Messages

1

Show"N"Tell ( Your Machines) / Re: My Shizouka AN-S

« on: August 26, 2015, 07:48:35 PM »

This is faster than the original?  I never saw it run with the original drive.

I tell it how many steps to run, then I double check the position with a prox sensor that reads the sprocket teeth.  That way it compensates for any backlash in the system or lost steps.  The prox is hiding under the gearbox.

2

Show"N"Tell ( Your Machines) / Re: My Shizouka AN-S

« on: August 25, 2015, 05:53:03 PM »

I have the tool changer working in full auto now.  All under Galil control.  Now I just need to get Mach3 to tell it what tool to grab next, and when.

Here's a YouTube video of it in action https://youtu.be/pHRFHeFeNcY

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Show"N"Tell ( Your Machines) / Re: My Shizouka AN-S

« on: August 15, 2015, 06:09:46 PM »

The switches are connected to the computer and the outputs are from the computer that drive the valves.  I did it this way so the computer can handle the tool change as well as operating manually.  When the TC is in manual mode, the buttons are available for use, when the TC is in AUTO control is only by the computer. When in OFF, none of the TC, PDB works.  There is a TC Manual subroutine running in thread 0 on the Galil controller.  I use thread 0 running in a continuous scan for all of these types of functions, as well as E-stop and other error monitoring.  The Auto TC sequence will run in it's own thread when called by Mach3.

The buttons/switches are

Tool In, BP
Tool Out, BP
Spindle Brake On/Off, 2 Pos, Sel Sw, Maintained
Auto/Off/Man, 3 Pos, Sel Sw, Maintained
Claw Open/Close, 3 Pos Sel Sw, Spring return, Center Off
Arm Tool/Spindle, 3 Pos Sel Sw, Spring return, Center Off
Turret CW/CCW, 3 Pos Sel Sw, Spring return, Center Off

4

Show"N"Tell ( Your Machines) / Re: Controlling five diffrent steppers off of one axis

« on: August 12, 2015, 09:34:31 PM »

I know this is an old thread but I'll answer anyway.

To do what you want would require five 4 pole (one pole for each wire) relays that could be switched on to power up the individual motors.  This could be controlled with a simple 5 position (SP5T) rotary switch.

Now the problem...You don't want to disconnect or reconnect the motor when under power, it would likely fry the drive.  When switching between motors you would have to power the drive down, switch to another motor, then power the drive back up.

5

Show"N"Tell ( Your Machines) / Re: My Shizouka AN-S

« on: August 12, 2015, 06:34:34 PM »

The TC alone on mine has 7 solenoids - Master Air, Arm In, Arm Out, Air Retard (cushions the arm during tool out), Claw Open, Claw Close, and PDB Engage. The spindle brake solenoid is mounted inside the main casting, along with a Master Air and Hi/Lo gear solenoids. I've not managed to get any details of the TC solenoid valves themselves as they're all shoe horned into where you've mounted the relays, but the solenoid coils are 220V, and everything points to them being a mix of normal 2/3 and 3/5 valves.

You are spot on.  I should have been more clear, my fault.  There actually were 7 solenoids as you described.  I counted valves rather than solenoids.  The Arm and Claw valves both have 2 solenoids.  I removed the Air Retard valve, not needed IMHO.  The PDB engage, and spindle brake still exist.

6

Show"N"Tell ( Your Machines) / Re: My Shizouka AN-S

« on: August 12, 2015, 01:55:23 PM »

We ripped out all of the control wiring for the TC (and everything else on the machine for that matter). There are only 2 solenoid valves that control the TC, one for the clamp, and one for the arm.  This machine had 2 additional solenoid valves that I think controlled the speed of the arm in various parts of the cycle, those came out also.

The solenoid valves are maintained position valves, and only require a 200ms pulse to shift.  Not the best control scheme, but it works.  There are 4 switches that are important, the arm in position limit switches (spindle and tool), and the clamp open & closed pressure switches.  There is one additional limit switch that reads some mid-position of the arm, not useful in this application.

