technical specifications for up-gradation of vertical ... specifications for up-gradation of ......

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RRCAT/ACDFS/SR/VTL/2014/1

Technical Specifications For Up-gradation of

Vertical Turret Lathe machine

INDEX

S. No. Contents Page no

1. Introduction 2

2. Qualification criteria of bidder 2

3. Terms and conditions 2

4. Scope of Work 3

5. Existing configuration of machine 4-5

6. Other features of existing machine 6

7. Supply of CNC system 6

8. Features of CNC system 7

9. Spindle Table Encoder 7

10. Spindle Drive Module 8

11. Electrical scope of supply 8

12. Electrical design 8

13. Mechanical scope of work 8

14. Supply of Documents 9

15. Important notes to Bidder 9

16. Acceptance Criteria 10

17. Warranty 10

18. Duration of Work 10

19. Annexure-I: Work execution certificate 11

20. Vertical Turret Lathe machine photograph 12

21. Test job drawing no. RRCAT/SRF/RC/FMDI/101/R6 and

RRCAT/SRF/RC/FMDI/101/R7 13-14

22. Compliance Chart 15-19

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1. Introduction

The Vertical Turret Lathe machine is located at Accelerator Component Design and

Fabrication Section of RRCAT. VTL Dynacut-150 machine was procured from Kirloskar,

India and was installed at RRCAT in year 1990. The machine is having Fanuc controller and

drives for axes movements. Machine is equipped with independent DC drive for spindle.

2. Scope of work

This specification covers the requirement for supply of CNC controller, Drive units for all

axes and spindle, operator and power panel, design of electrical system, electrical

connections, PLC development, commissioning of machine and inspection after up-

gradation.

The scope of work for up-gradation of VTL machine includes:

1. Supply, installation and commissioning of CNC controller, drive modules and

servomotors for two axes control.

2. Supply, installation and commissioning of DC drive for existing spindle motor

3. Supply and installation of spindle table encoder

4. New operator pendant

5. New power panel with suitable capacity panel air conditioner for all CNC hardware,

drives and electrical switchgears.

6. New wiring of control and power panel.

7. Supply, mounting and installation of ball screw for Z-axis.

8. Vertical mounting arrangement of Z-axis servomotor to be done.

9. Supply and installation of wipers for axes, V-belts for spindle chuck drive and new

bellow cover/telescopic cover /molded rubber cover for X-axis

10. Laser calibration of X-axis and Z-axis

11. Test job to be machined as per drawing nos. RRCAT/SRF/RC/FMDI/101/R6 and

RRCAT/SRF/RC/FMDI/101/R7.

3. Qualification criteria of the bidder:

The bidder must meet the following criteria to qualify for the bid.

3.1 The bidder shall give an undertaking to provide warranty/guarantee certificate with Serial

no. of items supplied to RRCAT from OEM of the CNC controller, axes and spindle drive

at time of supply.

3.2 Only the bidders having capacity and at least two years experience in the field of up-

gradation/retrofitting/reconditioning of VMC/HMC/Special purpose machine tools/Vertical

Turret lathe machines including complete scope of electronics, electrical and mechanical

work are eligible to bid.

3.3 The bidder shall have done up-gradation/retrofitting/reconditioning of at least one Vertical

Turret lathe machine of similar design & capacity. Bidder must submit letter from customer

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in the prescribed format as in annexure-I of specifications. Bidder shall provide detailed

information about the scope of work completed on that machine including electronics,

electrical and mechanical work.

3.4 Bidders are requested to give a list of their customers in India where they have done up-

gradation/retrofitting/reconditioning work of VMC/HMC/VTL machines. At least one such

up-graded/retrofitted machine shall be located in Government / PSU /industrial unit in

India and working in satisfactory condition with proper service support from bidder.

Bidders shall mention customer/company details including name of the contact person,

complete mailing address, email and phone number in the bid. These contact details will be

used for mailing official enquiries about bids. Clarification / information asked by the

purchaser shall be provided in the set time limit, failing which the bid may be rejected.

3.5 The bidder shall confirm his capability to support the spares, maintenance, calibration and

after sales-service of the complete system after up-gradation/reconditioning work during

and after the warranty period.

