MOVING, fast!!!! - Baton Rouge LA USA

[fozzyber2]

https://lh3.googleusercontent.com/-BpZrj9h99QI/VLQ4JKEd2RI/AAAAAAAAqQM/5v7fqSxDxSA/w361-h642-no/20150112_150947.jpg
Steel has arrived and cutting has begun
https://lh3.googleusercontent.com/-rWNud8OuTGM/VLQ4P7BDYBI/AAAAAAAAqP0/0fsuFcwQndQ/w1141-h642-no/20150112_151012.jpg

https://lh3.googleusercontent.com/-CeubbM7jM_8/VLSCMoyrYQI/AAAAAAAAqQ8/-iGBKXFPKi8/w361-h642-no/20150112_202542.jpg
cross beams cut and drilled

not bad for day 1

jerry

[lonestaral]

Nice equipment in the sunshine.
Wishing you a speedy build.:)

[darren salyer]

Love the forklift. Good luck with your build.

[Robert M]

All the best, enjoy !

[Duds]

Good start :)

[fozzyber2]

A little bit more is done, My laser cut kit came in and the z car is welded.
And yes I did countersink the 2 holes. All and all everything seems to be square and level....

https://lh4.googleusercontent.com/-TZq2crVA8AY/VL3FbXvjBHI/AAAAAAAAqgg/rpbWMYqjxY0/w1468-h826-no/20150119_210214.jpg

[fozzyber2]

CONTROL BOX STARTED

https://lh3.googleusercontent.com/-hFzVAvN_Rgg/VMRSwQpIvlI/AAAAAAAAqpQ/EFusoHSP0zk/w370-h657-no/20150124_201940.jpg

[MetalHead]

Lookin good!

[darren salyer]

Good to see bites of the elephant.

[smreish]

excellent start indeed!

[fozzyber2]

more work done on control box, doing things right and pretty takes so long....

https://lh6.googleusercontent.com/-WS-3rvAFz_A/VM7r0cx2q7I/AAAAAAAAq1c/HX3fn-8e4TM/w1141-h642-no/20150201_211521.jpg

[Fox]

That part definitively takes the most time, doing electronics neatly, and then your vast box, will fill up quickly (http://mechmate.com/forums/showthread.php?p=69501&postcount=204).

[fozzyber2]

I know this box is huge 20x30" but I also know I space plan like crap,
not much is going in it but when I'm done it will be full.

[Fox]

Old Gerald/Mechmate wisdom; your control box can never be too big :D.

[smreish]

I can tell you I filled every bit of a 20 x 30 and then some with the inverter on the wall outside the box. Wire management is SO much easier when you can see everything.
Good luck.

[fozzyber2]

good progress on table
https://lh3.googleusercontent.com/-aTNTclvWyZM/VNQ9doI0N4I/AAAAAAAAq_w/Nd0904ZrNNs/w1141-h642-no/20150205_220505.jpg

[fozzyber2]

before the flip
https://lh6.googleusercontent.com/-zu6-53QoHqk/VNPEqcL9VjI/AAAAAAAAq74/mYmYbkqmPMM/w1141-h642-no/20150205_132937.jpg

[Fox]

Good work, feels great when a pile of steel turns into a table huh :) ?

[fozzyber2]

A bit more progress
https://lh6.googleusercontent.com/-A40GI-DI0RM/VONsmHlAAfI/AAAAAAAArFg/X2p1ixxWybw/w1220-h686-no/20150217_103008.jpg

[darren salyer]

Nice. I'd hate to run into those beam ends while carrying a sheet of ply..
Wait till the gantry rolls the length of the table with a little push...great feeling, you're close to it.

[fozzyber2]

Well the frame is painted, and the sub rail for the linear rails is installed, now i am installing the linear rails.
I have a block mounted on the linear rail, the pins have a .022" gap and the wire is .016", center the wire and screw down the rail. should be with in +- .003 of straight. I have the wire insulated from the frame I'm playing with a ohm meter to tell when the wire is not touching the pins.


https://lh3.googleusercontent.com/-xUnc0qDVTDo/VYm3aUDDUiI/AAAAAAAAvV8/eAA9tgfI4Ww/w1179-h663-no/20150623_144535.jpg

https://lh3.googleusercontent.com/-aEKEHdYWO4Y/VYm3nsd92XI/AAAAAAAAvWw/X2fyCBpgWko/w1179-h663-no/20150623_144634.jpg

https://lh5.googleusercontent.com/-qB-NGVyDaBM/VYm3cptQ1oI/AAAAAAAAvWM/2VpLR44uqDo/w1179-h663-no/20150623_144551.jpg

[racedirector]

Very impressive Jerry, nice linear install. Will be watching with interest.

