Mazak Impulse - Oak retrofit build log
Posted: Mon Feb 01, 2021 4:53 am
So, this is the beginning of what will probably be a long and drawn out build. I really struggled to find information for this conversion so wanted to capture what I have learnt in one thread. Maybe it will help someone one day.
So, the machine... A 1997 Mazak Impulse vertical machining center. This machine was built originally as a high speed production drilling and tapping machine. It is quite small, weighing in at around 2000 kg (or 4400 pounds for those that haven't moved into the metric system yet) with a footprint of 1.5 x 1.8m. Great because it fits through a single garage roller door. However, this machine has all the things you could want for a conversion. AC servos, ball screws, linear guides, tool changer, flood coolant system, rigid tapping, 10 tool changer. In fact there is no major mechanical work required to convert this machine.
The original controller is a Mazak built IMAC-TP (EIA Dash). Actually very capable for its day and has 90% of the features that the Oak will offer. It almost pains me to change it. It does however have a few gremlins in it! The main reason for the retrofit is the controller has only 48k of program memory. An upgrade is available but it is over half the price of a retrofit and still not that much memory. I had hoped I could re-use some of the drivers and control gear but it is all integrated as one big controller and nothing can be used independently. Maybe I will get something for it on ebay. Most likely I will hang it on the wall as a souvenir!
When I started looking into retrofit options, everyone said "You will need to replace the servos". I couldn't understand why as they are already there, work fine and have suitable encoders on them, wiring is all in place and in good condition. So I persisted and have found solutions (I hope!). The spindle motor is also an AC servo which is unconventional but is probably what allows this machine to be able to rigid tap at 4000 RPM. But it turns out there are VFD options for permanent magnet motors in excess of 6000 RPM.
Requirements for a retrofit:
- The machine must not lose any capabilities both in its software or motion
- Needs lots of program memory as I want to use it for mainly 3D contouring aluminium
- Must stay as a stand alone machine that could go back into industry where it came from. I.e. no consumer PC and screen sitting beside it.
- Must be able to add a tool height setter and probe in future
- Must be able to rigid tap although I will accept not being able to do it at 4000 RPM
- Physical buttons on the control panel for the motion control and operator setup
- Touch screen and modern interface so can run CAM software on the controller
So, challenges I foresee:
- Using the OEM servo motors and encoders
- Using an AC servo motor for the spindle
- Fitting everything in the little control cabinet inside the back of the machine
- Making a nice new control panel
- Getting the pneumatic rack tool changers working safely
I will leave this post as just being about the machine and discuss other parts as I go...
The little machine Behind the machine. Coolant tank at the bottom, behind it is the control cabinet Inside the moving parts The control cabinet Here are some videos of the machine running
And the biggest gremlin, a software bug where trying to do an arc in the XZ plane causes it to lose its s#$t!
So, the machine... A 1997 Mazak Impulse vertical machining center. This machine was built originally as a high speed production drilling and tapping machine. It is quite small, weighing in at around 2000 kg (or 4400 pounds for those that haven't moved into the metric system yet) with a footprint of 1.5 x 1.8m. Great because it fits through a single garage roller door. However, this machine has all the things you could want for a conversion. AC servos, ball screws, linear guides, tool changer, flood coolant system, rigid tapping, 10 tool changer. In fact there is no major mechanical work required to convert this machine.
The original controller is a Mazak built IMAC-TP (EIA Dash). Actually very capable for its day and has 90% of the features that the Oak will offer. It almost pains me to change it. It does however have a few gremlins in it! The main reason for the retrofit is the controller has only 48k of program memory. An upgrade is available but it is over half the price of a retrofit and still not that much memory. I had hoped I could re-use some of the drivers and control gear but it is all integrated as one big controller and nothing can be used independently. Maybe I will get something for it on ebay. Most likely I will hang it on the wall as a souvenir!
When I started looking into retrofit options, everyone said "You will need to replace the servos". I couldn't understand why as they are already there, work fine and have suitable encoders on them, wiring is all in place and in good condition. So I persisted and have found solutions (I hope!). The spindle motor is also an AC servo which is unconventional but is probably what allows this machine to be able to rigid tap at 4000 RPM. But it turns out there are VFD options for permanent magnet motors in excess of 6000 RPM.
Requirements for a retrofit:
- The machine must not lose any capabilities both in its software or motion
- Needs lots of program memory as I want to use it for mainly 3D contouring aluminium
- Must stay as a stand alone machine that could go back into industry where it came from. I.e. no consumer PC and screen sitting beside it.
- Must be able to add a tool height setter and probe in future
- Must be able to rigid tap although I will accept not being able to do it at 4000 RPM
- Physical buttons on the control panel for the motion control and operator setup
- Touch screen and modern interface so can run CAM software on the controller
So, challenges I foresee:
- Using the OEM servo motors and encoders
- Using an AC servo motor for the spindle
- Fitting everything in the little control cabinet inside the back of the machine
- Making a nice new control panel
- Getting the pneumatic rack tool changers working safely
I will leave this post as just being about the machine and discuss other parts as I go...
The little machine Behind the machine. Coolant tank at the bottom, behind it is the control cabinet Inside the moving parts The control cabinet Here are some videos of the machine running
And the biggest gremlin, a software bug where trying to do an arc in the XZ plane causes it to lose its s#$t!