Comments sought on new build: A CNC Router for RC Gliders and Planes

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Originally Posted by JAZZCNC

Don't mess about with thermistors and shit just put a D type MCB and you'll be sorted.

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Cheers Dean.....D type MCB ordered....

Anything further to report Neil ? You were so close . . .

I'm back on it next week, other projects took precidence and one of us (only 3 in the office) was off for 6 weeks which meant extra workload. We've so many projects that need doing that it's a case of doing one at a time, We outsourced the plastic bearings that I was building the router up for so the rush is off but ill be back on the wiring next week!!!

OK so back on it today briefly (before having to go on the Lathe all afternoon re-necking pins for a customer order...) and ordered some more bits from Chalon so I can re-do the fuses from the transformer to the drives. otherwise I've just cleared the decks a bit whee other crap had been put on top of the control cabinet.

Once the bits arrive (more ferrules etc) I'll be continuing the wiring with a vengeance :hopelessness: and then re-looking at the safety circuits so I can get the machine up and moving ASAP :eagerness: expect lots of daft questions on control philosophy again......

Well bits came the other day so swapped out the MCB'S for fuses on the PSU to driver +ve leads as well as the 240V supply to the X axis driver.

Should I put a D type MCB in the 240V power feed before it goes through the door interlock (1st item the power goes through)???

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A bit of wiring this afternoon...

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I've taken one end of the screen back to the star point by soldering an earth wire to the screen and taking that back via the signal side of the cabinet.

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A bit more wiring.....

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I moved the -ve terminals from on the PSU to the din rail, neater and shorter wires...

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Wired up the Z stepper...

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Put a cable tie holder just to stop the cable from pulling for the time being until there is a cover on the Z axis and a cable gland in the cover...

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Unpacked the new PC for the router...

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Started it up....just need to load Mach3 on and do some configuring, wire X & Y steppers up and then we'll see what happens...

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Originally Posted by njhussey

A bit of wiring this afternoon...

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Beautiful work.

How about making some of these;-
http://www.mycncuk.com/attachment.ph...id=15670&stc=1

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Originally Posted by Clive S

Beautiful work.

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Cheers Clive!!

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How about making some of these;-
http://www.mycncuk.com/attachment.ph...id=15670&stc=1

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If I had a 3D printer I would.....now if there was someone out there who could make those then I'm sure I'd be in the market for 3 of them (plus a Nema34 one...).....:thumsup:

Looking good now Neil !

I'm no expert here but on my control layout I earthed the stepper driver end of my shielded cables, with the shield running all the way out to the motor without interuption. It looks like you have earthed the 'middle' of the cable if you intend to connect another cable from the terminal blocks out to the motor?

The photos are close in so I might have mis-understood. But you might be better turning the stepper cables around so the earth connection is done on the driver end, and the shields are joined to each other at the terminal block. Or better still might be to complete the run from stepper driver to stepper motor in one complete un-interupted cable, and earth the shield at the driver end.

Someone may jump in with the science on this one, and I could easily be wrong (!) but that was how I interpreted the earth shielding requirements.

Barry, im going to have the cables from the steppers coming in to the control cabinet and earth them to the star point and the cables from the drivers are also earthed at the star point. They connect via the din terminals. I'm also contemplating having a junction box on the machine and wiring to that and then the motors etc....

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Originally Posted by njhussey

If I had a 3D printer I would.....now if there was someone out there who could make those then I'm sure I'd be in the market for 3 of them (plus a Nema34 one...).....:thumsup:

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I made a few on the 3d printer but they take quite a few hours each.:thumbdown: But since then I have made them on the mill. I have made them with various plastics and also the reconstituted rubber from tyres that they seem to make decking and posts out of but that is full of crap and holes.
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On the mil they take about 20 min with the tool changes once setup. For the undercut I use a T-slot cutter.
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The order in the way I do it is from the solid drill the 4 holes then reduce the block down, hollow out the centre, profile the outside, do the undercut then turn the piece over in the vice then cut the bottom off to release the part. Then put it back in the vice to profile the gland hole out. This was all done from a dxf file with Vetric Aspire ..Clive

edit Tool used 6mm endmill, T-slot cutter and drill.

