Converting a Warco Mill to CNC

[i2i]

Not exactly what i meant. What i was suggesting is to drive the actual Z screw in the knee with a stepper "through a belt reduction if you require", but not through the angle drive present on the front of the knee.

[thorphar]

Not exactly what i meant. What i was suggesting is to drive the actual Z screw in the knee with a stepper "through a belt reduction if you require", but not through the angle drive present on the front of the knee.

I was interested in what axis' would require a belt system in order to reduce cost. I did some tests on the handwheels using a newton gauge and a lever. Here are the results I got.

Axis	NM
X	1.68
Y	1.41
Z-Via Knee	8.0

I also wobbled the handles and measured how much slack there was in the screw.

Axis	Slack
X	0.85mm
Y	0.06mm
Z - Via Knee	0.08mm

Im gonna do some more testing but it seems i could get away with out the belt system on the x and y and just direct drive with a 3Nm Nema 23 and use a belt system on the Z.

[thorphar]

In light of this recent discovery. I have re done my basket.

I use to use AM882 however, after looking around online someone mentioned the DQ860MA Driver being ok instead of the AM882. Im just worried about the lack of sensor less stall detection not being on the DQ860MA. Thoughts ?

Apart from the drivers im pretty sure on the rest, however if anyone see a major mistake, please let me know.

For the Z-Axis driven through the knee

2m2280N High voltage driver
Nema 34 - Sy85STH156-6204B 12.1Nm
suitible coupler to go between the Nema 34 and the z-axis rod.

For the x and y axis

Nema 23 3Nm
DQ860MA
Custom Power Supply
Coupler to go between Nema 23 and Axis drive.


I use to use flexible couplers, however in this kind of situation i believe a solid coupler would be appropriate. I don't know of any good suppliers for solid couplers however Im pretty sure I can make them.

[ZX12RUSH]

Like this.



Works quite well for a my uses.
Some of the parts used

Stepper motors
http://www.ebay.co.uk/itm/German-Shi...E:L:OC:GB:3160


Stepper driver
http://www.ebay.co.uk/itm/Single-Axi...item2ed842f005

Although I have blown 2 up. One was by turning the Travel handle while it Was moving.
With careful treatment they now seem ok. I would like to try something better. May be a Gekko....

Ball screws on X Y X
I bought 2 Chinese Ball screws with 4 Ball nuts , and had the machine the ends to 16mm, then made suitable sleeves to fit the bearings.
http://www.ebay.com/itm/2-anti-backl...:X:RTQ:US:1123

[Clive S]

Nice Job. Did you not consider higher voltage drives to run the nema 34 motors. ..Clive

[Richard]

Like this.



Works quite well for a my uses.
Some of the parts used

Stepper motors
http://www.ebay.co.uk/itm/German-Shi...E:L:OC:GB:3160


Stepper driver
http://www.ebay.co.uk/itm/Single-Axi...item2ed842f005

Although I have blown 2 up. One was by turning the Travel handle while it Was moving.
With careful treatment they now seem ok. I would like to try something better. May be a Gekko....

Ball screws on X Y X
I bought 2 Chinese Ball screws with 4 Ball nuts , and had the machine the ends to 16mm, then made suitable sleeves to fit the bearings.
http://www.ebay.com/itm/2-anti-backl...:X:RTQ:US:1123

Very nice looking build! So apart from blowing a few drives, any other problems?

[bogstandard]

You asked earlier on about drive belts.
Well this site from the UK seems to have almost anything you could want.

http://www.beltingonline.com/rubber-timing-belts-40/


John

[thorphar]

Thank you all for the advice and help relating to this conversion. Here is where ive got to so far. I have managed to create a mounting system for the x and y axis drives. I have three nema 34 1600oz stepper motors. I have a custom ball screw to drive the quill. What I need to complete is the quill drive system. Im hoping to use the 2 Axis CNC to help create the parts for the quill drive. Things having been moving slow due to problems that occurred with the Chinese supplier for the Stepper Motors.


I have attached a photo of the machine so far .

[ZX12RUSH]

EDIT
Posted twice

[JAZZCNC]

In light of this recent discovery. I have re done my basket.

I use to use AM882 however, after looking around online someone mentioned the DQ860MA Driver being ok instead of the AM882. Im just worried about the lack of sensor less stall detection not being on the DQ860MA. Thoughts ?

Stall detect only works after 300rpm so it's not such a big deal for a mill. But what is bigger deal is how they handle resonance better and give smoother running motors. The DQ860ma are not as good in my experience so I wouldn't use them over AM882 or better still the updated EM806.