# RF Plasma Spray Controlled Motion Manipulator

This request is for a new motion control system, we do not wish to
change any existing bearings, seals, belts or pulley hardware. This is
not a system upgrade, but rather one-to-one replacement of existing,
antiquated equipment. Please only accept quotes to replace the
programmable logic controller (PLC), operator interface display, servo
amplifier, and servomotors.

The replacement PLC, operator interface touch screen display and servo
amplifiers should be all mounted in a 19-inch rack mountable NEMA 12
class enclosure. The enclosure should be approximately six feet tall.
The enclosure should have a smoked polycarbonate type of front viewing
door, and a closeable door on the back. The display should be mounted in
the front of cabinet, with approximately a 10" screen for good
visibility from short distances.

The servomotors will be installed on the target manipulator and will be
connected to the cabinet by cables, from a distance of approximately 25
feet. The rotation servomotor adapts to an Indiana Power Transmission
Sys. Inc. Model: HQD-B-56C reduction gear box. Rotation should be
capable of 0 to 100 RPM. The translation servomotor has a 0.1875 inch
keyed slot and shaft that fits a pulley with a 0.55 inch inside
diameter. Shaft should be about 1.75 inch length from mounting surface.
The translation speed should be capable 0 to 2 inch per second.

The PLC will be utilized to control two modes of operation; 1) Mandrel
mode: controls rotation and translation of a round mandrel attached to a
2.5 inch diameter water cooled sting shaft that is manipulated inside a
low-pressure vacuum chamber. 2) Table mode: controls a flat tabletop
target in an X-Y fashion. It utilizes rotational motion to index the
table in the Y direction and translates the same way as in the Mandrel
mode. The system only operates in one mode at a time. If the sting is
set-up with a mandrel then "mandrel mode" will be selected, if the sting
is set-up with the X-Y table then "table mode" should be selected. These
are two separate modes of operation.

The display will be capable of accessing the program information in the
PLC and be able to create multiple schedules of motion, and be able to
store and recall them from that same display. The display will replace
existing displays and provide motion speed and position (actual speed
and RPM, not set point values) for both axes, and both modes.

A remote manual jog switch is to be provided, that can be operated from
25 feet away, at the chamber location. The jog switch will provide
manual rotation and manual translation control for both modes of
operation. The system will be capable of operating in a continuous mode,
or running a preset number of cycles for both table and mandrel modes.

The system shall be pre-assembled in the cabinet prior to delivery to
the facility. The servomotors shall be adapted to the existing hardware
upon delivery. **The price quoted shall include assembly, delivery,
installation, debugging and training provided to the operators of the
equipment. The equipment manuals for all of the sub-components are also
to be provided upon delivery.**

**[The current system hardware for the 2.5 in. diameter manipulator
(sting) shaft.]{.underline}**

The [rotation axis]{.underline} is belt driven from the reduction gear
box to the 2.5 in. diameter sting shaft, by the following components:

**[Rotational Servo-Drive Motor:]{.underline}**

Motor: Yaskawa Electric

AC Servo Motor

Type: USASEM-15A-C2K

S/N: 111828-1

[KW]{.underline} [KG-CM]{.underline} [RPM]{.underline} [A]{.underline}
[RATING]{.underline}

1.54 50 3000 10.4 Cont.

**[Rotational Servo-Amplifier]{.underline}**

Yaskawa Electric

CACR-SRCA -15BBB REV.E (O)

DF8101720-E0

**[Reduction Gear]{.underline}**

Indiana Power Transmission Sys. Inc.

Model: HQD-B-56C

Ratio: 17.445: 1

S/N: 123091-2

HP 2.75

The [translation axis]{.underline} is belt driven from the servomotor to
the lead screw, by the following components:

**[Translation Drive Motor:]{.underline}**

Motor: Yaskawa Electric

AC Servo Motor

Type: USASEM-03A-E2K

S/N: R05HA123

**[W]{.underline}** **[KG-CM]{.underline}** **[RPM]{.underline}**

308 10 3000

**[Translation Amplifier]{.underline}**

Yaskawa Electric

CACR-SRCA-03BBB REV.D (1)

DF8101720-D1

**[Reduction Gear]{.underline}**

None

**[System PLC Unit]{.underline}**

MITSUBISHI "MELSEC-A" PLC RACK SYSTEM

**CARD LAYOUT:**

**AINCPU, AD72, AY80, AX71, AY23**

System uses a "BEIJER ELECRONICS" display unit:

Model: E-300

Type: 02750C

24 VDC

The system also contains three readout devices, which are "Red Lion"
displays, which are fed from a PLC output card. The new display should
replace the old "Red Lion" displays. The I/O configuration should be the
same as identified in the existing Mitsubishi PLC card configuration
layout listed above.

Existing hardware items:

The system has three rotational bearings; two are used to mount the
translation table to the sting shaft and allow for rotation motion only.
The third is a Thomson ^TM^ linear ball bearing, model number CMB-40
19207 SOCN, which is mounted inside a feed-through chamber with multiple
wiper, quad and o-ring seals to maintain vacuum integrity.

The translation drive system is a table arrangement that supports the
rotational drive components, and uses two rotational Timken ^TM^ 2.5 in.
bearings clamps (P/N 925ODE), and a Sealmaster ^TM^ bearing model RPB
208-2 around the sting shaft which are secured at both ends of the
table. The table is attached to a ball screw arrangement that is mounted
to a 1 in. diameter, 4 threads per inch pitch, lead screw.