Messages

261

Show"N"Tell ( Your Machines) / Re: Denford Cyclone retrofit

« on: October 28, 2013, 08:40:42 PM »

Ok, I think I've finally cracked the ladder logic. The proof will be if it actually works...
I still need to add a couple additional timers to trigger a fault and disable the motor/solenoid if the turret fails at any point during the move.

The annoying thing is, I got an email from Dynomotion this morning telling me all about their new Konnect IO expanding board, which would of given me more than enough IO to handle what the PLC is handling. If only it had of been available a couple weeks ago when I ordered the PLC!
Only thing I'm not too keen on is the price of the Konnect as it's $199, which puts it at roughly twice the price of a CS IO module for an identical number of IO's.

262

Show"N"Tell ( Your Machines) / Re: Denford Cyclone retrofit

« on: October 27, 2013, 07:41:16 PM »

After several hours trying to figure out the ladder logic for the turret, I have come to the conclusion I hate ladder logic.

I can appreciate it's uses, but what could take a couple lines of reasonably simple code in a microprocessor, takes far too many rungs and holding variables and contacts. Plus it's a nightmare to move things around when you need to change things. I'm probably not helping myself by programming for the turret to spin both directions, but even the locking for one direction gets a bit complicated.

263

Show"N"Tell ( Your Machines) / Re: Denford Cyclone retrofit

« on: October 26, 2013, 05:42:00 PM »

Finished most of the wiring tonight. I've got 4 stray wires that I need to deal with. One is definetly the lubrication low switch although I may of disconnected it's partner when removing the old controller so that makes two, but I've no idea what the other two are :-/
I still need to tidy up the tool changer wiring as I just used the existing lengths to make sure it was all going to work, and deal with all the other loose odds and ends like getting all the wiring into the trunking.

I grabbed a quick photo with the phone before i headed in tonight-


Getting Tidier by mc_mtb, on Flickr

I've just remembered I still need to find out why the spindle encoder isn't outputting the B pulses.

264

Show"N"Tell ( Your Machines) / Re: Denford Cyclone retrofit

« on: October 25, 2013, 08:03:47 PM »

The IO module finally turned up today.
I've got it in and mostly wired up. The turret locked/thermal switches still need to be connected, and the Click to the Kflop (2 IOs and the serial cable), which I'm aiming to get done over the weekend.
After that, the main thing left is dealing with all the programming. I need to get the ladder logic finished, finish tuning the servos, sort the C code for the KFlop, and get the KFlop talking to Mach.

I'm considering switching the servos to torque mode, as most of the latest debates I've seen about Torque via Speed seem to say Torque gives better performace.


Yes, I ordered the Click via Lamonde. I had to wait for the main module to come from the states aswell.
I could of done the turret directly through the KFlop, however I would of had to make an interface board to make use of the low voltage inputs on the addtional header. I'm going to use the lathe as a bit of a test bed to see how well the KFlop works with a PLC for extending ins and outs, as I'm still undecided on how to handle the matchmaker as it's going to need a good bit more IO. I had been considering some custom arduino boards with modbus and 24V IO, but a couple Clicks may make life a bit easier.

265

Show"N"Tell ( Your Machines) / Re: Denford Cyclone retrofit

« on: October 22, 2013, 05:42:16 PM »

One of the Automation Direct Click PLCs.
Originally picked them for cheapness, but miscounted the number of inputs/ouputs needed, so had to buy one of the additional IO modules. One feature I skipped over during the orignal decision to use a Click PLC, is the Kanalog has a connector designed to connect directly to the Click plus comes with sample code to talk to the Click.

The order is late as apparently the courier has lost the last UK distributor order, so everything has had to be reordered.

266

Show"N"Tell ( Your Machines) / Re: Denford Cyclone retrofit

« on: October 21, 2013, 08:34:53 AM »

I've managed to get the new home sensors wired in. I still need to test/adjust them, but they're both in ready to go.
The X-axis servo is now bolted up, and ready to go.

All wiring outwith the control cabinet is now in place. It's just a case of securing the servo wiring, bolting the Z+ limit switch (the home switch is mounted onto the switch block) back on, and putting the various covers back on.

