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  1. #1
    Hi all,

    As the first materials for my CNC Router have started arriving, here are the results so far:

    The second pic shows the re-purposed 4U Server case housing the PS806-5 PSU and a 240v AC to 12V DC PSU for the fans (two 80mm fans will extract the hot air out the back). The 3 x PM752 drivers are int eh drive bay behind the blue 120mm fan in the lower left corner.

    My wiring routing will be largely as shown:

    Red= AC in to both PSU's - will probably wire both of of the same 3 pin input socket, which will be housed in a plate to be fixed to where the old expansion card slot are.
    Orange = the route I will take for the driver power from and to the PS806
    Yellow = the stepper wires and any other wiring e.g. limit switches, estop etc - I'll be using 4 pin XLR connectors
    Green = earths from everthing back to the yellow star point and then back out the case via the three pin connector

    The 12V DC motor wires will be roughly wher eyou can see them now running at the bottom of the case to the 2nd PSU.

    The main power switch will be in line with AC live and will be a two button start/stop similar to what I have on the front of my pillar drill.

    The breakout board will likely be mounted to the left of the PS806, with its feeds to the drivers going in the same side as the yellow stepper feeds.

    Oh and there is also a pic of where I have got to with the mechanical end of things (ignore the undersized work surface - that is being replaced with something large enough and additional supports added). The thin bed ali profile was a fail purchase on my part and will be replaced with the 30mm profile you maybe able to see sitting on top of it and the thin profile is going to become wall mounting for my guitars and maybe tools etc, so it won't be wasted.

    Got some more electrical stuff arriving soon to complete the enclosure and I have my ballscrews, bearings, supported rails etc, together with a 2.2kw watercooled spindle hopefully arriving from Chai soon.

    3NM Nema 23's are off camera until I have worked through the rail and ballscrew mounting.

    Cheers


    Chris

    PS. I am thinking that I should the VFD's earth back to the star point shown in the case in the pic and not back to its own 3 pin plug's earth (both will be on the same 32A spur, along with the PC that's going to run Mach3 so the whole rig is on its own RCD)?
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  2. #2
    I have to say that the first pic is a piece of art on its own :)

    Fiction is far more plausible when wrapped around a thread of truth

    Nothing great was ever achieved without enthusiasm.
    Ralph Waldo Emerson


  3. #3
    Thanks Fivetide - wish I had bought a self-reversing tapping chuck for my pillar drill - hand tapping all that profile was tiresome..

  4. #4
    Hi.
    First pic looks like a mechanical beast,but good!
    A little tip for tapping holes. I use my B&d pivot driver saves a lot of work and no aching hands!
    meerkat.

  5. #5
    Hi Meerkat,

    Thanks - "beast" is the target after Dean' comments further back :-)

    I made a little progress last night after putting a bracing structure and bearing onto the 2nd ballscrew extension - this has cut down flex considerably (i.e. hardly any movement even when leaning into it) and I did a test by jacking my motors up to 4000mm/min in MACH3 and had no stalling on full speed jogs. So a step in the right direction methinks. I'll likely push the speeds up again tonight and see where the stalling starts, but I'm quite happy with 4m/min, as in its original guise the machine wouldn't go above 2.5m/min reliably with the single ballscrew configuration.

    To do tonight will be to put the belt tensioning pulley on and take the slack out of that (the bracing has improved that also anyway). Then run some more tests to see if there's been improvements.

    I'll then think about plan b dependant on the results of that.

    Chris

  6. Just for giggles I set up my machine to where it stalled and then backed it off. Now this is a rough set up and I have NOT gone back and tuned the drives so that would change things as well. Given that I was able to get x(x/c) axis up to 17m/min V with 450mm/sec^2 A; Y axis was gotten to 11m/min V with 350mm/sec^2 A and Z to 7.5m/min V with 250mm/sec^2 A. Let's just say that is a bit scary in speed.
    -Michael
    Software SolidWorks 2024, Onshape, Aspire v9.5, Blender
    CNC Machine: http://www.mycncuk.com/threads/3661-...Second-machine
    3D printers both FDM/FFD and MSLA resin
    CSWA &CSWA-AM certified
    www.marino-customs.com

  7. #7
    Wow - effective limit switches are a must at those speeds I expect ;)

    Even 4m/min was hairy compared to what I've been used to previously when I tested it last night.

    Oh and a quick question or two: I'm running the same test job "cutting air" to see what progress I'm making as I make mods etc. to the machine and I notice that whatever max speed I set the motors to is what the test run seems to use as its rapids - I'm assuming that's normal behaviour?

    The other thing is when I first power up and load MACH3 the motors always seem to need one axis setting up in MACH before they "remember" the settings from the last session?

  8. #8
    Washout whats your buget for the complete unit ? Or should I say what are you aiming for as a buget lol ? I'm not going to attemt one for along time, although I have started to collect parts, i have the Mach3 controller.

    Fiction is far more plausible when wrapped around a thread of truth

    Nothing great was ever achieved without enthusiasm.
    Ralph Waldo Emerson


  9. #9
    I was aiming for about £2 to 2.5K to start with, which I should just about squeek within once I settle on which CAM software I'm going to buy.

    I'll then probably blow that budget when the itch for a 4th axis gets too much and I intend to replace some of the extrusion with plate, but I'll be happy just to get cutting something for now and do the upgrades and addons, when time and funds allow. The PC side of things isn't an issue, as you can probably tell by looking further up the rack in the enclosure pic, so I'm lucky in that respect....

  10. #10
    I think your rig looks awesome, and same here I want 4 ways but to be honest I need to get the one I have working first lol but I will follow the tread because I think the next one will be alot like yours.

    Fiction is far more plausible when wrapped around a thread of truth

    Nothing great was ever achieved without enthusiasm.
    Ralph Waldo Emerson


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