2004 KVAL COMMANDER DI fully automated CNC door machine
Installed in early 2005. The Commander is a digitally integrated CNC that was designed by KVAL to machine doors and jambs for hinges and lock cylinders. The machines software allows the operator to view a graphically depicted door and hinge and then select from various preprogramed door files for the machine to run. The software since it is PC based can be independently run on other computers in the shop, thus allowing the user to create door files and templates at the same time the Commander is operating. The Commander can also be run remotely through a network as this one previously was so that KVAL technicians can troubleshoot, diagnose and run the machine remotely from their headquarters.
The machine is in excellent condition and in full working order. The service and repair history is as well excellent. In 2009 the CPU was upgraded. The machine is currently on a skid made to factory guidelines. It was further reinforced and strengthened after the above photos were taken, to provide additional support. All parts have been packed and crated and all machined surfaces coated with LPS 3. Owner listed, negotiable.
Total three phase amperage requirements at 230 volts is 60 amps, and single phase amp load at 110 volts is 5 amps. The machine can either be run at 230 three phase if 230 volts is present, or by using the 460/480 volt Square D step down transformer provided with the machine for a shop only supplied by 460/480 volts.
The following photo galleries are all different, and contain 210 total images. Each gallery highlights a different aspects of the machine.
Option A1: Lever Lock Drill Attachment: 3-1/2" x 3-1/2" Hinge & Drill Gearbox Pilot hole drill gearbox for 4" x 4" hinge, including 6-drill hole pattern. Max. drill bit dia. is 5/32".
Option A2: Lever Lock Drill Attachment: 4" x 4" Hinge & Drill Gearbox Pilot hole drill gearbox for 4" x 4" hinge, including 8-drill hole pattern. Max. drill bit dia. is 5/32".
Option A7: 4-1/2" x 4-1/2" 8-Drill Gearbox, Pilot hole drill gearbox including (8) drills. Top & bottom drill sets. Max. drill bit dia. is 5/32".
Option D: -Anti-Static Bar Blow-Off System (option D): Includes static bars above and below the door to positively charge the dust particles and blow them off as the door is fed out of the machine.
Option G: -Corner Squaring Chisels for Door and Jamb (4) Chisels, (2) for the door and (2) for the jamb, are mounted onto the hinge router carriage. The chisels, when selected by the operator on the menu, will automatically move into position and square the corners in the hinge mortise in the door and then square the corners in the jamb mortise.
- 2004 Square D Sorel three phase 480/240 volt step down transformer. 72 output Amps. The transformer will accept three phase H.V. input voltages of, 504, 492, 489, 468, 456, 444, and 432 Volts AC..
- Two roll top tables, one indeed and one outfield. With six rollers per table, measuring 70" L x 41"W x 39"H.
- The original KVAL factory manuals; the operations and set up manual, and user / instruction manual. Included in are detailed parts diagrams and schematics of the entire machine as well as very detailed electrical diagrams. A few sections included are Maintenance, Setting Up the Machine, Troubleshooting, etc.
- Operating software, original software CD plus software manual.
- Extra tooling; one full case of H block stop pins, and one case that includes a full complement of new drill bits for the drill heads, drill head chuck key, carbide inserts for the boring heads, many other new factory KVAL parts, please see photos.
- Not shown in the photos of the machine but included are the four factory H blocks,
- Kootronic electrical cabinet air conditioner to maintain a cool and dust free enviroment for the computer CPU and other electrical components.
- Main electrical cabinet lock key.
-The KVAL Commander Di will accommodate either flush or raised molding doors with protrusions up to 7/8" high on one or both sides.
-Raised moldings must be a minimum of 4-1/4" from the lock and hinge sides of the door; "Commander-di" will also machine jambs that vary in thickness from 11/16" to 1-1/16" and at the same time as the door, or it can be used to machine jambs only.
-The jamb support bracket setups are Non-CNC controlled, and are moved manually by the operator. The setups can be done quickly and easily by the machine operator.
-Jamb width can vary from 3-1/2" to 7-1/4" when the jambs are attached to the door with hinges. Wider jambs can be machined along with the door and attached after the door has been fed out of the "Commander-di".
-Hinge sizes of 3-1/2" x 3-1/2", and 4" x 4", can be attached while the door and jamb are clamped in the machine. The door and jamb may also be machined for 4-1/2" x 4-1/2" hinges; however, the hinges can be attached only to the door or jamb while they are clamped in the machine.