4. Terms & Conditions:

4.1 Two part public tender procedure comprising of two separate bids shall be followed as

given below.

Part I. Technical bid. It shall also contain un-priced bid of price bid offer.

Part II. Price bid (shall include break-up of cost for all the major sub-systems, testing,

etc.).

4.2 Documents to be submitted with Part-1, “Technical Bid”

Bidder is required to submit following documents with the technical bid failing which his

offer is liable to be rejected.

Compliance chart is important part of these specifications. Point wise confirmation of

compliance chart duly signed with company seal shall be submitted along with offer.

Completely and unambiguous filled compliance chart shall be submitted at the time of

offer. Bids with improper information/ambiguity/non-submission of the compliance chart

will be liable for rejection.

Make and model of components/bought out items like CNC controller, spindle drive,

spindle encoder, ball screws, etc shall be clearly mentioned in compliance chart.

Bidder shall submit tentative weekly execution plan detailing scheduled execution of this

work.

Work execution certificate in prescribed format as in annexure-I on letter head of

company duly signed and with seal of company.

List along with contact details of their customers in India where they have done up-

gradation/retrofitting/reconditioning work of VMC/HMC/VTL machines along with

detailed information about the scope of work completed on that machine including

electronics, electrical and mechanical work.

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5. Existing configuration of machine

The machine was installed in year 1990 at RRCAT. The machine was conventional VTL and

later on retrofitted with FANUC CNC control, servo motors and drive modules for two linear

axes. The drive to DC spindle motor is fed by Kirloskar- TRK6 DC drive module.

S.No Description Make Make and Model Parameters

5.1 CNC Controller Fanuc O-TC

Type- A02B – 0098 – B511

5.2 X- Axis Motor Fanuc Model – 30 S

Type - A06B – 0590 – B005

Torque (Stall) – 37 Nm, 3 Ph,

Current (stall) – 16 Amp,

Voltage – 156 V, 8 poles,

Insulation – Class F,

RPM – 1200

Excitation – Permanent

Magnet

Pulse coder

5.3 Z-Axis Motor Fanuc Model – 30 S

Type - A06B – 0590 – B205

Torque (Stall) – 37 Nm, 3 Ph,

Current (stall) – 16 Amp,

Voltage – 156 V, 8 Poles

Insulation – Class F,

RPM – 1200

Excitation – Permanent

Magnet

Pulse coder

Inbuilt Electromagnetic brake

operating voltage – 90 VDC

5.4 Servo Amplifier

– X Axis

Fanuc Type- A06B – 6057 – H006

5.5 Servo Amplifier

– Z Axis

Fanuc Type- A06B – 6057 – H006

5.6 SMPS : I/P – 230 V AC

O/P – 24 V DC, 5A

5.7 Spindle Motor : Kirloskar

Electric

Co.

Model – KLDC 180 SX

(Separately excited DC

Shunt Motor )

Power- 60 /60/45 KW,

Rpm- 1575/3200/3750 rpm,

Voltage- 400/400 V DC,

Current- 164/123 Amp

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Excitation- 340 V DC,

Current- 4.8 /1.9/1 Amp

Duty – S1

With tacho generator

Cooling – Force cooling with

the help of blower fan

5.8 Spindle Blower

motor

3 ph, Induction motor 2.2 KW, 3000 rpm

5.9 Spindle Drive : Kirloskar

Electric

Co.

TRK6 – 4 U – 195 Amp Current:195 A

High speed and low speed

selection of spindle chuck with

help of gear shifter

5.10 Rail operation Traverse motor

(3ph Induction Motor, 5

HP, 1500 rpm)

Up ward & Down ward with

the help of traverse motor

Rail attached with Dead

weight Counter balance

arrangement.

5.11 Hydraulic system Hydraulic motor:

(3ph Induction Motor, 5

HP, 7.8 A, 1440 rpm)

DUAL PUMP

1. Fixed displacement type 15

LPM, 15 bar for lubrication.

2. Variable displacement pump

48 LPM, 30bar Working pressure

for counter balancing & indexing

of turret.

