Machsupport Forum
General CNC Chat => Show"N"Tell ( Your Machines) => Topic started by: Brian Barker on July 09, 2006, 01:13:13 PM
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Newfangled has just got there second CNC lathe It is a Compact 5 made by Emco and will be used to test software. The cost of the lathe was $900.00 and is in running condition! When I say running I should say that it needs spindle bearings… I turned on the spindle and it sounded like some one had put rocks in place of the bearings! So you will see that I have the spindle out of the lathe and the new 6006-2Z bearings are going to be on there way soon. I can only find ABEC 3 bearings from MSC ( www.mscdirect.com ) so I am going to call a few of the local bearing places to see if I can get ABEC 7 bearings . The ABEC number is the precision of the bearing, so a 7 is better than a 3… We could get into it more but I don’t see the point ;) . Even with the bad bearings the lathe gave a GREAT finish! I was taking about .050 at 2500 RPM in 6061 AL with the stock about 2 inches out from the chuck. So there is hope for this little lathe ;)
Now that I know everything is in working order I have to figure out what I am going to keep and what is going to go. The spindle motor is a German DC permanent magnet motor (very nice motor). The Emco DC spindle drive has a pot, LED display and a switch to turn it on and off. This will never do! I need to have CSS and don’t want to turn on the spindle motor on and off with a switch. I was going to get a KB electronics DC drive but there were not any dealers up here in Maine . So after looking on the web I found www.e-motorsonline.com and ordered a regenerative SCR DC drive. I was going to get a nonregenerative drive because they are half the money but this drive would not reverse and decelerate as fast as I would like . I ended up with a Minarik DCD01330 drive that is made to only run permanent magnet motors to the tune of about $183.00 with shipping.
I need to send a 0 – 10V to run the drive… I decided to order a DL06 PLC from automation direct with an analog card. I know this is WAY overkill but I know I will have all the IO that I will ever need . It cost about $300.00 and gives 20 inputs, 16 outputs, 2 analog in and 2 analog out! The extra I/O is going to be used on the tool changer.. The way Emco did there tool changer is VERY odd at best! Emco did the tool change based on time! They never knew where the tool was at any point and a tool change would only tell it to increment X amount of tools! This will never do! I plan to add proximity sensors to the tool changer so Mach 3 will know what tool is tool one and to sense when a tool has gone by (counter). This will be a great improvement over the OEM convention of running the tool changer!
There are steppers on the X and Z axis… I heard that the steppers were junk so I did a few testes to see if I could get the machine to miss steps. The first one was to hold onto the tool changer and have a friend rapid the Z axis. I am not a small guy so I figured I could stop the axis if the steppers were not any good . I am happy to say that the machine started to slide across the plywood bench as I was holding the changer! The drives that are on it now are running heavy amps (about 4) so they are getting hot! I am in hopes that the new G201 drives from Gecko will help keep the motor cool with the auto current reduction. I plan to use the OEM transformer (40 V) , rectifier and capacitor.
For breakout board I went with the PMDX-122 and PMDX-Sensor-S from www.PMDX.com . I had the PMDX-122 sitting here because I bought it from Steve at the CNC workshop . The PMDX-Sensor-S is a through beam type sensor that I am going to use to read the spindle/position for threading. This is going to make for a nice small package that should all fit in to the original cabinet.
That is all I have done up to this point I will post more when the parts start to come in.
Feel free to ask any questions that you like
Thanks
Brian
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Brian.. The steppers on these machines are 7.2 deg not the normal 1.8 deg. It is worth changing then for some better more modern motors.
I run two of these machines commercially for very small parts. Mainly in Acetal. One machine is very standard with the toolchanger (Which I never use cos it's sooo slow) The other is so heavily modified it could hardly be the same machine.