Here is a link to buy them http://www.soigeneris.com/nema_23_st...r-details.aspx but you would need to check carefully if they fit

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Originally Posted by njhussey

Barry, im going to have the cables from the steppers coming in to the control cabinet and earth them to the star point and the cables from the drivers are also earthed at the star point. They connect via the din terminals. I'm also contemplating having a junction box on the machine and wiring to that and then the motors etc....

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I think you are fine with the earthing effectively earthed part way down the cable as long as you don't make a loop ie earth both ends. I don't think it is a good idea with the junction box on the router in my humble opinion what is the point in chopping a perfectly good cable and then putting a join in it. ..Clive

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Originally Posted by Clive S

what is the point in chopping a perfectly good cable and then putting a join in it. ..Clive

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Well to start with the router will be floor mounted until I make the frame for it to live in vertically (at the rate I'm going that'll be months...)....so I was thinking to save having cables longer than I need dangling everywhere until it's finally sited I'd have a JB and when it's in its final position adjust the cables to suit....

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Originally Posted by njhussey

Well to start with the router will be floor mounted until I make the frame for it to live in vertically (at the rate I'm going that'll be months...)....so I was thinking to save having cables longer than I need dangling everywhere until it's finally sited I'd have a JB and when it's in its final position adjust the cables to suit....

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Ah I now remember you are going to mount it vertical. But you will still have to have the continuity of the screens in the JB. ..Clive

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Originally Posted by Clive S

Here is a link to buy them http://www.soigeneris.com/nema_23_st...r-details.aspx but you would need to check carefully if they fit

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The advert says they're for 57mm motors, not 60mm, so yes... be cautious.

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Originally Posted by Clive S

Ah I now remember you are going to mount it vertical. But you will still have to have the continuity of the screens in the JB. ..Clive

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Still umming and arring about the JB, makes it a more modular solution but then gives more scope to introduce areas that could cause problems....

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Originally Posted by Jonathan

The advert says they're for 57mm motors, not 60mm, so yes... be cautious.

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I think I'll make some myself when the machine is up and running, although it'll be tight for the Z axis motor as it's quite near the plate.....and I've got a Nema 34 on the X axis......

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Originally Posted by njhussey

I think I'll make some myself when the machine is up and running, although it'll be tight for the Z axis motor as it's quite near the plate.....and I've got a Nema 34 on the X axis......

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If you want the dxf etc give me a shout.

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Originally Posted by Clive S

If you want the dxf etc give me a shout.

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Cheers Clive, would appreciate the DXF and any other files you have....save me from re-inventing the wheel!!

OK so today I'm back on the limit switches. Below is the diagram I currently have, is there a way using the relay that I can have seperate inputs from each limit switch or is it not needed?

Attachment 15679

I'm going to have travelling switches on each axis (apart from the Z where I can probably get away with fixing it and have the trigger points on each end of the Z axis) and wire them back in shielded 3 core cable...

The home switches I'm going to wire individually into the CSMIO IP-M.....

Just putting the other related in and looking at the wiring....ive underestimated the number of 24v connections I need...having to put some more on the DIN rail now.....

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Just put the Z axis front back on to see where the limit points are to be...

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Running out of room!!!!!!!!!!!

Just managed to squeeze in a timer relay for cutting the power to the spindle (after the stop signal has been sent to the VFD!!) in the case if an E-stop.

Hope there's nothing else I need to fit in!!!

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It's alive...............:yahoo::victorious::beer::toot : well the Z axis anyway!!

Jogged it up and down and it moves, need to do the autotuning thingamy bob on the AM882 drivers for the current but it's working.....only took 5 bloody years :whistle:

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Well done Neal it's always nice when it moves the first time.:thumsup:

Cheers Clive, got the Y axis moving now and did the flick of Jumper 4 on the AM882 driver thingy to tune the steppers, now they don't whistle....now for the X axis......