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6. Other features of existing machine:

Size of Chuck: 1500 mm dia

Traverses: X axis: 850 mm, Z axis: 700 mm

Maximum Job Size: 1500 mm x 1300 mm

Operator pendant: Hanging type

Turret Indexing: Hydraulic operated

Side Tool Head: Machine is equipped with side tool head for machining of

large diameter jobs. Side tool head receives drive from

traverse motor through spline shaft.

Counter balance: Hydraulic counter balance cylinder for turret vertical

movement

Mounting arrangement: Z-axis servo motor is horizontally mounted and coupled to Z-

axis ball screw through bevel gear arrangement.

7. Supply of CNC system

7.1 CNC controller of Siemens 828D/Fanuc Oi-TD with latest applicable features along

with system control software for two axes simultaneous interpolation.

7.2 X-axis AC servo motor- 35 Nm or more (Make:-Siemens/Fanuc alpha series

motor)

7.3 Z-axis AC servo motor with integrated electromagnetic brake- 35 Nm or more

(Make:-Siemens/Fanuc alpha series motor)

7.4 Sinamics/Fanuc Latest applicable drive modules for X and Z axes.

7.5 Interfacing of CNC controller with spindle DC drive module for all necessary signals

like Constant Surface Speed feature (CSS), spindle motor speed control through CNC,

field failure protection feature, safety interlocks, etc.

7.6 Other required accessories like power module, PP module etc shall be supplied and

interfaced for complete and proper system.

7.7 Programmable logic controller (PLC) system with Input/Output card for interfacing

with the machine.

7.8 Operator front panel-10.4” Color TFT display with integrated Qwerty full CNC

keyboard with short stroke keys.

7.9 Machine control panel (MCP)-50 keys with override switches for feed and spindle

along with manual pulse generator (MPG) for both axes and Emergency stop button.

7.10 New Operator pendant for mounting of machine control panel and operator control

panel.

7.11 Siemens/Fanuc make remote handheld unit with MPG, emergency stop button, rapid

and jog keys for traversing the axes in jog mode.

7.12 Suitable capacity SITOP power supply for control voltage- 24 V.

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8. Features of CNC System

Following features apart from standard features are required in the system.

8.1 Number of axes -- 02 ( X and Z)

8.2 Simultaneous controllable axes -- 2/2

8.3 Least input increment -- 0.001 mm or better

8.4 Least command increment -- 0.001 mm or better

8.5 Feed rate override -- 0 to 120 %

8.6 Spindle rate override -- 0 to 120 %

8.7 Buffered user memory available shall be 3MB or more

8.8 Pitch error and backlash compensations

8.9 Integrated graphic simulation of part programs. Option to verify part programs before

execution.

8.10 Dry run option

8.11 Tool radius and tool length compensation

8.12 Tool data management option shall be available

8.13 Manual pulse generator for all axes

8.14 Special cycles like dwell time, program call, subroutines, etc

8.15 Parametric programming option with mathematical functions, trigonometric functions,

etc.

8.16 Subprograms and subroutines repeats options

8.17 Work offsets shall be provided.

8.18 RS232/USB option for backing of machine data, archiving series files and backing of

part programs data.

8.19 Compact flash card option for system data archiving, load and execution of part

program through machine.

8.20 DNC option for program run directly through flash card

8.21 Networking option through Ethernet port (RJ45) shall be available.

8.22 Look ahead option availability.

8.23 Diagnostic functions availability for easy troubleshooting of problems in machine.

8.24 On board user manual for descriptions of important operator functions, NC commands,

cyclic programming, drive alarms and HELP menu.

8.25 Canned cycles for various operations of VTL shall be available. The option to

parameterize these canned cycles shall be available.

9. Spindle Table Encoder

Supply and installation of new encoder for accurate feedback of spindle table position and

speed. Mounting arrangements and interfacing of spindle table encoder with CNC and

spindle DC drive to be done on machine. The external spindle encoder may be mounted on

spindle drive motor for speed feedback.