The modified one has a new 3/4" capactity spindle, with Angular contact bearings instead of those crappy deep groove bearings. This spindle has a large chuck mount, which is made to suit the air operated collet chuck i am developing. The dc spindle motor has been removed and turned into a dc servo for another machine! All remaining holes in the base have been welded up cos I use flood coolant. Removing that Loooong dc motor and replacing it with a 3/4hp 3 phase motor fitted in the rear we the psu used to live gave me room for a longer crosslide and ballscrew which turned to machine into a gang tooled machine.
I can run this spindle to 4500 rpm no problem and still be within spec of the bearings I have used.
But do bear in mind the headstock is a very light alloy diecasting! they dont take too kindly to much abuse....
Oneday I'll find time to finish it off! I want to completely enclose it oneday. If I get some time I'll post some pics somewhere.
Wayne....
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I was going to test the motors first... What did you end up putting on for Axis motors? I will not be doing any high volume work on this lathe because I have a Hitachi Seki that is a MUCH better production lathe with a 12 station tool changer and 20 Hp 4000 RPM spindle.
Thanks
Brian
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Hi,
Very intersting Brian. I'm currently doing a EMCO toolchanger module for the ModIO. It is my understanding that the toolchanger has to opto sensor it it. One for the home position and another for the tool position.
Every time a tool position is passed, the single tool position sensor is activated. It is also my understanding that there is a Motor Forward relay that when activated drives the changer in the forward direction. When deactivated, the motor is constantly driven in reverse to lock the changer in position.
It is my understanding that it operates as follows;
The home sensor tells you it is locked in tool position 1. So, initially if you don't know where the current changer position is the changer needs to be rotated until the home sensor is detected, then keep going until the tool position sensor is detected. Then turn off the Motor relay and the motor will reverse locking the changer into tool position 1.
We now know where we are. To select a tool position, the motor is enabled and the number of position sensor transitions are counted until the desired tool position is reached. The motor relay is de-energised and the changer reverses to lock it down.
BTW this changer has 6 positions though. Maybe it operates differently.
Also, I'm using the same ModIO register interface as I did with the Mazak tool changer. Maybe we should consider using it as a standard for tool changer modules as they all need the same type of control.
John Prentice wrote the MacroPump routine for it and it has been uploaded publically somewhere.
Cheers,
Peter.
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Thanks for starting this thread Brian, it should be an interesting project. I look forward to reading all the details and seeing more pictures as you progress.
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I have two of these machines one is in the original condition and the latest one has been retrofitted to use Mach3 by the previous owner. What I am interested in knowing is has anyone modified the Gib strip I understand it to be made of plastic.
Jim
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What I am interested in knowing is has anyone modified the Gib strip I understand it to be made of plastic.
Jim
Yes I have modified them after a crash cracked the originals. This caused the carriage to rock, I machined up some new ones using some low friction plastic I had in stock (I forget what material it was, but it's green) I made steel backing plates, which has made the assembly stiffer, But you have to counterbore for the cap screws as there's not a lot of room before the screw heads foul on the beds crossbracing.
removing and refitting the screws can be difficult. I drilled 2 holes in the pan to allow me to do this from under the machine.
Wayne...
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Hello Peter,
This one has no sensors on the tool changer :( I was shocked! an open loop tool changer is just a little scary :o
Could you tell me where your optics are on you changer?
thanks
Brian
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Hello Brian,
I will go down to my shop and take some pictures of the toolchanger I have on my Emco PC Turn 50. It is the same one as you have with the encoder disk fitted.
You have the schematics and a small picture of the optoboard that I sent you earlier.
I'll be back
Bengt
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Hi Brian,
Look at the new pictures of the optodisk setup on my Emco tool turret.
http://goto.glocalnet.net/Bengt.CNC.pages5/pictures.htm
Cheers
Bengt
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This one has no sensors on the tool changer :( I was shocked! an open loop tool changer is just a little scary :
Brian. Yep the C5 toolchanger is very open loop. The way it locks is even weirder! It reverses against the pawl, and holds it there with the motor reversed, I think at reduced current. It's a very special motor which allows this abuse.
