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#201

Nena
Member
From: Hoogeveen (NL)
Joined: 03 July 2016
Posts: 215
Member
29 April 2017 09:26 am

Almost Done! Tomorrow ill start with the Z axis! Its getting shape!!!

Machine_Nice.jpg

1 user likes this post: ktmman

#202

Nena
Member
From: Hoogeveen (NL)
Joined: 03 July 2016
Posts: 215
Member
30 April 2017 09:37 am

Almost Done with the Z axis, also made a test with the Z-axis Harmonic Drive if it can hold over the 60kg and it stays at his place, i still dont need to worry if the Y is comming down to ground when the power is switched off big_smile Its a monster big_smile Hope i can let the plates milled!

Machine_Axis.jpg
Machine_Axis2.jpg
Machine_Axis3.jpg

Last edited by Nena (30 April 2017 09:39 am)

1 user likes this post: ktmman

#203

Gilly47
Member
From: Mount Hunter, NSW
Joined: 18 January 2015
Posts: 182
Member
30 April 2017 10:04 am

WOW


1 wife 1 dog and a sieve

#204

Nena
Member
From: Hoogeveen (NL)
Joined: 03 July 2016
Posts: 215
Member
02 May 2017 09:04 am

Hehehe wow?! Expected something else? big_smile Almost done!!! If some one has an solution for the leaning forward of the machine big_smile still need to do some plates... but im getting there!

Machine_Almost.jpg

1 user likes this post: ktmman

#205

Gilly47
Member
From: Mount Hunter, NSW
Joined: 18 January 2015
Posts: 182
Member
02 May 2017 08:55 pm

thumbsup thumbsup


1 wife 1 dog and a sieve

#206

vonG
Member
Joined: 19 January 2017
Posts: 84
Member
03 May 2017 02:27 am

Damn Christian, that is going to be a heavy beast when the head and y-slide is on the top of the z-axis. Shouldnt you have some diagonal bars going backwards and to the sides too from the z-slides to make it more robust? The machine will be longer and wider but with the weight of the head and y-slide it will probably be needed.

Last edited by vonG (03 May 2017 02:31 am)

#207

Nena
Member
From: Hoogeveen (NL)
Joined: 03 July 2016
Posts: 215
Member
03 May 2017 08:33 am

I know, i need to find a nice simple construction that can hold the Y axis. I made the most simple solution but its also the most expensive one. So ill change the 'first' concept of the frame big_smile I need to, these extrusions are verry expensive!

Machine_Complete.jpg

Maybe i can solve this by using other extrusions... mayby 80x40?? ill see what i or others come up with big_smile

1 user likes this post: Gilly47

#208

vonG
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Joined: 19 January 2017
Posts: 84
Member
05 May 2017 02:58 am

Because of the weight of the head and y-slide there will probably not be any cheap solutions, unless you use steel instead of aluminum. You have the most simple solution drawn up. I would go with that, even if the price is a bit high. Better to have it robust.

Is there any reason you have the z-axis motor on the bottom? The risk of getting dust and water in the motor from the faceting is less if you have it on the top.
Are you planning to have an aluminum plate that covers the bottom of the machine? I know you planned to have a slide for the lap, but how are you going to protect it from dust and water?

#209

Nena
Member
From: Hoogeveen (NL)
Joined: 03 July 2016
Posts: 215
Member
05 May 2017 03:24 am

I like the simpel setup, it can be closed completely and i could make it sound proof but these extrusions cost me about 60€ the meter, so this setup is almost 1000 euro's including the corner mountings. First it should be handy to get my parts milled... Im still looking for a other solution but this simple solution is still the best. Mayby i should use 40x80 or 80x80x40 extrusions. I dont know it yet.

The motor is upside down becourse if im turning the spindle, the head will hang on just 6 m6 bolts and also the bearing wil hang on just 4 bolts. If i do it this way so the motor upside down the complete weight is upon the spindle head and the bearing and the bolts are then only for fastning not for holding the weigth. Hope you understand what im saying big_smile

I also like the idear of a closed cabinet for cutting stones big_smile

#210

vonG
Member
Joined: 19 January 2017
Posts: 84
Member
05 May 2017 03:53 am

Have you checked on how much the smaller extrusions can take? Does the price differ a lot between the bigger and smaller extrusions?
I understand why you want to have the motor on the bottom now, but will it be safe there?

Closed cabinet sounds great, but how will you get rid of the dust and water that will whirl around in the cabinet and affecting rails, bearings and motors? You need to have a clean area, the dust will contaminate the laps and you will get scratches on the stones.