We used small PLC relays with low current, 24VDC coils to interface with the Galil controller.  The relays are also available in a 5VDC coil depending on your needs.  All of the control code is in the Galil controller.  As soon as I figure out how to do it, Mach3 will send a tool change request to Galil, and Galil will fire back a ''OK, I'm done'' message when the tool change is complete.

I think your KFlop has the same capabilities as the Galil, it just programs in C or C++ rather than DMC code.

The relays are the little black modules on the panel, these are in banks of 4 relays.  Only 4 are used for the TC.  The red solenoid valves control the TC, the other 3 valves control the spindle brake, the power drawbar, and the one on the lower right dumps the air pressure to the TC manifold on E-stop.

7

Galil / Re: Galil Error 22 Begin not possible due to Limit Switch

« on: August 06, 2015, 07:51:13 PM »

OK, I figured it out. I'm running a 4080 controller, and had D(W) and E(A) axis enabled in Mach3.  Neither of which have the limit switch inputs wired in.

D axis is reserved for future expansion of a rotary axis.  E axis is the tool changer and is not under Mach3 control.  E axis is operated via DMC code resident on the 4080.

Since the limit switches are set for Active Low, and not being pulled high, it looked like they were tripped.  I disabled the axes in Mach3, and my problem was resolved.

8

Galil / Galil Error 22 Begin not possible due to Limit Switch

« on: August 06, 2015, 05:35:08 PM »

OK, no matter what the configuration is, when I try to run G-code I get the LS error.

It works fine in jog from the keyboard, also I am able to jog from Galil Tools.  My MPG that is wired outside of Mach3 works just fine, Mach3 doesn't even know it's there.

Motors and encoders are all running the same direction, no problem there
Limit switches are wired Active Low, Galil is set to CN0=1
Active Low boxes are checked in the Galil Configuration
Debug file shows a CN 1 is being sent on startup
Again Keyboard Jog works fine

I have tried every possible configuration in the Ports and Pins config, including removing all reference to the limit switches.
I have also tried un-checking the Active Low boxes in the Galil config and tried every possible configuration in Ports and Pins

Again, everything works until I try to run g-code, and it still works after I try to run g-code.

Any ideas?

Thanks, Jim

9

Galil / Re: Galil / Mach3 communications

« on: August 05, 2015, 02:23:23 AM »

Hi Jim,

That's interesting, that is exactly the mill I'm working on.  It's a small world. And I built a new gear box with a stepper drive to drive the chain.  I looked at the original TC controls and decided that it was a nightmare.  I just ripped out all of the original control box & wiring and half of the valves, then wired everything into the Galil 4080 controller.  All of the hardware works under manual control, but I have not written the Galil program yet, that's the next phase of the project.  So in my case all I need is a signal from Mach3 that gives me the tool number and says ''change the tool''  then I'll fire back a ''tool is changed'' signal to Mach3.

If you want drawings of the gear box I'll be happy to post them, or send them to you.

(I hope it's OK to post a link here  )
You can see the build at http://www.hobby-machinist.com/threads/shizouka-an-s-build.33868/

Jim

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Mach4 General Discussion / Re: New people welcome !! Come in here and introduce your self!

« on: August 05, 2015, 01:40:20 AM »

Hello All.

I joined this group because I'm helping another member (alloy) do a CNC upgrade on his Shizouka AN-S milling machine.  Alloy wants to use Mach3 / Galil controls.  I have about 20 years experience with Galil hardware and programming, but have minimal experience with Mach3.

I'm a semi-retired controls engineer, tool&die maker, machine designer/builder.  I've done a number of CNC conversions using both servo and stepper systems, in addition have a extensive background in motion control for other uses.  These days I just kind of putter around in my shop, turning perfectly good metal and wood into chips and saw dust.  I also spend a lot of time hanging out at The Hobby-Machinist forum.

Right now the Shizouka AN-S moves under it's own power, and we have control over the servos from the Galil Tools screen, and the MPG.  Also the DRO on the Mach3 screen works fine.  That's as far as we have gotten so far.  Next will be integrating the tool changer.

As the Shizouka AN-S project progresses, I will be asking questions as I get stuck, and will be counting on the members here to bail me out   If I see questions come up on this board that I can help with, I'll be more than happy to jump in with my $0.02

Jim