I still reckon my gangtooled version is much faster tool to tool.
Wayne...
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Thank you guys :) I was going to build the pick ups for the toolchanger with Prox switches or micro switches... The more I think of it I the more I like the micro switch Idea :) I have worked on many full sized CNC lathes in the past and this is how it was done... Thank you for your help!
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Good day Brian,
We have meet at the two CNC Workshops in Cameron Illinois, 8) and I am the individual who designed a tool changer for the Compact 5 and now that you are planning the retrofit of your compact 5, I want to know if you want the design drawings. We discussed the programming of this turret and I still will need your assistance to make it work.
My Conversion used Servos, and I Plan a Stepper motor is to be added to power my newly designed 6/8 position tool turret. I can send you the turret design drawings that I used as a starting point for the design. I used it on a converted MAXIMAT 8. My system uses 300 in/oz max servos, Sound Logics COMBO interface board, 2 Gecko 320 servo drives, a Gecko 210 Stepper motor drive, Miniark Motor Controller, and mach 3.
I would ask that you do not release the plans to the public as I am seriously planning to market the turret. You can contact me offline.
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Hi Brian
Your new CNC Lathe looks to be in very good condition. Where did you pick it up from? I have noticed that allot of Schools have these types of Lathes. I plan to follow your thread as I would someday like to either convert or purchase something similar. Keep up the good work. Take lots of pictures. All the best
Regards
Bill
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Hi Brian,
I don't have one of these changers. Just adding a module in the ModIO for Bengt and another user.
It looks like from the photos that Bengt has taken that you could add the sensors like on his changer.
Cheers,
Hello Peter,
This one has no sensors on the tool changer :( I was shocked! an open loop tool changer is just a little scary :o
Could you tell me where your optics are on you changer?
thanks
Brian
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Peter if there is anything that I can do to help with the Mach3 side of it I am here :)
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Peter if there is anything that I can do to help with the Mach3 side of it I am here :)
Hi Brian,
Thanks for the offer. At the moment things are OK. I am usingthe same Modbus interface I used on the Mazak Lathe Toolchanger. John Prentice wrote the MacroPump script for that, and it should work for the Emco toolchanger module as well. There might also be some info on it in the Wiki.
I have included the Register set used for the toolchanger with a brief description of their use. Effectively, you just set the new tool number in a register, change the value in the 'Count' register to initiate the change. Another input register is monitored until it's value is the same as the output count register's value. When the values are the same the toolchange has completed. Then check the status register incase there was a problem with the change.
There is also a "current tool" register that can be read to find out what the cureent tool position is in the changer. Anyway, have a look at the include below.
BTW, it would be good if we could come up with a "Standard" toolchanger interfave for Mach3. It would make things easier in the future.
Cheers,
Peter.
********************************************************************************
The ModIO will read the 2 optical switches and drive the Motor direction Relay.
I presume when the relay is off, it is driving the motor in reverse to lock the
turret.
Also do you have an indicative measure of the time it take the Turret to rotate
360 degrees.
I need to know this for safety time-outs .
The EMCO changer has 2 inputs, a turret home switch and a Turret position
switch. The home switch indicates that the turret is lined up with tool position
one locked. This switch will activate whenever the turret passes position 1.
The other switch the turret position switch input is the input from 6 turret
position switches in parallel. If any one of the 6 switches are activate then
this input will be active. Therefore, this input doesn't indicate what tool
position we are at, just that the "Next" tool position has been reached. There it
is necessary to keep track of where the changer is relative to the home
position (Tool 1)
The changer will work as follows;
On startup or after an error occurs we assume we are lost. When the first
toolchange request comes in, the changer will rotate until it sees the home
switch input go active. When it sees this it knows where it is, tool 1, and can
then move to the requested position.
There is also a timeout. If the home switch is not found within the configurable
timeout, an error is assumed to have occured, and the changer stops.
