Cutting Gears on Two MechMates! #38 & #130 - Parnu, Estonia

[ifffff]

Havent done not much meanwhile. Z axis is projected and details milled out. Made it from 15mm thick 6082 alu sheet with 50x20 reinforcements to minimize deflection.
z.jpg
And other free time what i have after dayjob, is gone for building complete new dust extraction system with one big central unit instead of small blower on each maschine.
2018-01-25 12.35.07.jpg
More about it and more pictures tomorrow.

[ifffff]

As promised some more about new dust extraction system. As i earlier posted here idea is to vent that air what is coming trough dust extractor filter outside. For that i ordered special bags made from pvc tarpaulin material. Those bags are over dust filter bags and have output for air what is vented outside. Outputs are behind bags, trough wall and not visible on picture.
2018-03-04 16.11.08.jpg
Now i have clean workshop air .No extra fine particle dust on air.

Blower is Holzmann ABS 5340P. It has 5hp (3,7kw) motor. It has huge suction power, and already on first tests was clear, that this is way too much. I installed for blower fan speed regulating VFD (Invertek Optidrive E3). On blower fan speed 1800 rpm it has enough suction power to serve 1-2 125mm pipes together (main pipe is 250mm).
That blower running on 1800 rpm is unbeliavably quiet. When smaller units are screaming on high rpm, then its working sound is comparable with cordless drill.
Shortage is, that on colder days is workshop colder due air exchange and needs more heating power, especially when dust blower is running long hours. But spring is around corner and that isnt problem anymore

[IamDave]

System to keep the lungs free of dust. Very good idea. I wear the little white masks, when I am cutting and sanding. It is amazing how dirty they get. Thank you for the posting of pictures. You guys are inspiring to me.

[ifffff]

I suggest to buy instead of those scrappy white masks 3M half facemask. Example: https://www.pksafety.com/halfacres60s.html or https://www.pksafety.com/3m-7500-lea...tor-combo.html and fine dust filters https://www.pksafety.com/3m-p95-filter.html for them.
Dont buy it over internet. Go to store and find put what size / mask fits perfectly with your face. I have both of them what i linked, but 7500 series fits better to my face.
They wont leak between face and mask like those white masks, and end of dusty workday there is huge difference how much dust have you on your lungs. Of course those white ones are better then nothing, but..... they are quite poor.

[ifffff]

Some of Z axis details are screwed together, i hope to finish it tomorrow.
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And started to install electronic and wiring
2018-03-07 18.56.56.jpg
2018-03-07 18.57.07.jpg

[ifffff]

Completed today Z axis. Flex buy pressure applyed one hand, measured on spindle bracket is about 0,08mm. To comparision, applying same force on #38 z axis i can bend it almost 1mm.
More pictures about it:
2018-03-08 14.38.23.jpg
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2018-03-08 17.42.18.jpg

[IamDave]

Your z looks awesome and sturdy, good for cutting thick materials.
Today I use my new mask like you suggested. I breathe good. .

[IamDave]

oops

[jeep534]

wonderful job it gives me inspiration for getting on with my build

happy hunting
archie

[jhiggins7]

Love your Z axis. Thanks for the great pictures. Is it your own design?

[ifffff]

Yep, my design.

Got finally most of wiring job done and it moves.
2018-04-08 12.06.30.jpg
And today started assemblying spoilboard.
2018-04-08 12.06.19.jpg

I having some kind of problems with those Leadshine closed loop steppers. They are making sometimes weird noises, and if i rush them drivers are getting very hot. I wrote to reseller, seems what they answer. But i hope that i did not buy for 2000 euros pile of crap instead of high end steppers.
Running on 10000mm/min
https://www.youtube.com/watch?v=ud2LOupiKAw
Running on 8000mm/min
https://www.youtube.com/watch?v=WjY_z5t57Oo
There isnt even no possibility for bad contact etc, because i did not use connectors. Wires are soldered together.

[IamDave]

I hope you get the problem worked out. You have more in motors, than I do my whole build already. I watched the videos-Nice.