Resolution of encoder: Minimum 5000 ppr

Make: Any of Siemens/Heidenhain/Renishaw/Allen Bradley/Givimisure

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10. Spindle Drive Module

DC drive module for existing spindle motor of the rating specified at point no. 5.7 of

technical specifications. DC drive shall be any of - Siemens/Fanuc/Allen Bradley make.

Spindle drive module shall have features enabling its integration with the CNC controller for

activation of necessary features of VTL like Speed control of spindle motor through CNC,

Constant surface speed feature, field failure protection feature, safety interlocks, etc. The

integration is to be done by supplier.

11. Electrical scope of supply

11.1 Supply of new operator panel and machine control panel

11.2 Supply of new electrical power panel to house all required CNC components, axes

drive and power modules, spindle power module and all electrical switchgears.

11.3 All required switchgears, control transformers, line filters, etc. for operation of machine

shall be supplied.

11.4 Electrical power panel (preferable make RITTAL or equivalent) shall be supplied with

suitable capacity air conditioning unit.

11.5 Signal multi core cables, power cables, profibus cables, conduits, connectors, terminal

strips, glands and their channels will be supplied.

12. Electrical design

12.1 Design of new electrical circuit as per new hardware.

12.2 PLC logic development as per new design.

12.3 Electrical design, laying of equipments and their interfacing.

12.4 Complete new wiring of electrical panel, operator panel and control panel as per new

design.

13. Mechanical scope of work

13.1 Supply and installation of ball screw with associated nut assembly for Z axis (Ball

screw class- C5 or better; preferable make-HIWIN/THK/REXROTH/PMI). Minimum

diameter of ball screw shaft shall be 40 mm. All necessary end and support bearings,

housings and other accessories for mounting of ball screw shall be supplied and

installed.

13.2 Vertical mounting arrangement of Z-axis servomotor to be done. Drive feed

mechanism, mounting brackets and coupling mechanism for Z-axis to be designed and

installed.

13.3 New wipers for X and Z moving slides.

13.4 Supply and installation of new V-belts for coupling spindle motor and gear box.

13.5 New bellow cover/telescopic cover to be supplied for protection of ball screws.

13.6 Inspection of X and Z axes with Laser interferometer after completion of up-gradation

work.

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14. Supply of Documents

14.1 Adequate documents i.e. operator manuals, programming manuals, parameter and

servicing manuals (2 sets of hard copies each) of CNC control system and drive

modules shall be supplied. Manuals in soft copy may be provided but hard copies of

manuals are essential.

14.2 Licenses, test certificates and software CD/DVDs supplied as standard with the

controller package by Siemens/Fanuc shall be supplied to us by supplier.

14.3 Ladder diagram and machine parameter data developed by supplier shall be provided in

hard copies (three sets) and soft copy on a CD in doc or pdf format. Ladder diagram

shall be provided with proper comments and detailed description for easy

understanding.

14.4 NC data, machine parameter data, PLC data and other relevant data shall be provided as

machine backup soft copy.

14.5 Electrical circuit diagram as per new design shall be provided in three sets of hard

copies.

14.6 Complete set of electrical/logic/mechanical drawings of installed equipments (2 sets of

hard copies each) shall essentially be provided.

14.7 Inspection/test reports of all bought out items shall be submitted along with the supply

of items.

15. Important notes to Bidder

15.1 Entire up-gradation work shall be done at RRCAT only.

15.2 Supplier shall ensure the supply of their offered items from respective OEMs to

RRCAT, Department of Atomic Energy, before submitting their offer.

15.3 At least four personnel of our centre shall be trained at our works for operation,

programming and maintenance of equipments installed.

15.4 Electrical cables of reputed make like Finolex/Lapp/Polycab shall be used wherever

needed, for machine wiring.

15.5 Electrical switchgears, pushbuttons and other electrical switches shall preferably be of

Siemens/equivalent make.

15.6 All cable glands, conduits shall preferably of Igus make or equivalent.

15.7 Compliance chart attached with the specifications shall be properly filled and submitted

by the supplier at the time of part-I, without which the bid may be liable for rejection.

15.8 No partial offer will be entertained. The bidder shall bid for complete work of up-

gradation including supply, installation and commissioning of the system. The

offer shall be complete in all respects and signed by the bidder. Any

unsigned/incomplete offer may be liable for rejection.