When a tool change is requested and the current position is known, the changer
rotates the turret counting the number of times the position input goes active
until the desired tool position is reached.
There are also 6 outputs used as position indicators, plus a status indicator
output. The position indicators will illuminate when the turret is at the
indicators position. That is, indicator 2 will illuminate when tool position 2
is reached.
The status indicator will illuminate whenever the tool changer is activated.
It will extinguish when the change operation has completed. If an error has
occured and the change is aborted, the indicator will flash until the next
valid operation has completed.
Once the desired position is reached, the motor forward relay is de-energised
and the motor reverses, locking the turret into the desired position.
Note, the position switches on the turret are positioned to be activated once
the turret has passed the tool location. The reversing of the motor rotates the
turret back to lock into the tool position.
There is also a manual change input switch. When activated, the turret will jog
to the next tool position.
Modbus Interface
================
The Emco changer interfaces by a number of Modnus registers as defined below. A
number of the registes are configuration registers and are used to initially
configure the changer. There are also a set of registers that are then used to
control the changer during normal operation.
Config registers
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register 150 Turret Config
This config register is used to enable the EMCO toolchager module. To turn ON
the module, bit 1 needs to be cleared. Therefore 0x00FD should be written to
register 150 to enable the changer.
register 151 Change Delay timeout HI BYTE
register 152 Change Delay timeout LO BYTE
These 2 registers make a 16 bit timeout which if it expires will abort the change
and error. If you set the time out registers 151 and 152 to 0x10 and 00x0, you
will get a time out ofapproximately 30 seconds. each bit in the hi register 151
is worth about 2 seconds. With the default value of 0xFF and 0xFF the timeout
is over 500 seconds
register 153 Reverse Delay timeout HI BYTE
register 154 Reverse Delay timeout LO BYTE
These 2 registers define the time delay between between turning off the forward
relay and indicating that the toolchange has completed. THis delay is to allow
the changer enough time to lock the turret. With the default value of 0xFF and
0xFF the timeout is turned off.
Output Registeres
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register 1100 Requested Tool
This register contains the tool positon for the next tool change. If this
register contains 0 when the tool change is requezsted, a dummy tool change
occurs. This is a good way to synchronise the Tool Change Counter 1101 output
rgister and the Tool changed count 1201 input register.
register 1101 Tool Change Counter
This register is used to initiate a tool chage operation. Whenever this register
value is changed a tool change occurs. Therefore to change a tool position, the
position to chage to is first written into register 1100, then the contents of
register 1101 are changed. It is best to increment it as this helps debugging.
Input Registeres
-----------------
register 1200 Current Tool
This register contains the current tool positon If this register contains 0
it indicates that the tool changer is "lost"
register 1201 Tool Changed Count
This register is used to determine when a tool chage operation is complete. This
is indicated by this register having the save value as register Tool Change
Counter 1101.
To perform a toolchange, the value of 1101 is changed to initiate the change.
When the change is complete, register 1201 will contain the same value that was
written to 1101.
register 1202 Tool Change Error Code
This register is used to determine the state of the last change request. If the
change was completed with an error, this register will contain 0x0000, otherwise
it will contain an error code.
register 1203 Tool Change Mode
This register contains the changers internal state as the change is occuring. It
is only used for debugging purposes.
Changer Operation
=================
To use the changer, the module must first be enabled by writing 0x02 to register
150.
Initially register 1100 should be written with 0x0000. Then, write0x0001 to
register 1101 to perform a dummy change.
Then to perform a tool change, write the new tool position to register 1100, then
increment register 1101. Register 1201 is then checked until it changes to
the same value of
*******************************************************************************/
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I am thinking about doing this in a plugin... I could make a dialog that would do about any toolchanger :) I hope to started that after I get the project that I am working on now done :(
This is going to be a good year!