[ifffff]

Spoilboard is ready and surfaced
2018-04-10 15.57.54.jpg
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2018-04-10 16.26.41.jpg
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First test cuttings made too:
2018-04-15 16.49.38.jpg
Bought from ebay tool setter for Z axis. https://www.ebay.de/itm/IP67-CNC-Aut...72.m2749.l2649 Repeatability is as promised. 0,001mm. I added this upgrade to #38 too.
2018-04-15 17.13.41.jpg

Still having problemis with motors. Lowered driver current settings, as Leadshine reseller suggested, strange sounds are disapered, but now i havent any power anymore. It is able to move max 6000mm/min, higher speeds stalling problems appear. On same time drivers are coing very hot. Everything what is possible to test is tested, even took computer, smoothstepper and BOB from #38 to be sure that problems arent on input signals to drivers. Now ordered one more motor -driver set what is tested for Leadshine Germany reseller and is working. When it arrives can i go on and find out what is causing problems.

[IamDave]

Ivo your work is amazing.

[ifffff]

Got on friday new and tested driver-motor set. With new driver everything seems to work fine.

Motors stalling due too large postition difference, it was able to move max 8000mm/min, stalling on 10000mm/min :
https://www.youtube.com/watch?v=ynruS3uWVhA

on 75% current setting extreme jerky movement, but due encoders and closed loop system there is no position loss on stop:
https://www.youtube.com/watch?v=wP7aPyxdEtQ

Installed new driver and now i am able to move axis 20000mm/ min and more without any problems:
https://www.youtube.com/watch?v=Zyxa15ml2Go

Now i am waiting what Leadshine reseller is answering.

[IamDave]

Glad your getting it sorted.

[ifffff]

Sent drivers back to reseller. Now i am waiting their standpoint on this case.

[ifffff]

Got new drivers, and its running again. Now its working smooth and without any strange noises, vibrations etc.
Those 3 phase steppers are quite powerful. Tried to move axes 50000mm/min - no problem. But limited max speed to 8000mm/min. Safety first, and i am sure that running it so fast will broke something soon.
Second good thing, they havent resonance on any speeds. Cuts are on all angles perfect. I cant say that for chinese steppers/drivers what are on #38.
Also ordered stickers for number.

[IamDave]

Alrighty Ivo. Anxiously waiting, to see it cutting stuff. I am watching and learning.

[ifffff]

And it is down again. Spindle VFD starting to give e.oc.n error messages. According to google propablly bad current sensor inside huanyang vfd.

[ifffff]

Checked socket and wire connections. Nothing did not seem loose but tightened everything and it is working again. Lets hope that it will be so. It may be socket what connects wire to spindle. Earlyer i had on #38 2,2kw spindle (now both have 3kw unit) and that 2.2kw original socket was problematic. I threw it away and soldered wires directly together. If problems again appear, seems that i should to it again. I hate pluggable sockets on CNC. Always they are source of problems.

[IamDave]

So you think is better to not use connectors, and to solder the motor wire connections as well.

[ifffff]

Well... There is lot of industrial connectors what are very good. But usually those connectors what are coming with chinese stuff are problematic. At least my experience is saying so.

[IamDave]

Yes. I was going to buy connectors, but have decided to go with the heat shrink but joints. They have lasted well (10 Years) on my other machine.

[pblackburn]

I use Amphenol connectors. I replaced the originals. I have it posted about those in Tom's thread here

[rischoof]

hello Ivo, I also replaced directly the connectors from the chinese spindle by emphanol connectors.
I used emphanol for the spindle and harting Han for the motors. on the machines build by the company I work for , we use a huge ammount of connectors. never saw anny problem wiht emphanol or harting. avoid lemo connectors...
The wires are shrinked to the pins. at home, I do soldering. once had the problem that a small soldere wire (when removing the soldering rod) makes shortcut between the pins. Now I use my glasses during soldering
You have a very nice z axis

[IamDave]

Amphenol connectors. Thank you for pointing it out to me. I do really appreciate it.

[jeep534]

Originally Posted by IamDave

Yes. I was going to buy connectors, but have decided to go with the heat shrink but joints. They have lasted well (10 Years) on my other machine.

aircraft use only crimp wire to wire connections (with proper crimping tools)

archie

[ifffff]

I had little debt. Missing stickers.
2018-08-17 12.38.48.jpg
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Milling sprockets from 7075 aluminium sheet: https://www.youtube.com/watch?v=m9hT5NXK0Ng
5mm one flute endmill
Spindle 24000rpm
Feedrate 2000mm/min
Stepover 3mm
Stepdown 0,7mm
Those are "safe" settings. It can cut aluminium long hours without breaking endmill. At #38 was safe to cut 7075 alu 2x slower due flex.
Result:
P4190497.JPG
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[lonestaral]

Nice work.
I will try aluminium when my spindle is running.