#211

Nena
Member
From: Hoogeveen (NL)
Joined: 03 July 2016
Posts: 215
Member
05 May 2017 04:20 am

The laps need to be cleaned off after every cut. Im not that scared about the dust. It should run as a normal lap so there isnt that mutch differents in the setup. If the setup gives problems with the dus or the coolant i will take action, but im shure it wont traffle far. It always stays a semi(almost)-automatic system. Some of the things need to be done with hand.... For now i need to complete the build and make shure if its going to run as hoped big_smile

The extrusions are calculated in 40's so 80x80 is 4 times more expensive as a 40x40.

Last edited by Nena (05 May 2017 04:25 am)

1 user likes this post: Gilly47

#212

Nena
Member
From: Hoogeveen (NL)
Joined: 03 July 2016
Posts: 215
Member
12 May 2017 09:09 am

I'd rendered the machine (image). I also send the images for to be milled big_smile The base is there but not all of it... still need to do some of the plates. I also have a solution for the aluminium. The extrusions that are on the image wil be 80x80 and 120x80 but the rest will be 80x40. Still need to draw the complete thing. Its a start. Also driving the motors is still a little problem. I have tried Raspberry Pi 3b but the card is unstable, also the output from the lpt port is unstable. So the next step is to try Arduino. The problem is the 200Khz to get the motors up to 3000rpm. But it should work with Arduino and make a simple driver for it, so it should work driving all steppers on a single Arduino.

render.jpg

I hope to draw the complete basic machine and build the thing first and then draw the lap base and the rest for some sensors.

3 users like this post: Billy, Gilly47, ktmman

#213

thegoldman24
Newbie
Joined: 16 March 2017
Posts: 7
Newbie
15 May 2017 12:02 pm

Have you considered installing 45 degree support brackets on all pieces to give the frame more sturdiness.rigidity. Just a thought.

#214

Nena
Member
From: Hoogeveen (NL)
Joined: 03 July 2016
Posts: 215
Member
19 May 2017 07:26 pm

thegoldman24: Shure, but first the aluminium plates.

Im redrawing the complete design, the mill costs were to high :- ) But its good to redo your things becourse i did find some flaws in the design! Im already drawing again for a week or so and hope to complete the design again within a few days. Its the same setup but with some changes.

#215

Nena
Member
From: Hoogeveen (NL)
Joined: 03 July 2016
Posts: 215
Member
20 May 2017 09:06 am

Almost done! Still need to do some litle importand things, as like drawing the plates for the last sensor... for the rest? almost done... Made some new rendering images!!! Im also going to try to controll the complete machine under Linux... Mayby a better platform and more stable!

bijnaklaar.jpg
sensor.jpg

Greets,

Christian

2 users like this post: ktmman, NeilM

#216

ken2m
Member
From: Thomastown, VIC
Joined: 02 April 2016
Posts: 157
Member
20 May 2017 03:10 pm

Christian, firstly I'd like to say WOW what an incredible project, I have been watching it since the start, well done.

I have made an X Y table that is computer controlled and know some of the dificulties you have and will face. My project ran on DOS as an operating system and the program was written in "C" and assembler.

Just thought i'd throw in a thought. With regards to the Z axis, is there a reason the motor is at the bottom as it would be more likely to be water/coolant/dust damaged. Ken.

#217

Gilly47
Member
From: Mount Hunter, NSW
Joined: 18 January 2015
Posts: 182
Member
21 May 2017 12:37 am

thumbsup thumbsup thumbsup thumbsup


1 wife 1 dog and a sieve

#218

MakkyBrown
Member
Joined: 10 May 2015
Posts: 16
Member
21 May 2017 11:26 pm

Instead of using laps you could use tools like on a concave faceting machine. Be a lot easier to setup and automate swapping between tools. I've been thinking of building a cnc mill myself though not as big as yours. Nice project smile

#219

Nena
Member
From: Hoogeveen (NL)
Joined: 03 July 2016
Posts: 215
Member
23 May 2017 05:27 am

MakkyBrown:

I Know, there is space to build a concave system for it to, then im going to use a 2.2Kw spindle motor for it. It is all possible. But it is important to get the basic correct. There are so manny idears for the machine, but i want to let it work first ;-)

ken2m:

Thanks for watching! The motor is upside down becourse it can hold more weight this way, otherwise i need to turn the ball screw nut the other way and i dont want to take the risk of putting over the 100 steel balls back into the nut becourse the ball screw has 4 ball slides. if im turning the ballscrew the weight will be on the bolts not on the ball screw nut. This way all the weigth is on the nut.

What was your max rpm under DOS with your software?! And the pulse speed?!