Brian
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Brian,
I have a new board that has built in most of the electronics hardware you would need for a project like this. Saving lots of bucks, time, and making it pretty simple to do (Isn’t this mach is about?). This I the board bengt used http://www.cnc4pc.com/Multifunction_CNC_Board.htm. He was one of “beta” testers.
If you would like to consider using it in this project I would gladly send one for testing. This is new board I can use all the feedback I can get. I also have a bidirectional breakout board for the second parallel port and inexpensive optical sensors that could also send and you will find very useful reading the index pulse, home positions of the axes and tool turret.
I have Hardinge HC lathe that I converted and use it mostly for testing. I run the 8 post tool turret with a macro that you help me with. I added an index pulse on the turret for homing on start up and a sensor on the turret lock. So the machine will not start until the turret is securely locked.
With that setup I run an automatic bar feeder and still have enough inputs to read back the encoder’s position of the axes servos.
Please confirm if you want to consider testing this board.
Arturo Duncan
http://cnc4pc.com
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I am thinking about doing this in a plugin... I could make a dialog that would do about any toolchanger :) I hope to started that after I get the project that I am working on now done :(
This is going to be a good year!
Brian
Once the craps out the way :D
How about this for an off the shelf toolchanger ?
(http://homepage.ntlworld.com/stevenson.engineers/lsteve/hidden/taig%204th%20axis.jpg)
The bore is a thru bore with keyway, just right for accepting a backplate for tools.
Ignore the chuck it's just posed there for show as a 4th axis on a small mill.
John S.
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John,
That will work, but you would still need to add a turret lock a couple of sensors. The turret could loose position while cutting and you would never know, causing a serious safety issue. If you mounted an encoder or use servo and read the encoder position you could monitor the turret position at all times.
From my experience an adding a mechanical lock using a solenoid pneumatic valve and pneumatic piston will do. The sensor for the turret home and turret lock are a MUST.
Your proposed solution will imply major mechanical reforms for Brian’s small machine that already has a tool changer.
Arturo Duncan
http://cnc4pc.com
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Hi John S,
That gearbox looks like the same one I was bidding on in Ebay a while ago! Is that where you got it?
John (Bloy)...as Amnz
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Arturo,
This wasn't touted as a replacement for Brian's tool changer but more for a conversion of a centre lathe to CNC.
This also answer Bloy's question in the same post, these are off the shelf units, made in Italy to quite a high standard and available in a number of ratio's.
As an idea these cost about 80 UKP each, new.
You couldn't make one for the price given hardened worm, bronze wheel and 4 bearings. I have had one of Brian's tool changers in pieces and they are crudely made.
There is tons of backlash in the worm and wheel, in fact it's a gear not a worm, and it relies heavily on being driven backwards against the pawl
My idea was to take one of these, fit a stepper and a large top hatted disk, the smaller diameter to fit inside the final drive worm and the larger diameter disk to carry 6 or 8 tools.
On the rear of the disk would be machined 6 or 8 ratchet teeth for a pawl to lock into.
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I just got in the Minarik DCD01330 DC drive for the spindle :) I hooked it up as a test and WOW did that ever make that motor work better! The spindle will go from 0 - 3000 RPM in about .5sec ! The spindle can now go full forward to full reverse (3000 RPM) in about 1 sec, This is going to be very good for CSS :)
This is a small update but there will be more as the parts start to show up
Thanks
Brian
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Arturo Duncan from cnc4pc.com send me some boards to test. So I will not be using the PMDX that I had on the shelf... I have a CNC punch press that I think it will go on :) . The Board from CNC4PC ( C11 - Multifunction CNC Board ) is making it so i will not need a PLC! The board has all the stuff to do 0-10V! On a machine this size I need all the room I can get! He also sent along the C3 - Index Pulse Card that will be used to read the spindle index pulse... after I have all that tested and running I will be adding an other parallel port for the two MPG's :)
The geckodrives are in and I was talked out of using the old motors (thanks Art!) So I got new motors from AutomationDirect.com , it is 39.00 for a motor and 9.00 for a 20 foot cable! That is a very good deal because I didn't want to add wire to the motor cable...