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16. Acceptance Criteria

16.1 The bidder shall give an undertaking to provide the warranty/guarantee certificate with

Serial no. of items from OEM of the CNC controller, axes drives and spindle drive at

time of supply of items.

16.2 The machine will be tested for proper functionalities that includes job programming,

simulation, machine status diagnosis, alarms, security features, auto, manual and hand

wheel mode operation. The machine may be run continuously for 12 hours for

verification of machine features. The bidder has to prove the machine functionalities at

time of final inspection.

16.3 All existing features of the machine will be retained and shall be demonstrated at time

of final inspection.

16.4 Test job as per drawing nos. RRCAT/SRF/RC/FMDI/101/R6 and

RRCAT/SRF/RC/FMDI/101/R7 have to be made on the machine by the bidder after

commissioning of system. Raw material and required tools for trial job shall be

provided by RRCAT.

17. Warranty

NC and drive components, operator panel, machine control panel and all other electrical

and electronic items shall be warranted for trouble free operation for 12 months from date

of commissioning of the CNC at our works. During the warranty period all defective

parts, necessary lodging and boarding charges of service personnel as well as cost of

repair of defective items shall be fully borne by the supplier.

18. Duration of work

Up-gradation work including electrical and mechanical scope shall be completed within

two months of start of work at RRCAT by the bidder. Bidder has to communicate the

work starting date at least two weeks in advance to RRCAT. Machine will be rendered to

bidder for above work on that date and two months time from start date would be

provided for completion of work.

Bidder shall provide tentative weekly execution plan at the time of part-I of technical bid

detailing steps of execution of this work.

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Annexure-I

Work execution certificate

(Format shall be provided on company’s letter head with signature and seal of company at time

of Part-I of technical bid)

S.No Details

1. VTL machine make

2. VTL machine model

3. Size details of machine

Axes traverses

Safe working load

Table size

4. Year of up-gradation/retrofitment

work done

5. Details of work done

Electronics

Electrical

Mechanical

6. Contact details of Authorized

person

Name-

Designation-

Email id-

Telephone no.-

Fax no.-

Signature of Authorized person

(With company seal)

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Vertical Turret Lathe machine

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Test job drawing no. RRCAT/SRF/RC/FMDI/101/R6

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Test job drawing no. RRCAT/SRF/RC/FMDI/101/R7

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Compliance chart for Bidders

(Bidder / supplier must fill in the following chart and enclose with the part-I of tender)

Sr.

No

Technical Specifications Specified values Bidder’s Offer Deviation if any –

justification for deviation

1. Qualification criteria of bidder

1.1 The bidder shall give an undertaking to provide

warranty/guarantee certificate with Serial no. of items

supplied to RRCAT from OEM of the CNC controller,

axes drives and spindle drive at time of supply of

items.

YES/NO

1.2 Bidder shall have at least two years of experience in field

of VMC/HMC/Special purpose machine tools/Vertical

Turret lathe machines up-gradation/retrofitting/

reconditioning work.

YES/NO

1.3 The bidder shall have done up-

gradation/retrofitting/reconditioning of at least one

Vertical Turret lathe machine of similar design &

capacity. Bidder must submit letter from customer in

the prescribed format as in annexure-I of specifications.

Bidder shall provide detailed information about the

scope of work completed on that machine including

electronics, electrical and mechanical work.

Completely filled

annexure-I

1.4 Bidders shall give a list of their customers in India

where they have done up-gradation/retrofitting work of

VMC/HMC/VTL machines. At least one such up-

graded machine shall be located in Government / PSU

/industrial unit in India. Bidders shall mention

customer/company details including name of the

contact person, complete mailing address, email and

phone number in the bid.

List of customers with

contact details

attached -YES/NO

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2. Supply of CNC system

2.1 CNC controller of Siemens 828D/Fanuc Oi-TD with

latest applicable features along with system control

software for two axes simultaneous interpolation.