I'm still waiting for the additional IO module for the PLC so I can get the tool changer wired in, but the majority of the wiring is in place already for that. It's just a case of connecting up the turret sensors/control cable and the contactors.
Other than that, I just need to finish wiring in the servo fault relays so the drives all stop on a fault, and connect the KFlop enable relay into the E-stop circuit so nothing powers up until the KFlop has booted.

Nothing much will happen this week though, as I'm away until friday on a training course.

267

Show"N"Tell ( Your Machines) / Re: Denford Cyclone retrofit

« on: October 13, 2013, 06:43:30 PM »

Managed to get the Z-axis motor bolted on during the week, along with various bits of wiring. I ran the auto-tuning for it today which shaked things about a bit, but not anywhere near as much as hitting the step button in the KFlop step response screen. I had meant to hit the move button, but clicked the wrong button, which resulted in moving the servo motor a quarter turn and back again as quickly as possible.

I went to connect in the home sensors, but turns out they're NAMUR output which means there's no easy way to connect them into the KFlop, so I'll need to order some new ones.

I got the spindle wired up today, and tested it. Spins up nicely, however the encoder doesn't appear to output B signals, just A and Z despite the label and wiring having the full compliment. I'll need to get a scope on the extra wires and see what's happening. I'm not too bothered about the lack of B, it's just I'll need to figure out how to set-up the KFlop to handle it.

Also spent some time removing all the remaining extra bits and wiring, and the cabinet is looking neater already -

Looking Neater by mc_mtb, on Flickr

I started to finish of the X-axis motor mount, but can't find a suitable tap, so I can't get the X-axis bolted on until that turns up.
And I'm still waiting for the additional IO module for the PLC to turn up.

268

General Mach Discussion / Re: Machanical Automatic Tool Changer

« on: October 10, 2013, 06:44:06 PM »

KFlop is the main controller board with only low voltage inputs/outputs, and the Kanalog is essentially an add-on board that provides analog inputs/outputs, aswell as relay drivers (8 x 80Vmax outputs) and 8 each of 24V tolerant inputs/outputs.

The main difference between the CSMIO's and KFlop, is the CSMIO is essentially setup through Mach, whereas the KFlop has it's own configuration (and CNC) software.
For basic operation KFlop setup involves configuring axis via it's own dedicated software, then copying the generated C code into a init.c file which is then linked to Mach. Anything that relies on critical timing (i.e. such as homing where motion has to be controlled quickly on a switch change) or custom functions, have to be coded in C. There are lots of examples included with the software (you can download it from the dynomotion website and have a look at it), and Tom Kerekes provides brilliant support for any queries.
However, if you're not comfortable dealing with C code, it's maybe not the bext option for you.


As for testing drives, a simple method Tom Kerekes recommends, is a 1.5V battery combined with a 1k resistor. Connect them in series to the drive analog input, and see if the motor spins. The low voltage means things shouldn't suddenly take of, and the combination with the 1k resistor should minimise the risk of damaging anything by connecting things wrong.

269

General Mach Discussion / Re: Machanical Automatic Tool Changer

« on: October 08, 2013, 11:59:59 AM »

Think the Kflop is 3.3v but the kanalog may be 24v, not sure on that, if not you will likely need extras to interface..

KFlop is a mix of 3.3V and 5V tolerant (i.e. will only source 3.3V, but can withstand 5V input). The Kanalog can handle upto 24V through the optos, or 80V through the FET relay drivers, however the biggest drawback I find is the Kanalog only has 8 opto inputs. It does have other inputs available via a pin header, however they're low voltage. It also has eight 0-10Vanalog inputs, which you could probably use for digital inputs with a little bit code.

270

General Mach Discussion / Re: Mach4 question

« on: October 08, 2013, 11:54:31 AM »

As others have said, although not to clearly, is Mach in either form is not the limiting factor. The limiting factor is the hardware being used to generate the steps.
A computer printer port is only good to 100kHz, but reliability at anything above the lower settings (33 & 40Khz?) can be an issue.

What you need is some form of external controller, such as a SmoothStepper which is good to 4Mhz. Another possible options that I can think of are a KFlop, or a CS-Lab whatever (CSMIO?), but there are others offering various features.