TMC: Add 12K Spindle Option

Unscrew the 4 screws holding the tool holder clamp switch panel and slide it inside the spindle. The sheet metal surroundings need to be removed. Technician needed to adjust the height of the spindle for access to the left side and cut some zip ties for wire space.

Just loosen top bolts and leave them installed. Lower bolts are hard to access especially on the left side, so remove them first. You need to remove two plugs for the EHW option if so equipped. Careful of the wiring on the right side cover with EHWs. After the lower bolts are removed, remove upper bolts with panels. Panels can be heavy and awkward.

Turn off air supply from the rear panel. Disconnect air lines from the pneumatic cylinder. Remove the four nuts holding the cylinder platform and set it aside.

Note the orientation of the blue and black air lines at the top of the spindle. You may extend the existing air lines during this process. Make sure the blue line goes to the top of the air cylinder and the black hose goes to the bottom. You risk a mill crash if the hoses are reversed.

Remove tool detect sensor and wire. Remove the four stand offs.

Release the jam nut from the two belt tensioning screws. Remove both tensioners.

Loosen the 4 bolts that hold the motor mounting plate to allow for belt tension release. Remove the belt from the spindle motor sliding away as needed from the spindle for clearance.

E - Stop mill.

DO NOT AT ANY TIME ATTEMPT TO LIFT MOTOR BY HAND AS IT WEIGHS APPROXIMATELY 80lbs.

Use caution when moving the motor with cables attached. They could be a trip hazard or get damaged.

Two People for lifting over 50 lbs is recommended. Remove four screws holding motor. This is an 80 lb motor, two people needed to lay it on its side. Possible to use hoist but don't need to remove it from the mill for this upgrade.

DO NOT AT ANY TIME ATTEMPT TO LIFT MOTOR BY HAND AS IT WEIGHS APPROXIMATELY 80lbs.

Photo shows 8 screws removed then 2 of 4 jackscrews installed preparing to slide out the tapered bushing. Remove the bushing and slide pulley away from the motor.

New pulley with tapered bushing shown (inset), also shows the larger size of the new pulley. Slide larger pulley onto the motor shaft. The tapered bushing holds onto the shaft and securing the pulley bore.

Photo shows new larger pulley installed.

Clean tapered bushing and push it and the pulley all the way against the shoulder on the motor shaft, as high up as it goes. Tighten the tapered bushing like a tire installation criss crossing the center to tighten another bolt on the opposite side. Go all the way around and then again to confirm they are all tight.

Clean the nose of the spindle to prepare for lowering into spindle replacement tool. Install spindle tool LOOSE to allow for slight position adjustment. Lower spindle until fully seated. Tighten table bolts on tool.

A - While lowering spindle carefully align spindle with tool for equal contact to the support tool. B - Loosen spindle bolts, they stay in for support. C - Use jackscrew to start to force spindle out of casting. You want to keep the spindle touching the tool on the table while raising the casting just a little at a time.

A - Jackscrews are removed while slowly raising the casting. B - Continue to raise casting slowly. C - Top of spindle pulley now showing.

Remove spindle from mill. use caution because the spindle is also heavy and oily (slippery).

Carefully wrap new spindle to place it in position. Wrapping protects the side as well as the top plate.

CAUTION - careful attention to the black shaft sticking out at the top of the new spindle. This is incredibly sensitive and cannot be dropped or hit against things during moving. Use care!

A - Original spindle. B - New spindle is carefully wrapped to protect outside surface as well as the top most metal plate. C - New Spindle.

Once new spindle is placed on tool holder, the wrapping can be removed.

Spray WD 40 up into spindle cavity in casting. Wipe inside cavity after spraying to make sure fully cleaned (no dirt, debris, etc.). Then clean and check both upper and lower flanges for dirt and burrs.

Spindle O-rings are covered with lube. Special attention is given not to plug oil passageway. Don't get the lube close to oil passageway to allow for the lube to be compressed during installation. To protect that passage way after installation, a 1/2" o-ring is inserted into the flange above the hole on the casting (see insert).

Lower the casting very slowly keeping in mind the holes in the spindle need to be aligned with the holes in the casting. 1- O-Ring is pre-installed here. Make sure it is still in place before assembly. 2-Add an O-Ring at this location. Make sure the "OI" hole on the flange aligns with the new O-Ring on the spindle. Twist the spindle as needed.

Stop the spindle flange close to the casting to test the alignment of the holes.