Oh, put an "OH SHITTTTTTT..." button on the router end where the pc is at the moment....want to be able to hit it if it all goes pear shaped, especially as I've no limit switches at the moment!!!

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Originally Posted by njhussey

Oh, put an "OH SHITTTTTTT..." button on the router end where the pc is at the moment....want to be able to hit it if it all goes pear shaped, especially as I've no limit switches at the moment!!!

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Just wait until it's doing 15m/min down the table towards you:onthego:

Well all 3 axis are moving now, I need to check the alarm circuit and all settings on the drivers and in Mach as it trips and Estops after about 5 mins whether running or not....

Vid of all 3 axis running...

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Tomorrow is wiring up the limit switches....and home switches...

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Sounds very sweet too! Given that you are also running at around 70V it must be down to the digital AM882 stepper drivers ? - mine are DQ860MA on 1600 microsteps but still have a hint of roughness when running.

Bit worried about your 5 minute e-stop trip problem - something getting warm?

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Originally Posted by routercnc

[emoji481]

Sounds very sweet too! Given that you are also running at around 70V it must be down to the digital AM882 stepper drivers ? - mine are DQ860MA on 1600 microsteps but still have a hint of roughness when running.

Bit worried about your 5 minute e-stop trip problem - something getting warm?

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Cheers!! I'm not too sure what it is, could be I have the Nema34 drive configured wrong, could be an earth problem, could be my E-stop circuit....I'll try isolating one thing at a time tomorrow and see :)

Well after earthing the frame, taking off the additional Oh Shit!! switch, taking out the driver alarm safety circuit it was still tripping out....so I swapped the Pilz for a standard relay and just wired the E-stops to this....seemed to sort it so I'm presuming that either the Pilz is faulty or my wiring circuit to it was crap....

Now trying to get the driver alarms into the E-stop safety circuit....and failing so far, but it's early days....

Did I say before that I hate electrical stuff.......

Question.....

On the Leadshing AM882 alarm output it's not completely going to closed connection....reading the manual I need a 2k resistor greater than 0.125W??

Can someone who's electrickery minded please explain it to someone stupid what I need?

The diagram (real rough sketch...sorry!!) of what I've been playing with (need to alter so I'm putting the 0V through the E-stops really) today below....

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Well after a false start (I used the info from the sticky thread on the 2.2kW spindles to wire the spindle connector) wiring the spindle I got it going. My plug had the pin numbers very feintly on it which I ignored....until it kept tripping the socket....then I looked and saw I'd wired one pin to the earth....so a bit of re-wiring and off it spun.....so that's another tick in the box...still don't like electrics ;)

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Originally Posted by njhussey

Well after a false start (I used the info from the sticky thread on the 2.2kW spindles to wire the spindle connector) wiring the spindle I got it going. My plug had the pin numbers very feintly on it which I ignored....until it kept tripping the socket....then I looked and saw I'd wired one pin to the earth....so a bit of re-wiring and off it spun.....so that's another tick in the box...still don't like electrics ;)

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Are you going to control the spindle speed through Mach or with a pot?

Thinking of doing it through Mach Clive.

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Originally Posted by njhussey

Thinking of doing it through Mach Clive.

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Well if you do want to fit a pot on the vfd it can be done for about £2 :- post one http://www.mycncuk.com/threads/7388-...ighlight=speed

Cheers Clive, I might fit one and then have it as an optional overide, I fancy using Mach to control the speed through the IP-M's 0-10V output...

Set up the Spindle on Friday....manual only at the moment...

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Just putting the limit and home switches on the machine now.....going to wire them direct to the IP-M I think rather than daisy chaining them through a relay....can always add that later...

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Ordered energy chain (plus ends!!), 100mm cable tray, small cutting bits, 4" rotary table, chuck & tailstock (4th axis), Full ER20 collet set, a few small 1mm and 2mm endmills and a few V carving/engraving bits and some other odds and sods....more fixing and wiring of the limit and home switches tomorrow morning...

Energy chain is here, will look at mounting that now it's here, don't trust dimensions off a data sheet....

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