Specify make, model

and enclose datasheet

2.2 X-axis servo motor- 35 Nm or more (Siemens/Fanuc

alpha series motor)

Specify make, model,

ratings and enclose

datasheet

2.3 Z-axis servo motor- 35 Nm or more with

electromagnetic brake (Siemens/Fanuc alpha series

motor)

Specify make, model ,

ratings and enclose

datasheet

2.4 Sinamics/Fanuc Latest applicable drive modules for X

and Z-axes.


ratings and enclose

datasheet

2.5 Interfacing of CNC controller with spindle DC drive

module for all necessary signals like CSS, spindle motor

speed control thorough CNC, field failure protection,

safety interlocks, etc.

YES/NO

2.6 Other required accessories like power module, PP module

etc shall be supplied and interfaced

2.7 Programmable logic controller (PLC) system

2.8 Operator front panel-10.4” Color TFT display with

integrated Qwerty full CNC keyboard with short stroke

keys.

2.9 Machine control panel (MCP)- 50 keys with override

switches for feed and spindle along with manual pulse

generator (MPG) and Emergency stop button.

2.10 Siemens/Fanuc make remote handheld unit with MPG,

emergency stop button, rapid and jog keys for traversing

the axes in jog mode.

2.11 SITOP power supply for control voltage- 24 V.

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3. Features of CNC System

3.1 Number of axes 02 ( X and Z )

3.2 Simultaneous controllable axes 2/2

3.3 Least input increment 0.001 mm or better

3.4 Buffered user memory 3 MB or more

3.5 Compliance to all other features as mentioned in point 8

in the specifications.

(YES/NO)

4. Spindle Table Encoder

4.1 Supply, mounting, installation and interfacing of new

encoder for accurate feedback of spindle table position

and speed.

Resolution of encoder:

Make:

Minimum 5000 ppr

Heidenhain/Renishaw

/Allen Bradley

/Givimisure

5. Spindle Drive Module

5.1 DC drive module for existing spindle motor of the rating

specified at point no. 5.7 of technical specifications.

Make-Siemens/Fanuc/Allen Bradley.

Spindle drive module shall have features enabling its

integration with the CNC controller for activation of

necessary features of VTL like Constant surface speed

feature, spindle motor speed control through CNC, field

failure detection, safety interlocks, etc. The integration is

to be done by supplier.

Specify make, model


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6. Electrical scope of supply

6.1 Supply of new operator panel and machine control panel

6.2 Supply of new electrical power panel to house all required

CNC components, axes drive and power modules,

spindle power module and all electrical switchgears.

6.3 Supply of all required switchgears, control transformers,

line filters, etc.

6.4 Supply of electrical power panel with suitable capacity air

conditioning unit.

6.5 Supply of signal multi core cables, power cables, profibus

cables, conduits, connectors, terminal strips, glands and

their channels

7. Electrical design

7.1 Design of new electrical circuit as per new hardware.

7.2 PLC logic development as per new design.

7.3 Electrical design, laying of equipments and their

interfacing.

7.4 Complete new wiring of electrical panel, operator panel

and control panel as per new design.

8. 8 Documents

8.1 Complete set of documents as per point no. 14 of tender

specifications.

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Seal and Signature of Bidder

----------------END OF SPECIFICATIONS------------------

9. Mechanical scope of work

9.1 Supply and installation of ball screw for Z axis with

associated nut assembly and all other items (Ball screw

class- C5 or better, diameter-40 mm or more, preferable

make-HIWIN/THK/REXROTH/PMI).


class of ball screws


9.2 Vertical mounting arrangement of Z- axis servo motor to

be done. Drive feed mechanism and coupling mechanism

for Z-axis to be designed and installed.

9.3 New wipers for X and Z moving slides.

9.4 Supply and installation of new V-belts for coupling

spindle motor and gearbox.

9.5 New bellow cover/telescopic cover to be supplied for

protection of ball screws.

9.6 Inspection of X and Z axes with Laser interferometer

after completion of up-gradation work.

10. Acceptance criteria

10.1 Test jobs to be machined as per drawing nos.

RRCAT/SRF/RC/FMDI/101/R6 and

RRCAT/SRF/RC/FMDI/101/R7 after commissioning at

time of inspection.

YES/NO