Lab Router requirements and Specifications

The Lab has limited space and restrictive door size. Existing and local
easily available power is limited. The physical dimensions and power
draw specifications listed must be considered as [maximum]{.underline}.
The Router head type, size and collet style are considered critical in
order to maintain interchangeability with existing tooling and to
minimize storage space requirements.

**Machine Type**

The machine type shall be fixed gantry with a moving table with a
detached controller supported by a windows based PC (IBM Style personal
computer).

**Machine Construction**

The general construction of the machine base and Gantry shall be of all
steel, which has been welded, and stress relieved with a total weight of
less than 3500 pounds.

**Gantry**

The Gantry shall be fixed.

The maximum height of the Gantry or any attachments including the router
head shall not exceed 71.5 inches at rest or at any time during the
operation of the machine.

The maximum width of the Gantry or any attachments including the router
head shall not exceed 80 inches at rest or at any time during the
operation of the machine.

The position of the Gantry (legs) supports shall allow for a minimum of
two inches clearance on both sides of the moving table.

The Gantry (leg) supports and lower table attachments shall not exceed
65.5 inches in width.

The Gantry to table clearance (router head included) shall be a minimum
of 12.0 inches.

The Gantry shall [not]{.underline} be supplied with a misting attachment
but [shall]{.underline} have provisions for attachment of a mister
should one be required in the future.

The Gantry shall [not]{.underline} be supplied with an air drilling
attachment but [shall]{.underline} have provisions for attachment of an
air drill should one be required in the future.

The Gantry cross table motion shall be sufficient as to allow the center
line of the tool axis to traverse off the table surface by a minimum of
.250 in.

**Table**

The moving table size shall be not less than 48x48 inches or more than
52x52 inches.

The moving table shall be made of steel, aluminum or phenolic or any
combination of the three and have T-slots, which accept standard T-nuts,
running the full length of the table. If the table is made of aluminum,
phenolic or any combination the T-slot tops shall be removable and
replacement parts shall be readily available.

The table movement shall be sufficient as to allow the center line of a
.5 inch tool to traverse off the table surface by a minimum of .250 in.

**Machine Base**

The machine base dimensions from the floor to 32 inches above the floor
shall not exceed 65.5 inches by 115 inches.

The Machine Base shall have a minimum of four (4) and not more than six
(6) adjustable leveling/support feet with a minimum footprint of 9.0
square inches each.

**Tolerances**

Resolution shall be .0001 in/pulse.

Repeatability shall be +/- .001 inch or better.

Positioning accuracy shall be +/-.002 in/ft or better.

**Speeds**

Machine cutting speed shall be from Zero to at least 600 ipm.

Machine rapid traverse (G00) shall not be less than 800 ipm.

**Router Head**

The Router Head shall:

Be a minimum of 5.5 HP and be capable of 24000 RPM.

Have a ISO 30 Pneumatic Chuck Spindle that supports tool holders with a
LR32 taper.

Have a minimum of twelve (12) inches of travel in the z axis.

Be supplied with a minimum of four (4) complete tool holders to include
collets. (one ea. 1/8, ¼, 3/8, & ½ in.)

**Ball Screws and nuts**

The machine shall be supplied with Ball Screws on all axis' (x,y,z,).

Ball Screws shall have a minimum size of 25 mm.

Ball Screws shall be supplied with adjustable Ball Nuts.

Ball Nuts shall be preloaded for a Zero Backlash.

Ball Screws and Ball Nuts shall be easily operator serviceable and
adjustable.

**Servos**

AC brushless Servos shall be supplied on all axis' (x,y,z).

Servos shall be a minimum of 750 watts and be equipped with serial
encoders.

**Controller**

**Physical**

The Controller shall:

Be a stand-alone unit with a cable attachment to the machine of not less
than ten (10) feet or more than twelve (12) feet.

Have the provisions for anchoring to the floor.

Have a cabinet strong enough to be lifted by fork truck from the bottom
or small shop crane from the top and resist twisting, bowing and
racking.

Not exceed any of the following dimensions: width\--48 inches, depth 22
inches, height 84 inches.

**Hardware**

The Controller shall:

Have a minimum 32-bit CPU running at a minimum speed of 133 MHz.

Utilize a 64-bit or better system for calculating motion profile
algorithms.

Be capable of a minimum of 5,000 vector/second sustained calculations
and execution.

Have a minimum 1,000 line look ahead capacity.

Be capable of interpreting standard M&G codes (EIA 274D) and HPGL
(Hewlett Packard Graphics Language).

Be capable of having machine parameters and programming done on site and
changes made by the operator with little assistance (Phone support and
or literature).

Have the ability to run off of a Windows™ based PC (not supplied)

Be capable of a Mid program start with minimum effort.

Have a high-speed Ethernet card and connection

Have at least one EIA Modbus serial port.

**Software**

Software shall:

Allow the operator to view a program by code and graphically in two (2)
and three (3) dimensions prior to sending the program to the machine to
be cut.

Be supplied which will track actual cutting time on a specific program
and the time and date the program was actually run.

Be supplied to allow full DNC (Distributed numerical control) capability
with DNC running in the background of Windows™ with out interfering with
other operations on the PC.

Have the capability of supporting S-curve, Cubic spline, and And
Circular interpolation.

Be supplied which allows the operator to set minimum and maximum Router
spindle RPM between 100 and 24000 RPM.

**Hand held controller interface**

The Machine shall have a hand held controller interface, which shall
allow the operator to move safely around the machine with full access
during operation. The hand held controller shall have ability to but not
be limited to the following:

Set Cutting speed and Spindle speed.

Override Feed rate.

Set home and offset positions.

Set max depth of cut (Z-Max motion).

Automatically set Z=0 at the material surface

Return to home position.

Jog.

Pause and resume at any position.

Retract from surface, replace tool, reset tool to Z=zero, return to
surface and resume program.

Find, select and run programs from memory.

Run DNC programs from host computer.

Cut basic geometric shapes with out off line programming.

**Calibration**

The machine shall be laser calibrated to include the mapping of the
table surface.

The Calibration process shall be documented. Documentation shall include
a minimum of: Type of equipment used and last date of calibration of the
equipment, Date and time of calibration, Process used, Temperature and
humidity at the time of calibration.

Software and all information required to recalibrate the machine shall
be supplied.

**Miscellaneous**

The machine shall be equipped with an automatic surface sensor which
allows for easy, rapid and accurate tool tip calibration and setup.

**Delivery**

Delivery shall be not more than four (4) weeks from the award of the
contract.

**Installation and Support**

A qualified installation and training technician shall be sent to
install the equipment and train a minimum of two operators in the use
and maintenance of the equipment.

The installation and training technician shall be available no later
than five business days after delivery of the equipment.

The actual date and time of the installation and training technicians
visit shall be arranged with the Purchasing units lead technician

**Warranty**

A minimum of one year on parts and labor shall be included with the
purchase of this equipment.