Well I am off to start working on the little lathe :)
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Brian,
How is this project comming along?
Arturo Duncan
http://cnc4pc.com
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You are Good! I have the drives in the machine and the breakout board is in place! (BTW the board seems to be working well at this time) I need to get a new computer or have the other one worked on :( I get a checksum error and have not had time to look into it... I will post pics soon as it is starting to look more like a lathe at this time!
Thanks
Brian
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Brian,
Will the new board from Arturo Duncan the C11G control the motor speed on the compact 5, I know it works on the Seig X3 Mill
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Brian,
What's happened to this thread? I guess you've finished your retrofit long ago. Could you post some pictures tell us the results?
Thanks,
Daniel
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I got busy and didn't have time to finishe the project :( BUT I have a friend that finished it for me .. He still has the lathe but I should be able to get back here in a few more weeks! As soon as I have the Lathe back here I will be sure to post a pic or 5
Thanks
Brian
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Brian,
I'll be looking forward to seeing them.
Thanks,
Daniel
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I had been looking for one of these lathes, then in a week I had 2 of them. Im going to sell the CNC, which looks just like Brians in the first photo of this thread. The machine is complete with turret and it all runs. Ive been able to figure out how to do some simple programs on it to test it.
I will be putting it on ebay later this week, but if anyone on this forum wants it let me know, we can save the ebay commission. Its in Maine, and I could deliver it to the CNC workshop, or anywhere along the way.
ron ginger
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I am thinking about doing this in a plugin... I could make a dialog that would do about any toolchanger :) I hope to started that after I get the project that I am working on now done :(
This is going to be a good year!
Brian
Hi Brian,
Did you ever get your hands to do this 'plugin' ?
I am still looking for a simple way to handle my ATC with one Input only, there must be a way but I am not the VB guru to do this.
Macro or Brain, what do you say Brian?
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At this time after working with the other guys on lathe toolchangers I am thinking about using a Stepper to run my toolchanger ;) That seems like a better system in the end... Also I think you need to have an input to rezero the toolchanger when you start the machine... Ron Ginger has this all working and will have ti at the workshop so we can play with it and see how it works ;)
Thanks
Brian
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I think you need to have an input to rezero the toolchanger when you start the machine...
Why is that so? If you leave your toolchanger always with tool#1 you only need one input. You can also use a switch/relay to select either Index pulse or pulse/tool to do your Zeroing.
I have done some tests with G04P3000 and got the changer working perodically, the problem seems to be time. One full revolution is just under 14seconds with the original motor and the index pulse is 0.59sec and each tool pulse are 1.41sec
There must be a way to do this, time is not critical for the toolchange for me. Work on this is ongoing....... ;)
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Yes there is. Use the ModIO to control the toolchanger. ;)
Cheers,
Peter.
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Dear friends,
I have been pushing this idea for a long time now. I have asked for help from our local VB guru Henrik Olsson and now yesterday evening he came up with a new solution, we now have a macro that works to my specs that is one output and one input to control the original Emco ATC with it's original relayboard.
I have been running tests last evening and this morning and so far it has worked well after some adjustments
Enclosed please find the testfile I have used, you need to do some editing to suite your setting in MACH3 and to make it fully functional as M6Start file
Looking forward to here your comments out there and how this works on your ATC's
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Final M6Start macro for my Emco PC Turn 50 is enclosed
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Made some tweaking of the code, this is to be sure tool is locked in place before code is run
New lines added !
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I have a customer that has a EMCO compact 5. He want me to retrofit it for mach3. It has the tool changer that looks just like your. He wanted me to put a bigger stepper motor on it but it doesn't look like a motor at all. Is that a solenoid that rotates the changer? If so what is the voltage, AC or DC and the amperage required. If anyone else has an answer that would be fine.