Use the cross pattern to install the spindle bolts. Use the stepped torque system every 10 ft/ lbs to a final torque of 30 ft/lbs.

Install and tighten belt using Gates Sonic tension Meter 507C to 113 Hz by adjusting both tensioners. Tighten four M12 motor bolts to 50 ft/lbs.

Replace short standoffs with the longer ones, short end down into casting.

Install clamp shaft (with left hand threads) into tool clamp cylinder and base. Set the distance to the shaft by turning the shaft until 2 1/2" are exposed from the flange to the end of the shaft.

Because of raised portion of the 8/12K spindle at the top, a clamp tower has to be installed. This is done for both 12K and 12K CTS mills. Mills with CTS have a rotary valve installed in the clamp tower. This procedure covers the 12K without CTS, The kit provides air to the spindle.

Part number is 31225, the fitting is 31226, air tube is 31227 8/12K Air Blast Extension Kit is used to modify the extension clamp tower. Photo shows how the kit will look assembled in the clamp tower.

The clamp tower is the extended one that comes from Peng JIng. We are just bridging the gap from there to the spindle. The air blast comes through the bolt. We redirect that through the shrink valve with CTS, but obviously no shrink valve on 8/12K alone. This assembly is just the fitting, aluminum tube, and 3d printed part.

Careful attention is made to the tool change cylinder bolt for the top of the clamp tower. One end has internal threads which should be placed on the lower end closer to the spindle.

Completed 12K Air Blast Extension Kit

Place the clamp tower on top of the spindle add the tool clamp cylinder and base on top so the shaft fits through the clamp tower. Inset photo shows the clamp shaft threaded inside for securing adapter to connect aluminum tube.

Adjust height of the clamp tower by placing 5 mm hex wrench under it and tighten the two set screws on top. Add nut with left hand threads to the clamp shaft. Replace 4 nuts and washers on the tool clamp cylinder.

First mount the push to connect fitting on the bolt. Then, slide the air hose into the spindle (don’t let go). Tilt the 3D printed brace and insert it into the tower. Feed the air tube through the brace, and up to the push to connect fitting. Secure the brace with 3x screws - M6-1.0x40 (26B).

Use blue and black rubber tubing supplied with the kit to extend the length of the tubes to the spindle. At some point, mills will come with longer hoses.

Assemble proximity sensor as shown. use two bolts to fasten bracket to casting in front of the spindle as shown. Gap between the spindle and edge of sensor should be 0.030". Rotate the spindle and make sure the light comes on and off. This will check the gap for proper operation of the sensor.

Install new front sensor and module, with wire changes as shown. Light weight module floats on the right side of spindle, mixed in the wires so does not need to be secured.

Typical location for module.

TMC left rear corner without the 12K Spindle Oil Cooler pump installed. Note that there are two sets of holes drilled and threaded in the casting for options to be installed.

Installed bracket in the proper location to support 12K pump.

Bracket is secured by 4 bolts included in the 12K kit.

There are four bolts included in the kit that need to be installed from the bottom of the pump through the bracket into the pump housing for support. The two in the front are labeled with two others in the rear.

Pump connections are shown for the two hydraulic lines and the electric cable. Illustration shows the specific location for the outgoing and incoming coolant.

Always on when the mill is operational so no switching on and off.

Cable routing shown for the power and control wires from the pump of the 12K oil cooler.

Install circuit breaker on the right side of the bottom rail in the cabinet. Cable "Spindle Oil Cooler Pump" contains the smaller cables L1-22, L2-22, & L3-22 to connect to the bottom row of the circuit breaker. Power wires L1-7, L2-7 & L3-7 are connected to corresponding terminal blocks TB 16-1, TB 18-1 & TB 20-1.

Route cable from the pump opening through the wire controls and to the computer module, second row from the right and third connector from the bottom. Computer module is labeled with "P28-IN-SPD-Oil-Press" just below where the cable goes with the same name.

Oil cooler assembly control cable consists of pump power cable and sensor feedback cable. Both cables are in the same housing when connected to the oil cooler pump. The housing runs across the rear of the spindle where they separate.

The sensor feedback cable enters the electric cabinet from behind on the inner corner mount with the chassis along with other signal cables. The power cable enters the electric cabinet from behind the outer side along with other power cables.

Hoses have to traverse a long path going through the flexible loop on the spindle. Hoses start from the pump and are connected to fittings along the back of the first bracket.