[Fox]

Watching with interest... Still have my linear rails laying around here somewhere, running the diy v rails and so far no reason for the linear, but it was a 2day chore to make then v rails.. Youre saving that effort. I had similar approach in mind for the install.

[Alan_c]

Nice method for aligning the rails...but the colour...oh boy the colour!!! :eek::rolleyes:

[fozzyber2]

Yea the color... It's kind of my thing.....
My company logo.....
http://cypressgraphics.com/images/Cypress_Graphics_Sign_Logo.gif

[Gerald D]

My first car was a Moriss Minor painted verde matese from Alfa Romeo. Some examples: https://www.google.com/search?tbm=isch&q=verde+matese+alfa+romeo&ei=j5SLVdHgJpPX7Ab79IPQDg#tbm=isch&q=verde+matese+alfasudAddress&tbm=isch&tbo=u&source=univ&sa=X&ei=BpSLVcSyLM3y7Abthb3wAg&ved=0CCoQ7Ak&biw=1278&bih=863#tbm=isch&q=verde+matese+alfa+romeo (https://www.google.com/search?q=verde+matese&rls=com.microsoft:en-ZA:IE-Address&tbm=isch&tbo=u&source=univ&sa=X&ei=BpSLVcSyLM3y7Abthb3wAg&ved=0CCoQ7Ak&biw=1278&bih=863#tbm=isch&q=verde+matese+alfa+romeo)

It was useful over standard zinc-chromate paint (https://www.google.com/search?q=zinc+chromate&rls=com.microsoft:en-ZA:IE-Address&source=lnms&tbm=isch&sa=X&ei=dpOLVeTkOoqX7Qaxn4iwAg&ved=0CAgQ_AUoAg&biw=1278&bih=863#tbm=isch&q=zinc+chromate+green)

[fozzyber2]

linear rails mounted and z car on. Feels like I'm making progress!!!!!
https://lh4.googleusercontent.com/-H1txGLQ053A/VZvf50azmdI/AAAAAAAAvoE/vxAriGHbovQ/w1428-h803-no/20150707_091913.jpg

[MetalHead]

Makes me want lime sherbet :)

[fozzyber2]

more progress, she is a beast!!
https://www.youtube.com/watch?v=5LTkIHYzLFE

[Robert M]

So....now it has a hart beat....you must me a :D guy !!
;)

[jhiggins7]

Looking good, Jerry. I see movement in 3 dimensions. Great feeling isn't it?

[Slipery]

Congratulations on the movement. I particularly like your Z axis was thinking of doing something similar on mine. Was it purchased or built?

[fozzyber2]

Feels great to see her moving. 47/64

The Z axis, I built ( over built) ,with linear bearings and a ground ball screw from Korea.. 3/4" Al plate and 3/8" sided plates.

The z with stepper weights 47 lbs, and 64 lbs with the spindle

https://lh3.googleusercontent.com/IS4G4FCiINDYXvs1-U9zd6N3ZkWF2nFO_MR2KaXQmESk=w1620-h911-no

https://lh3.googleusercontent.com/plVtuqeK6B2f1a-fQca1PRy7xukEoY6NJAzV7oytYAwg=w1620-h911-no

[Slipery]

Thanks for the photos. Already have the supported linear rails and when I got looking into it found it was cheaper to go with ball screw from china than ACME threaded rod and anti-backlash nuts. Do you now think that 3/8 (10mm) aluminum all round would have sufficed?

[IN-WondeR]

What type of spindle is that?? It looks to be an ATC spindle!!

[Tom Ayres]

It Does look like it...

[IN-WondeR]

Found it. It's a blurry customs AVX spindle... ;)

[fozzyber2]

Yes it is an ATC from blury customs.
I don't think I'm going to have it setup as an automatic tool change, more of a really quick change spindle....

I think for the base plate 1/2 would be as thin as I would go. for the moving plate keep the 3/4"

[fozzyber2]

More and more progress:
https://lh6.googleusercontent.com/-29uWTVPCBe4/Vb7I-ncz-TI/AAAAAAAAwAk/nUiKX5i6JTg/w426-h758-no/20150802_205040.jpg
Spindle and z axis mounted along with some wiring.