Dan
Newfangled has just got there second CNC lathe It is a Compact 5 made by Emco and will be used to test software. The cost of the lathe was $900.00 and is in running condition! When I say running I
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Hi Dan,
Sorry to say but I have never seen Emco ATC that is solenoid driven, the one I have been playing with is DC driven with toolchange rotation clockwise seen from the chuck and locking counterclockwise with a ratchet/pawl. If you have the original mechanics I suggest you stay with the original setup as intended as you will get problems with the gearing ratio so the stepper will probably not hold the tool in position without mechanical aid = reversing - using the ratchet/pawl for locking up the tool in position.
The macro was written for PC-Turn 50 so it is possible that you have to modify the code. Sorry to say I do not have the lathe anymore so I cannot not help you on this.
The DC motor goes full voltage clockwise and reduced voltage with polarity change in reverse as it holds the tool in position all the time it is powered up, this is how it works on the PC-Turn 50.
Hope this helps
Cheers Bengt
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Do you know what the voltage and current requirements are for the dc motor?
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Do you know what the voltage and current requirements are for the dc motor?
Hi Dan,
I believe it is 24V. I should have a schematic for the toolchanger somewhere.
Cheers,
Peter.
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Thanks. Looking forward to seeing that schematic.
Do you know what the voltage and current requirements are for the dc motor?
Hi Dan,
I believe it is 24V. I should have a schematic for the toolchanger somewhere.
Cheers,
Peter.
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Do you know what the voltage and current requirements are for the dc motor?
On my Emco Compact 5 it is a 12VDC motor. I used two relays to switch the power polarity to the motor in correspondence to a signal from Mach3. The reverse polarity being simply fed through a resistor. I used a slotted disk on the back of the turret shaft and an optical sensor to count the tools, and I have simple macro to control this.
Daniel
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You are correct. I checked the toolchanger with a 9V battery and I see that it runs one way into a stop and the other way continuously. There are no other wires for sensors to determine what position the tool changer is in. So it looks like I would have to add the optos.
Thanks for the info. Would you please email me the macro you used for the tool changer and do you have a schematic of how you set up the two relays?
TIA
Dan
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Dan,
Tell me to which email address you want me to send you the macro.
Daniel
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Email the macro to dmauch@seanet.com
Thansk I appreciate this.
Dan,
Tell me to which email address you want me to send you the macro.
Daniel
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Just emailed it to you.
Daniel
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Hi to all,
I think I am Dan customer. Anyway if I am not, I am in the same position. I do have that kind of lathe with tool changer and I want to retrofit to be driven by Mach3.
I intend to use one of Dan units (G540). What else do I need?
Seems the biggest problem it is that motor on tool changer. What do you guys recommend in order to have a proper working machine?
RGDS
Gabi
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Hi Gabi,
If the motor is a DC motor keep it and make suitable controller for that.
The PC Turn50 that I had was controlled DC motor, I have sent drawings, pictures and schematics to Dan. The macro can be found here at this forum.
Cheers Bengt
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Hi Bengt,
Can you send my that drawings, pictures and schematics to me? My address is: balsanu_gabi@yahoo.com. In the emco Yahoo group it is a guy Robin (very nice guy) which has converted his lathe and tool changer too for Mach3.
http://www.youtube.com/watch?v=PEaIpP7XOkg&feature=fvw
That I try to do.
Thank you in advance
RGDS
Gabi
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Well that is with a stepper motor he is using, I think that one is easy to do and if there is a macro to run it so go for it. PC Turn50 was factory made with slotted disk and a controllerboard built in to the original controller cabinett.
Here you have to make your own disk so it is easier to use a steppermotor. You get much faster tool change with the stepper motor approach.
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Exactly. i intend to buy from Dan his G540 unit with 3 motors (X,Z and tool changer). What else do I need?. How can I connect that optical sensor (with that slotted disk) with Mach?