-Note: If pilot hole drilling for the hinge screws is required for this machining setup, drill gearbox option "A-3" is required. If machining for 4-1/2" x 4-1/2 and attaching the hinge to the door and jamb while clamped in the machine is required, option "HA" is required to revise the jamb supports and allow for the increased space between the door and jamb.
-The "Commander-di" is also equipped with a computer controlled pre-drill system, which uses manually installed drill gearboxes complete with air motors and chucks, to drill pilot holes for the hinge screws. Each drill gearbox is also equipped with locating brackets and mounting base to allow for quick change from one drilling pattern to another.
-The pilot hole drill gearboxes can be purchased (sold separately) from KVAL and are made to match the screw hole pattern for each type of hinge. Pilot hole drill gearboxes for 3-1/2' x 3-1/2', 4" x 4", 4-1/2" x 4-1/2" full or half hinges are listed available.
-Programming: "Commander-di" uses a flat screen panel connected to a Pentium processor utilizing a Windows based operating system. The KVAL developed software will graphically depict an image of a door with hinges. Pre-programmed door files or recipes are accessed with mouse and keyboard which are included by touching the on-screen drop-down list, and then touching the appropriate file name. Depending on the selected file, a graphic image of the door changes the hand, number of hinges and locks, along with a list of parameters along the right side of the screen.
-Because the system is PC based, there is virtually no limit to the number of different patterns that can be stored for future use. For those who prefer template creation remote from the machine, the software license allows installation on any computer in your company running MS Windows 98, NT, 2000 or XP - for instance from a production manager's desktop.
-New templates can be transferred via Ethernet, Internet or Portable Memory Storage device. The computer is equipped with network cards for connection to your facility's computer or DSL line, allowing for downloads, backups, as well as remote support from KVAL's service center in California.
-Barcode scanning, which automatically reads barcode labels on incoming doors, then automatically selects the correct program pattern for that door is available from KVAL.
-Machining Parameters: 1-3/8" - 2-1/4" door thickness x 18" - 48" door width x 6'6 -10' door length including raised molding doors with moldings up to 7/8" high, and located not less than 4-1/4" from the door edge and jamb width without adjustment from 3-1/2" to 7-1/4" for pre-hanging.
-Hinge knuckle height to 5" (max. 4-1/2"x 4-1/2" for pre-hanging) 1/4" or 5/8" hinge radius; no hinge, 2-hinge, 3-hinge, 4-hinge machining sequence; No Lock, 1-lock, or automatic 2-lock machining.
-The computer controlled movements include: Door indexing stop; lock bore location(s); hinge depth; hinge height and backset; hinge width; hinge locations; square or 3ø bevel hinge pocket machining; hinge hole pre-drill (gearbox patterns optional).
-To properly pre-hang doors beveled on the hinge side, a software selection can be made at template creation to automatically tilt the router in the gap between door and jamb to rout the jamb square and door at (30) sizes including 3-1/2", 4" and 4-1/2" hinges can still be mounted with a hand held screwdriver.
-Automatic adjustments, non-CNC, include: Door width; face plate centering on door thickness; door infeed, positioning and out-feeding. Door automatically feeds into the machine and against door indexing stop.
-Clamping in place against the stop is fully automatic, leaving the operator free to select the blank hinge jamb for the door and insert it as soon as the door is clamped. Completed slabs or pre-hung units automatically convey out with the press of a foot pedal.
-Remaining manual adjustments: Face plate size (up to 1-1/4" x 12" square or bevel); face bore backset (2-3/8" - 5"); indexing of hinge jamb clamp fixtures and H-blocks; selection of appropriate door jamb stop to match end dado or rabbet; insert spacers for jamb height adjustment when hinge size changes.
-Standard Components: 3-Phase PERSKE high frequency TEFC motors for both hinge and face plate machining; 5 HP 3-Phase face boring motor; 3 HP latch boring motor; GALIL MOTION Control Board and Windows P4 computer in air-conditioned cabinet; precision ground ball screws, bearing rails, and linear ball bearings for CNC movements.
-Construction Details: "Commander-di" is built on a structural steel frame for stiffness, and weighs over 5,000 Lbs. This insures accuracy of machining and durability for the life of the machine. The routers are all totally enclosed, fan cooled 3-Phase high frequency motors. These router motors are all equipped with double-row bearings on the shaft end to insure durability. The lock face bore motor is a 5 HP, 3,450 RPM, 3-phase motor.
-Electrical Requirements: 1-phase, 6.0 amps @ 120-volts; 3-Phase, 66 Amps @ 230 Volts. Electrical panel is built according to Underwriter's Laboratories specifications and the UL label is applied.