Small rigid router - Design advise needed

[mitchejc]

what controller you are using? If it works without a plugin with mach3 it certainly can home double long axis separately.


It will be best to start stop the spindle with relay and control the RPM via 0-10V. What is the model of your VFD?

We will help here so you do it right. Its not difficult.

Thanks silyavski. I'll be using a cheap controller I bought before I joined this group and I hope to upgrade to CSLABS CSMIO/IP-M later this year so no dual axis homing.

In bench testing I've been able to control my VFD speed from controller but I'm unable to figure out how to switch it on and off with my controller. My VFD is a Sunfar E300. The model number says E300-2S0022L. Attached is the manual

[Boyan Silyavski]

Thanks silyavski. I'll be using a cheap controller I bought before I joined this group and I hope to upgrade to CSLABS CSMIO/IP-M later this year so no dual axis homing.

In bench testing I've been able to control my VFD speed from controller but I'm unable to figure out how to switch it on and off with my controller. My VFD is a Sunfar E300. The model number says E300-2S0022L. Attached is the manual

These are the basic steps to make the VFD work with your spindle:

F0. 0 1: External input signal (0~10V / 0~20mA)


F0. 2 1st part of LED 1:Control by external terminal
F0. 2 3rd part of LED 1: Valid
F0. 2 4th part of LED: Self-startup when power-on 0: Prohibit




F0. 4 Upper freq [F0.3] ~ 1000 Hz 400/ if your spindle is 24000rpm, if not divide RPM/60


Check if these 2 are by default 10: if not set
F0.5 Acc time 10:
F0.6 Dec time 10:


Spindle speed control:
connect from BOB to terminals 10V/+/ and CM/common/
F1. 1 AI input upper volt [F1.0] ~ 10.0V , Leave that to 10 if you board outputs 0-10VDC for spindle control, change to 5 if the board outputs 0-5VDC
F1. 3 Max setting freq 400/if your spindle is 24000rpm




Protection:
connect terminals Ta Tb /NC normally closed/ to the ESTOP circuit, so that if the inverter trips it will stop the machine


When you are finished with all of the above:
F0. 10 Parameter read-in protection 2: Only allow to modify this parameter


How to turn it on off and the speed control:

not all the info is relevant to your case, so remember your settings from above, but read about mach 3 , relay assignment and checking the speeds. You will need a cheap tacho
If you dont have a relay output/alsmost impossible/ , you will need a cheap ??V relay/depends of voltage output of your board/ from ebay.

http://www.cjh.com.au//PWM%20Spindle...ng%20Mach3.pdf

[mitchejc]

@ Silyavski, thank you very much for taking the time to go thru my VFD manual to help me. I think I'll get it going now and I will also connect the VFD failure relay to my EStop circuit.

@Neale, Ahh, thx, now that makes a lot more sense to me. I can now see why one would use this. I guess emulating the functionality by using a few relays that drop out on estop would not be impossible but getting the reset functionality to work would be very difficult for me, so it would be a lot easier to just use a component. Had a look on RS-online but new they are expensive so I'll try and find a second hand or discontinued one from a seller thas will to send here. Just wondered why on earth they call some models a PNOZ, do they know what it sounds like when you pronounce it in english :-)

@Eddy, thanks that's a very useful link.

BTW you guys were right, I did a cad layout of my control box this weekend and its MUCH larger than I thought if I follow the component manufacture's guidelines for spacing between parts. I'm going to need a small lotto win to complete this machine if I want a nice PNOZ, a steel enclosure and a CSMIO/IP-M. Scratching around to see if I can't maybe liquidate some other redundant hobby stuff :-)

[mitchejc]

Just thought I'd post an update. My build has been delayed a bit mostly due to lack of budget but I finally got going again. Got lucky and a friend contacted me to cut 6 x bench-rest rifle stocks which helped a bit for the hobby cash-flow. My stock making hobby is what what got me into cnc in the first place :-) Here's a pic of one getting cut




Anyway back to the topic. Got a nice 800x600x220mm steel cabinet for a very reasonable price (+- 70GBP). I was concerned about my ability to cut holes etc in the steel but got it done relatively painlessly using a Dremel and those small clip-in cutting disks.




I cut a alu panel to replace the steel one that came with the box.



I made an air filter box with a cheap car filter to house my huge fan and keep stuff out of my control box.



I think I have figured out what I want to do with my wiring. I'm a bit further along but these were the last photos I took.

[mitchejc]

WHOOHAA, its running!

Finally completed my control box. Decided to chuck 4 of the safety circuit relays and replaced it with an Arduino which resulted in a simpler overall setup. E-Stop button works as expected and any fault or position loss will stop all motion.


Steppers now mounted


Have to do the wiring of the machine now, fit cable chains, zero and limit switches etc but could not resist to try a few test cuts. No machine bed yet so I just clamped a vice on a few blocks of wood. Took a lot of effort to get this far but thinks are finally comming together and I'm absolutely over the moon with how the machine cuts. Part below was cut 15mm deep with a 6mm HSS endmill at 1000mm/min @ 3mmDOC and finishing cut at 500mm/min and 6mm DOC.

[JAZZCNC]

Decided to chuck 4 of the safety circuit relays and replaced it with an Arduino which resulted in a simpler overall setup. E-Stop button works as expected and any fault or position loss will stop all motion.

Looking good but how do you work out that an Arduino can replace Safety Relay/s.?. . . . It's a Computer.!! . . . . . . In which case you may have just saved your self the hassle altogether and just used the I/O you had already.! (unless you didn't have enough I/O to start with.!)

[mitchejc]

Thanks Jazz. Apologies, that came across wrong, ill try to explain. I wanted any fault signal to disable all movement and I could not figure out an easy way to combine the 4 stepper driver fault signals into one so I got them to switch 4 small relays and then wired the relay switches in serial so if any one opens it cuts my 5v enable circuit etc.

There are probably better solutions but I replaced those 4 relays with the arduino using 4 inputs and 1 output. Arduino Inputs connected to stepper driver fault outputs and the 1 output connected to all driver enables and spindle relay. The few lines of code check the inputs and if any change is detected it takes the output pin low disabling all drivers and switch the spindle off. Ive tested this to death and it works like a charm.

Not sure I understand what you mean about the spare IOs. I do have spare inputs available on my controller but i dont want to rely on mach3 alone to stop everything or is that not what you mean?