RGDS
Gabi
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Tak a look at the macro that guy is using, there you can see what port or ports he is using. Have you contacted him to get some pictures or can you see on the video how many slots there is. One is OK and do some math from that index. Look at the macro.
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Here it is that macro. I think that was made it by Graham but maybe I mistake. That disk has only 1 slot. Where I can find that DRO code for Mach?
Macro:
' Boxford 160TCL Toolchanger Macro.
'
' Works by turning CW to just past the tool position
' and then CCW into a stop.
' Axis setup as rotary e.g. move 360 = 1 full turn.
If IsLoading() Then
' Do Nothing, program loading
Else
' Dim Variables
Dim Num_Tools As Integer
Dim CW_Steps_Per_Tool As Integer
Dim CCW_Steps As Integer
Dim HoldingDRO As Integer
Dim Requested_Tool As Integer
Dim Current_Tool As Integer
Dim CW_Feed As Integer
Dim CCW_Feed As Integer
Dim moves As Integer
Dim total_move As Integer
' set up some vars
Num_Tools = 8
CW_Move_Per_Tool = 360/Num_Tools
CCW_Move = 10
HoldingDRO = 1050
Requested_Tool = GetSelectedTool()
Current_Tool = GetUserDRO(HoldingDRO)
CW_Feed = 1500
CCW_Feed = 1000
Current_Feed = GetOEMDRO(818)
' start tool change
Message ("Requested Tool No=" & Requested_Tool)
If Requested_Tool > Num_Tools Then
Message "Requested Tool No. too high, program stopped."
Code "M30"
End
End If
If Requested_Tool < 1 Then
'Message "Requested Tool No. too low, program stopped."
Code "M30"
End
End If
If Requested_Tool = Current_Tool Then
' do nothing
Else
' lets do some changing
If Requested_Tool > Current_Tool Then moves = Requested_Tool -Current_Tool
If Requested_Tool < Current_Tool Then moves = Num_Tools - Current_Tool +Requested_Tool
total_move = (moves * CW_Move_Per_Tool)+(CCW_Move/2)
Code "G01 x-10 F1300"
Code "G0 z-10"
Code "G91 G94" 'incremental & Feed per minute
Code "G0 A" & total_move '& "F" & CW_Feed
Code "G0 A" & "-" & CCW_Move '& "F" & CCW_Feed
While IsMoving()
Wend
SetCurrentTool Requested_Tool
SetUserDRO HoldingDRO, Requested_Tool
Code "G90" ' back to absolute movement
Code "F" & Current_Feed
End If
End If
' end of tool change
RGDS
Gabi
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bump
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I have modified both an Emco 200 turn and an Emco compact 5. The turn 200 is full house, having the following: 8 station tool changer, parts catcher, pneumatic collet chuck, pneumatic tail stock and hydraulic bar feeder. The machine runs from Mach 3 but uses 2 break out boards. The sensors in the tool turret have been replaced with four 5mm proximity switches and I put together a macro (M6Start) that only requires the normal Mach tool number and offset code e.g. T101 for tool 1 offset 1. The sensors in the turret give the tool position in binary and the 24vdc motor is switched into reverse with 2.8vdc from a regulated PSU. This voltage will put the maximum wattage into the motor that will allow it not to burn out. The main drive motor was changed to a VFD controlled 2.2 kilo watt motor and the speed controlled by Mach 3.
OEM Macros were also written to control the pneumatics and hydraulics.
The Compact 5 followed the same system, but the turret was modified and 3 proximity switches, to give the correct binary, were fitted to it. The same M6Start macro was adapted to provide for 6 positions, The original moter on the turret was missing and it was replaced with a generic part (Currents might differ from the original so I will refrain from publishing the ones I use0)
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Hi Myford,
It certainly sounds like a very interesting project that you have undertaken.
If you have the time it would be nice if you could start a new topic on your Emco machines with some pictures and more detailed descriptions / explanations on how you have made everything work with Mach3.
Tweakie.