First bracket requires fittings for both coolant hoses.

Long hoses take a loop here to compensate for the spindle travel. Bracket in the center to manage the fluid hoses needs to be removed and have fittings added. This steps routes the cables into the spindle.

Hose connections shown for the supply of coolant from the pump as well as a connection to returned heated coolant back to pump.

This step will give instructions on how to program the AC Drive. File name stored in the laptop has the format 29166-TMC-12K AC Drive. File names correspond to the mill; TMC 5/7/10/12/14. with the 12K option. You will need a USB 2.0 Type A and B and a laptop with the Drive Wizard Industrial Software. .

Prior to programming verify there are no errors displayed from the AC Drive. Use a standard USB 2.0 Type A and B to program. Next, connect B side to AC Drive USB port and A side to laptop.On the laptop launch the 'Drive Wizard Industrial software.

In the software open Drive selection & Communication Setup icon. Notice it will generate a window, on that window verify that it reads USB connection. Next press TEST it will start loading the appropriate parameters for the AC Drive.

The revision for the AC Drive parameter program file may change. Check with your Lead and/or Supervisor for the latest revision.

Click on View Edit Drive Parameters Click Open icon, select 29166-TMC 8K Rev 18 file, click No, Click OK.

Click on Write Parameter icon, click Close, Click Yes. (Software will download parameters to AC Drive) AC Drive has been successfully programmed.

Update the ProtoTRAK software to Version 2.4.0 or later.

Run Service Code 142 to save the machine's configuration to USB flash drive. You will get a message to confirm to save the file to the USB.

Follow the steps in the attached document, "Instructions for Upgrading TMC Config Files" to edit and rename the configuration on USB flash drive. The attached document is provided at the end of this guide.

Replace the Machine ID Key with the 12K version of the machine's current model. Cycle power after replacing the Machine ID Key.

Confirm the spindle runs in forward and reverse.

Warm up spindle for 5 minutes at 1,000 RPM. Measure Spindle RPM’s with tachometer, and confirm on screen that they match at 3K, 6K, 9K and 12K.

Run Service Code 141 to load the new configuration back into the machine. You will see a message confirming your interest to load a file from the USB. After the file uploads into the mill, you will be asked to cycle power.

An automatic tool change requires that many components of the TMC work in concert with one another. With the spindle change, it is important this is done.

These components include the ATC (Position relative to the centerline of the spindle), the spindle (Orientation of the spindle drive dogs relative to angle of the tool holder held in the ATC), the Z-axis (tool change height) and the Automatic Draw Bar (being in state of clamped or unclamped).

The arrow shows the dogs lined up with the center of the ATC where it can change tools when changer is aligned.

The arrow is the spindle aligned with ATC ready for a tool into tool slot #1.

Let’s start with spindle orientation. Spindle orientation is like any other setting regarding the ATC, it is a critical one, as a crash would be the result of an improper setting. Spindle orientation centers the drive dogs of the spindle for proper engagement of the CAT40 tool holder when it is held in the tool carousel of the ATC.

Go into SETUP on the pendant, select SERV CODES from the bottom row menu and then enter "510" at the prompt.

Select F2 Spindle orientation from the main menu. The second screen will give you step by step details in order to make sure the spindle and the system software are properly synchronized.

Follow the instructions on the screen carefully. Purpose of this is to double check the tool change height.

TRAK recommended oil: Quality ISO 32 oil, Anti-Wear additive. Pump capacity 4 liters which may need to be topped off once lines and spindle passageway is filled.

Fill spindle coolant pump with fluid. Run the pump to prime the system. The system holds more than the filling tank in the pump enclosure. This is a good time while the filling tank is not full to verify system operation. The return hose connects to a metal pipe that goes down into the filling tank.

When the level is low, you should be able to see bubbles in the fluid coming through the system. Now look over the whole system for leaks. This includes the fittings on the bracket at the rear of the mill as well as the junction plate at the top of the spindle. All of the hoses and fittings should be checked for leaks. Run test 10 - 15 minutes.

Fill the tank to about the top of the gauge while the pump is working.

Caution heavy item: use two people as needed to pack spindle for return shipping.

The 8K spindle that has been removed from the mill for this upgrade is a valuable resource and needs to be well oiled, wrapped, boxed and crated reusing the original new spindle packing materials.

TRAK gets over $2,000 credit for the return of unused spindles which will go back to production and be installed in another mill. Contact shipping for proper handling and paperwork.