy task, drilling out one of the screws and taking great care not to damage the table.

To straighten it out, it took some patience, a vice, a polymer hammer, some pieces of wood.

Bending carefully, hammering it with quite some force, it is no thin metal but a pretty solid sheet. Amazing how crudely the carrier handled the shipment.

Some more knocking and bending.

Eventually, cleaned the plate and mounting surfaces with engine cleaner, still having some old cans around, but ordinary petroleum also works, and doesn’t attack plastic.

One great addition to the machine – a very nice German-made adjustable high-precision grinding vice, gifted to me by a relative. The vice has some little rust, but I will give it a good polish before using it on the grinding machine.

CNC Tools

Tool Grinding Machine SAACKE UW II NC: “the small one” arrived

Leave a comment

Over the last several month the electronic workshop has suffered from little work with test equipment repair, I think, we have an economic crisis – nobody seems to be interested in keeping their old equipment going, if even the new equipment is idle. More time to spend with traveling and other tasks, including, finally getting a new tool grinder.

For the fabrication of microwave components, like, mechanical filters, test antennas, etc., I am using custom-made tools of HSS (high speed cutting steel), mostly the parts are made of brass of Ni-Cu(-Zn) alloys, so HSS tools are superior for precision machining, compared to, for example carbide tools that don’t hold a sharp edge well.

Usually, we are considering small cutters here, 6, 8, 12 mm diameters. A radius tool, for example, for internal turning or single-edge milling.

…precise angles must be kept to keep the cutting edge going.

Also, for very tiny pieces, with complicated internal features, single point cutters don’t work well, so I need to resort to strong, custom made step cutters. Note that the shapes are calculated according to electric requirements, but the practical fabrication needs tests and adjustments, and eventually, repeatability, to get good results. Otherwise, the parts will randomly scatter in performance and it is hard to make a set of, for example, 3 pieces, without making 10 pieces scrap, with all the wasted time for machining and, especially, testing.

These tools can be cut by hand on a so-called cutter grinder, earlier introduced by Deckel company of Munich, model “SO”, but now available as import from China, at quite reasonable quality and cost (still, about EUR 1000).

While this little marvel is working very well, it demands outmost focus and consideration when grinding cutters, and is very time consuming to use. Re-grinding tools reproducibly takes practically the same effort than just making a new tool – all angles have to be set again, and all at the same risk of error and misoperation.

In effect, I have been using tools even when a little bit blunt, at a loss of surface quality, burrs (which are extremely bad, because we cannot polish these electric precision parts without destroying the precision, and burrs do show up in refection coefficients and gains).

A solution – we need to get computers and controls involved, in short, CNC. Buying a good CNC tool grinder, 4 axis to also be able to cut and re-sharpen gear cutters or mill cutters, will set you back at least 100 kEUR, including various expensive software options and difficulty in keeping it going without a service contract.

So I have been shopping around for a more affordable option – buying a solid heavy mechanical machine suitable for retrofit (for example, adding a new motion controller – using LinuxCNC on my other machines, fixing some electronics, replacing some or all of the drives and axis motors; but using all the existing mechanical system, the existing grinding spindle, etc.). This search has been underway since last year August, and after finding a machine, even paying, the seller damaged it so badly in his warehouse that he returned the money, still, no machine for me. Eventually, I found this very interesting machine, Made in Germany in the 80s, based on one of the best and solid designs of a manual machine, the SAACKE UW II. The main features are (hardened) roll-bearing supported long table with ball screw, tapered roller bearing A axis (heavy enough for milling), and prismatic cross-slide (trapezoidal screw) on wide-spaced support, along with a 1 mm-per-turn Z adjustment (high precision worm gear).

The introduction of the machine, considered by SAACKE as “the SMALL one”, no less than 80000 DM in 1985… probably equivalent to 90 kEUR today.

The 1 kW spindle is by far enough for the purpose, the machine can also cut very large milling cutters, flat grinding and round grinding (also tapered grinding) is all easily possible because of the 900×140 mm table.

Having found the machine at a reputable dealer in December 2023, it took several month until I could actually buy it, eventually, got it for very reasonable money, just about 2 EUR per kg, shipment included!

It arrived on two pallets, well secured and packaged. But with some parts sticking out. Already in phone conversation with the seller we had the concern of damage, but there was no practical way to transport it here at reasonable effort, rather than just giving it to a commercial carrier on pallets. Surely, I would always suggest you have your machines point-to-point delivered, even drive the truck yourself.

The transport took more than a week, and the carrier probably loaded and unloaded it several times from the truck, eventually, inflicting various damages to the machine. Fortunately, they didn’t drop it altogether.

A broken fan, a completely broken and ripped-off side plate, a broken roller, etc.

Quite some effort to disassemble the parts, find replacements, etc. – commercially, hard to fix, but we are talking about a major retrofit and modification anyway, so we can do it step-by-step in the evening and on (rainy) weekends, not counting all the hours.

One great plus of this machines are the full manuals, even of the motor drivers (using Berger Lahr 51117/50 stepper motors, really big ones!). For some control boards, and the PEP computer (the old brain of this machine), at least connection diagrams.

The main electrics of this machine, very nicely made in a general control cabinet, with all high quality contactors and fuses.

The cabling and connectors are all of the highest quality, costly, heavy duty German-made design.

The old control boards, in a nice rack. I am planning to use the existing motors for the table and A axis, the cross-slide and Z (which has one shared driver), haven’t made a decision yet, will just get it working for test reasons I believe.

The feed of cross-slide and Z is done by a feed control system rather than the 2-axis control (table X and rotary A axis that is controlled by the computer, coordinated motion to cut spiral flute cutters).

Soon will power it up. Just a note – this machine didn’t have ground connected, but wired as PEN connection, with a N-PE bridge. So it needed some testing of isolation (which it easily passed), and has already grounded 220 VAC and 24 VDC control voltages (adjusted the tap to get the voltages down a bit – design for 220 V, but I am getting about 230-233 VAC here). So if you get into such adventures with old machines, please make sure to contact someone knowledgeable about electric systems, don’t just plug it in!

Next up will by a study of the motors and drivers, some cleaning, some tests of the mechanics (have some precision granite square here to check for any wear/perpendicularity, and a high precision encoder to check the A axis).