Warco Major CNC build log

[ptjw7uk]

I hope the rj45 are not being used for current carrying as they are not propper connections just insulation displacement connection for signal etc.
Even the punch down connectors are not that good for current much better to get solder or screw types.

peter

[bambuko]

...they are not propper connections just insulation displacement connection...

As an ex(retired) AMP guy ...
Perhaps you would like to re-phrase this statement :nope:
They are perfectly "proper" for the job they are designed for :clap:

[ptjw7uk]

Possible but I have spent hours trying to find the one that wasn't done proper, even had trouble with the puch down ones.
There again in the past I have known screw down terminals to cut through the wire.
Best ones I remember were the old round plessy ones as long as you had all the tools they were easy!

peter

[Robin Hewitt]

Everything tested okay barring a couple of missing components so I fitted the cpu.

I couldn't find a 180R resistor to drive the opto isolator, one resistor pack and RS came up no stock on the USB socket, had to fudge a right angle component in to a vertical. :whistling:

Nothing there that will stop it stepping so I can get on with the firmware.

It protrudes through a cut out in the mill stand door, so on the back it has 5 push buttons, a speed control pot and a socket for the pendant. Everything else comes out the front inside the plinth.

The switches will be three press on/press off for main motor, suds and quill lock, a pause button and and an 'everyone off'.

[Robin Hewitt]

A quick progress report..

Slight mis-wiring on the USB and I didn't notice I needed a 1 Meg resistor across the crystal before it would spark up.

Whatever, the computer now makes the dee-dum USB noise when I plug/unplug the controller and a test program can read inputs and write outputs under XP.

Probably doesn't sound like much but from here on it's only typing. Fortunately I've got my big brother doing that bit for me :naughty:

Robin

[Robin Hewitt]

I cut some metal and it came out a bit naff, see before and after pic, arrow points to the problem bit.

Two changes, I wrote my own dxf to G-code software taking control of the tool path. Bubba, over on CNC zone, told me the Warco column pinch bolts were naff.

I've been measuring the new part and dimensionally it is slightly undersize, somewhere between -0.00 and -0.05mm

Theoretically with a bit of compensation I could get the tolerance down to .025 mm if I always used this tool and this collet :dance:

Bubba suggested I changed the bolts. I looked at them and found they had worn badly. When I thought I was doing them up tight I was actually trying to swage a new thread. I fitted overlength M16's with spacers and anti-seize compound. I can now use a ring spanner rather than the awkward Warco offering and it seems to like it.

[Jonny]

Any further news?
I have the smaller Machine Mart one made redundant 6 years ago, very accurate.
Was rather intrigued by the lead screws, i broke mine 9 years ago and close on £200 and 6 months delivery from MM.

I always left a ratchet and socket at the back for the two nuts.