routercnc_MK3

[EddyCurrent]

Nice looking dust shoe, I need to study it better when I get time. I liked this idea, don't know if it can be applied to your; https://www.youtube.com/watch?v=tBzoQw4du8E

[routercnc]

@Silyavski
I guess you mean CAM toolpath control to avoid any clamps? I have some low profile clamps so should be OK there.
With regard to adding brushes - yes I've considered that and with the lower plate being removable I can try different designs and use the best one for the job.

@Eddy,
Thanks for the link to the video. He does go on a bit! During cutting mine will behave a bit like that, but with the advantage of rising up out of the way when the cut is finished. His looked static from what I could tell.
Also, the lower plate on his is completely open, whereas mine is only open locally around the cutting bit so should give better extraction. I also think my magnetic removable plate means it is quick to get everything out of the way and change over to jobs which don't really need a dust shoe such as aluminium machining.

[EddyCurrent]

Eddy,
Thanks for the link to the video. He does go on a bit! During cutting mine will behave a bit like that, but with the advantage of rising up out of the way when the cut is finished. His looked static from what I could tell.
Also, the lower plate on his is completely open, whereas mine is only open locally around the cutting bit so should give better extraction. I also think my magnetic removable plate means it is quick to get everything out of the way and change over to jobs which don't really need a dust shoe such as aluminium machining.

The only aspect I was drawing your attention to was the piece of 4" flexible ducting around the spindle collet area

[routercnc]

I'd glossed over that but you are right - that is a good feature and would improve dust collection still further. I don't think I could fit 4" hose, but something smaller in diameter and just tall enough to make a seal with the spindle during cutting should work. I'll look into it . . .

[routercnc]

Some progress. Putting my hand under the extractor shoe feel likes a reasonable draft so I think it will do the job.

I won't be cutting anything for a bit as I've decommisioned the control box to make the new upgraded version. Here is the old control box - low voltage basic all-in-one system which has run well for over 5 years now, but time for an upgrade:

It was pretty clean inside as you can see so the filter on the left was doing its job well.

Here is the revised electrical layout - the one I posted a while back would not have worked as the relays were linked in series! There are some other 'improvements' as well:


Here is the progress on the new control box:


As you can see I was inspired by Eddy's control box to make a better job of it this time round.

Top row left to right:
Invertor/VFD 1.5kW
12V PSU (ancillaries, BOB, safety relay and limits)
60V 10A PSU for X1, X2, Y2 drivers
32V PSU for Z driver (out of old machine)

Next row:
permanent 12V terminal block
permanent 0V terminal block
relay switched 12V terminal block (the photo is now out of date as I had intended to use this as a 5V terminal block)
Master relay with 4 outputs - latching function, driver relay control, BOB e-stop trip, Spindle run inhibit
4off 30A automotive relays (5pin) to control the drivers
star earth point terminal block

Final row:
Breakout Board - Fairly cheap board (~£10 ebay) but with space for something much bigger/better should the need arise(!)
3off DQ860MA 80V drivers for X1, X2, Y1
1off MD542 48V driver for Z

Tool collection so far - That bootlace ferrule tool (orange) makes a really nice job of the cable terminations, thank you to those who recommended that route:


I've posted the front control panel in another post but will repeat it here for completeness:


I've ordered the Pokeys board which will fix to the back of this control panel, keeping all the wiring local on the front panel and just leaving the USB to run to the main board. This will control the feed start/pause/stop/rewind, feedrate override, and feedrate reset in Mach3 using the Pokeys plugin. All other functions will be hardwired in simple circuits.

Now a question on the relays. Earlier in this post I asked about diodes across the coil - 1Nxxxx series was mentioned but when I looked this up recently there were so many to choose from! So I did a google search specifically on suitable diodes and found mention of an SR5100 5A 100V Shottky Diode so bought a set of 5 for about £2 as I was buying some other stuff anyway. Before I fit these to the relays are they suitable?

Can someone confirm that the grey bar on the part is the 'bar' in a diode symbol and that this faces the positive end of the relay - see layout diagram.

[Boyan Silyavski]

Just some random thoughts on buttons.

I was thinking adding the same buttons. Though i don't see a reason for spindle controls there. Its clearly seen on the mach3 screens/ok i have MSM Mill screen /, or at the VFD/if you have it on the wall like me/.

I see the need though of these buttons, most are same as yours, ordered by importance / to me at least/. Mist flood and vacuum are last, as these are controlled via the program and relays or/and manually turning valves.


Reset

Start
Hold
Stop

Find Zero Z /Touch plate/
REF ALL

Go to XY0
Go to Z0
Go to TC position
Go to Park position


Mist
Flood
Vacuum

[routercnc]

silyavski,

I think in the end it comes down to how you use the machine and personal preference. I looked at lots of commercial panels to see what could be useful and ended up after many different options with the panel above.

The VFD will be inside the cabinet so I can't see the screen. I've not been able to find a long extension cable to detach the panel and put it on the door. Any links to one welcome!

Although there is control for VFD on/off, it is also under Mach3 control for on/off so it is just a manual override option.
I thought about Mach3 spindle speed control and in the end just went for the manual pot direct to the VFD. I tend to cut the same things at the same speed. It would be very easy to get Mach to also control the speed and then wire the pot to the Pokey system if I change my mind. Keeping it simple for now.

My buttons are laid out in order of running sequence left to right. Power on, then e-stop reset to energise the relays, then switch on lights and pumps if required, then start the spindle and set the speed, then run the cycle, with a feedrate override tuning dial right at the end.

I have a seperate MPG pendant so no need to add controls on the panel.

That's my version anyway . . .