All the 34 aluminium plates will be milled now, costing around the 875 euro's +/- $1000 AUD. Hopefully i can start soon with building the machine big_smile Also the software.

Last edited by Nena (23 May 2017 05:30 am)

1 user likes this post: Mackka

#220

ken2m
Member
From: Thomastown, VIC
Joined: 02 April 2016
Posts: 157
Member
23 May 2017 10:40 pm

Just thought i'd put it out there as sometime any designer can have a pre concieved idea that may not be the best idea. Good job on thinking reguarding the loading.

From memory (it was about 20 years ago) I was using 4 phase stepper motors 200steps/rotation and could get 120rpm but with limited torque driving 2 phases at the same time (in effect microstepping but missing the main steps). Maximum driving one phase at a time was about 60 rpm. These were done through the parrallel port. Using a dedicated processor would have been the way to go, but 20 years ago it would have been a costly project with limited capability. Ken.

#221

Nena
Member
From: Hoogeveen (NL)
Joined: 03 July 2016
Posts: 215
Member
09 June 2017 09:27 am

Hmmzz.

Rasberry Pi doesnt going to work, but ordered a Teensy 3.6 card for controlling the motors now. I think that will work! I need to spin the motors at 3000rpm. Some of the plates of the base machine are already ready! big_smile Also checking the things what i still need to buy... the extrusion aluminium. The overal machine size will be 1600x1200x880mm.

100_1666.jpg
100_1667.jpg

Greets,

Christian

2 users like this post: B5MECH, ktmman

#222

Nena
Member
From: Hoogeveen (NL)
Joined: 03 July 2016
Posts: 215
Member
16 June 2017 06:04 am

Yeah! A Nice first start! Also tried one of the rotary sensors! I got data out of it, and it wasnt that hard, took me 10 minutes to get the rotary encoder to work, the largest problem i think i still have is running the motors on 3000rpm... but didnt do any tests with the new teensy card yet! Everything looks promesing! Im still thinking about how im going to do the automatich lap changer... Dont got a good solution for that yet. Its more for fastning the lap after the change of lap. I dont want to use a nut for fastning the lap but a sort of push and pull but im not there yet. I hope the next plates will be finished next 2 weeks or so. Also ordered the aluminium extrusions for the overal build.

Ill keep ya in touch! And if some one has a good idear for an automatic changer please come up with your idears!!! thumbsup

Img_3235.jpg

2 users like this post: 7.62marksman, ktmman

#223

ken2m
Member
From: Thomastown, VIC
Joined: 02 April 2016
Posts: 157
Member
16 June 2017 10:22 pm

I realise that an auto tool change would be nice but I worked as a toolmaker for many years and when using synthetic and natural diamonds we made sure the wheels were placed on the spindle the same way all the time. Also any dirty surface would cause runout. A small runout causes the wheel to only cut on the high side and it is an intermittent cut, this may happen for the first 30 minutes or so before the wheel ran true again. We used centre punch marks to allow us to have the laps running as true as possible. Ken.

#224

Nena
Member
From: Hoogeveen (NL)
Joined: 03 July 2016
Posts: 215
Member
16 June 2017 10:46 pm

Hi Ken,

Thats true. I was thinking about that every lap gets its own base plate and the thinking was to clean the plates every time when the cutting is done but that the cutting proces is continuous. If the mounting gets dirty it is a possibility that the plates are not leveled perfectly, but this can be avoided simply by overhanging on the joint. Uhm?!

A nice way to setup the laps is for example using a iso 30 / sk30 mount or something like that. So that the SK30 is already atached to the lap base plate or already mounted to the lap. And for moving the laps by using electro magnets. So if i get my hands on a sk30 spindle ill use the inside of the spindle for the lap.

Christian

#225

Nena
Member
From: Hoogeveen (NL)
Joined: 03 July 2016
Posts: 215
Member
19 June 2017 09:31 pm

The head of the machine is almost done! The bearing holder needs a littel cut of 0.1mm becourse it has a little deviation of 0.017mm and its to tight in the plates so that i am not able to use set screws. Also im hoping to get the next aluminium plates this week and the extrusion is also send to my parents in Germany. So also those will arive this week i think big_smile

The cuttinghead will get a automatic tool changer SK15/CAT15/ISO15 at the front to hold and change the stone automaticly. Dit find a nice one but im not yet shure about the acuracy of that thing. It says 0.01 of acuracy but well see!

The toolchanger: http://www.usovo.de/shop/Milling-spindl … anguage=en

A Photo:
Img_3240.jpg

Last edited by Nena (19 June 2017 09:35 pm)

2 users like this post: Gilly47, ktmman

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