Limit switches
https://lh5.googleusercontent.com/-IYSLzFEDnsA/Vb7I_sfkEII/AAAAAAAAwAs/A-05JQgFF2I/w1347-h758-no/20150802_205051.jpg

Hard stops
https://lh5.googleusercontent.com/-wQBXZ-9mC-s/Vb7JBlQxeCI/AAAAAAAAwA0/UQ5n1SVpTlU/w1347-h758-no/20150802_205059.jpg

[fozzyber2]

I made a temp mount for an air drill to make some holes.https://lh5.googleusercontent.com/-HxUaFk0Dsms/VdXm5fQOzBI/AAAAAAAAwS4/YhmG3qWJNEA/w1347-h758-no/20150820_094030.jpg

A little add on, this is a 60in x 120" x .375 (3/8") steel plate. as my table base, weights about 750lbs.!!!!!! it is bolted down with countersunk screws.
https://lh5.googleusercontent.com/-uYsSlVaCTDs/Vdd32QFYXRI/AAAAAAAAwT4/yFWRE60QMqg/w1347-h758-no/20150821_141112.jpg

[fozzyber2]

Gluing down the plemnium
https://lh3.googleusercontent.com/-PJ_HfUobnWA/VeMwh8C87RI/AAAAAAAAwcQ/fGjduvudbes/w551-h309-p-no/20150830_113412.jpg

Vac system plumbing.
https://lh3.googleusercontent.com/-58Kw3VB2WcA/VeO00DXn7MI/AAAAAAAAwck/IfBtXKYUk6c/w551-h309-p-no/20150830_205833.jpg

Vacuum grid cut and being sealed.
https://lh3.googleusercontent.com/-ECV7q03SQM0/VekCBBIGUuI/AAAAAAAAwjw/s4S7ywOZ_To/w1347-h758-no/20150903_212917.jpg

[Robert M]

Woaoow Jerry, this look really like a fine detailed & attentioned machine...Congrats !!
But... Don't wonna be a bummer, has anyone ever advise you, when you "gluing" a plemnium pannel ( or any pannels :p ), the glue has to be poured, avoiding using these zillons gallons on top :p..:D..;)

[darren salyer]

Probably could have laid a piece of plastic sheeting over the top, and used the vacuum to hold it down...

[fozzyber2]

For gluing the plenum, vacuum would not have worked, the pic with the water jugs is gluing the first layer of MDF to the steel base plate. No way to really seal it up, to pull the 2 together. I use a PUR construction adhesive. to bond the mdf to the metal. I spread it with a notch trowel.
Once dry I cut my grid into the first layer of MDF. and sealed it with a mix of half glue and water. From there I surfaced the grid, Laid down a sheet of 5x10 LDF held it down with the vacuum, made a skim cut. pulled that sheet off brushed glue on the tops of the grid, then put that sheet of LDF on top and held it down with vacuum to dry. The Jugs of water were free from my neighbor who has a lawn treatment company. total weight of water was about 1800lbs.

I have been running a modified shopbot for about 4 years, and I told myself when I started this project I was going to fix everything I did not like with the shopbot, and no shortcuts. (within reason).
So far I think I am going to be happy. The steppers might get changed out to Clearpath servos soon but so far all the extra weight I put into it seems to be paying off.
I might nick name it HULK.......:rolleyes:

[fozzyber2]

A vid showing come cutting of the grid.
https://youtu.be/ZP8GFxZ-4rQ

[Tom Ayres]

Jerry, You've done an excellent job of it, also love the color. Looking to hear more about the linear bearing performance and how you like it. :D

[jhiggins7]

Jerry,

Thanks for sharing the details of your vacuum hold down construction. Please keep 'em coming.

BTW, slap some logo's on your MechMate and get a serial number.

[darren salyer]

Awesome job. Thanks for the explanation on the plenum ... My suggestion of using the vacuum was more to suggest an alternative to the next builder to come along, than a critique of your method. I can see where it wouldn't have worked well with the addition of the steel plate into the mix.
The cutting vid looks great.
Again, Well Done!!

[keastab]

linear rails mounted and z car on. Feels like I'm making progress!!!!!

Just a quick question about where you purchased the linear rails and are they one piece full length rails or did you "splice" them together using 2 sections?
thanks

[fozzyber2]

www.anaheimautomation.com
one piece no splices.

x and y with bearings was about $1600

[fozzyber2]

I have made a few changes to the machine most notable is the addition of a HSD ATC 6 HP spindle.. she is a beast!!!! I cut UHMW at 450 ipm 1in DOC at 18k rpm. with a 3/8 bit
The blurry customs spindle just did not work out in many ways..... The HSD was more money but worth it in every way.

Removed bad links - MetalHead

[MetalHead]

Jerry

Can you repost your pictures?

[fozzyber2]

15874

15875

15876

The 2nd smaller stepper is a "z" for the dust foot, it runs as switch controlled and independent from mach3, I bought the 2nd z axis from open builds, cheap and works for what it needs to do.

[Alan_c]

I am as green as your machine! that thing is a beast, do the steppers cope OK with the extra weight, I know that 6hp spindle is quite heavy.

[Fox]

Big machine, crazy that huge steel bottom sheet, but it should warp less then mdf :D !

How are the linear rails vs de V-rails, any noticeable difference ? I do not see any reasons to upgrade right now, but still have the linear rails laying around.

What kind of Steppers are you using to pull the gantry beast along ?

Did you check your gantry flex when the Z car is in the middle vs the sides ? I am interested to see with your very heavy Z. It should be quite noticeable.

Why did you opt for the air cooled spindle vs a watercooled when upgrading ?

[fozzyber2]

I have 5:1 reduction boxes on my automationtech steppers (1200 inoz) and I have the jog at 600 ipm fast enough.... and it does it very well.
The steel plate does help with vibration and does keep the mdf from moving around. I take .005" to level about one a week. I love the rails, never again will i deal with vee rails. My gantry only flexes about .005 when i stand on it and I'm 220lbs, that is with the spindle installed. But my gantry bars (CROSS MEMBER TUBES 10 20 440 )are made from 2"x4"x.25" NOT 2x4x .125 as the plans called for. I did this for extra strength as well as I wanted to drill and tap the tubes instead of adding a bolt plate.
I went with the air cooled because that is alot more common in the more industrial style type spindles. it works well and after going to air it is not that big of a deal.

[fozzyber2]

I also added a wireless tool setting gauge. LOVE IT!!!
I got my off of ebay. it is like this one.
http://www.ebay.com/itm/DT02-CNC-Universal-Wireless-Tool-Setting-Gauge-Presetter-Controller-1-Micron-/262742777415?hash=item3d2cb09e47:g:vZUAAOSwv-NWZosx

[Fox]

Thanks for all the answers.

I also have a thicker gantry and modfied z, I saw similair flex and interpolated it either way and shimmed compensation under my rails. For normal trough cutting its completely irrelevant, but when cutting parts with pockets etc that interlock, or when onionskinning, a 0.1 mm depth here and there adds up to non fitting, or hard to remove pieces.
Interesting toolsetter, but I wonder... What if the wireless signal fails...your machine will keep running and ruin the tool setter and your bit ?

[fozzyber2]

I think the gantry flex is a non issue. if it is flexing with the the weight of the spindle it is only .001 or ,002 at most.
plus it is going to flex the same amount surfacing the table as when it cuts.
as long as I have my vac on it will pull the martial down and the cuts will be parallel

[fozzyber2]

tool steer only $49 if it gets killed no big deal.
you do have to test it on start up to clear or the tool set program will not run

[vallie4]

Excellent job so far! Keep them coming!

[IamDave]

I also have used a ShopBot. You are way more secure than the old models the Mechmate was based on.

[robtown]

As for your Z axis...
What happens when you power the control box down?

Does it sink?

I'm considering some updates to my old Shopbot, linear bearings, ball screws and a new z axis.

Thanks,
R

[swatkins]

www.anaheimautomation.com
one piece no splices.

x and y with bearings was about $1600

Could you post the parts you used?

[Panovak]

I reached out to Jerry via his business email because I too was interested in his linear rails. He got them from
Anaheim automation- tbi rails, 20mm.
The machine is apparently still running very well

[swatkins]

These ? https://www.anaheimautomation.com/products/linearcomponents/linear-guides-item.php?sID=557&serID=40&pt=i&tID=1162&cID=543&dsID=569

[Panovak]

I'm not sure if they are the TRS or TRH but yes those.

[fozzyber2]

20mm Rail - 2400mm length, end length 1 of 30mm, end length 2 of
30mm ***Specials are Non-Returnable***
15 lbs each
TBI-TR20N-2040-30-30 2 195.00 1 week 390.00
TBI-TR20N-3700-20-20 - 20mm Rail - 3100mm length, end length 1 of
20mm, end length 2 of 20mm ***Specials are Non-Returnable***
27.38 lbs each
TBI-TR20N-3700-20-20 2 329.00 1 week 658.00
TBI-TRH20VL-N-Z0 - 20mm Block, TR Series, High-Assembly, No
Flange, Long Length, Normal Accuracy, No Preload
.672 lbs each
TBI TRH20VL-N-Z0 8 36.00 5 weeks 288.00
TBI-TR20-BOLTCAP TBI-TR20-BOLTCAP - Bolt Cap for TR20 rails - 9.5mm Diameter 250 0.10 In stock 25.00
Freight Charge Freight Charges going UPS ground for approx. 70 lbs. 1 290.00 4 days 290.00

[Panovak]

Haha. Thanks Jerry!

[ybmech]

That looks good!
I'm working at the complete partlist and the Solidworks construction + EPLAN drawings. For me a lot to do before starting to build the frame..