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Messages - jrslick22

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151
Show"N"Tell ( Your Machines) / Re: AL54b (lathe) project from New Zealand
« on: November 07, 2010, 04:24:02 AM »
For those of you who have not yet worked it out, yes that gaping big hole in the middle is for all of the chips, the plan is to have some kind of bin under the machine that I can empty every so often, i have to work out how to get the coolant out of the bin and into the tank which will also be underneath. I have bought a tank and pump already but have not yet decided if ill keep the tank, its sort of tall and small generally.

152
Show"N"Tell ( Your Machines) / Re: AL54b (lathe) project from New Zealand
« on: November 07, 2010, 04:11:57 AM »
You can see in this next picture that I have the wheel plates welded up and the wheels bolted on, also i have removed the gearing off the old motor system. Originally the machine was set up with 6 different speeds 125rpm to 2000rpm. I managed to find a brand new 2hp 3ph motor for $70NZD ($50US) with a native rpm of 1400, this was the slowest i could find, there were some 3hp motors for around the same price but i was worried about the physical sizing.
So why did i choose 1400rpm, with the vsd ill be able to slow it down to what ever speed I want, I was however worried about the cooling of the motor at low speeds as well as the torque I figure the closer to the native rpm of the motor the better for cooling. If i want to go faster I can gear it up some, ill be running at top speed so cooling wont be a problem and with twice the motor power torque shouldn't be a problem ether.



For some reason i can edit my first couple of posts, if someone can help me with this i have resized the images.

153
Show"N"Tell ( Your Machines) / Re: AL54b (lathe) project from New Zealand
« on: November 07, 2010, 03:36:41 AM »
After thinking about it a lot and spending way to much time looking at pictures on the Internet i have decided that it will be a fully enclosed machine, this way i don't have to worry about the coolant or the chips getting out or the dust getting in (I share the floor with a woodworker).

This is a work in progress so don't be surprised if something changes.

Here is the new stand with coolant drain:



154
Show"N"Tell ( Your Machines) / AL54b (lathe) project from New Zealand
« on: November 07, 2010, 03:27:48 AM »


280mm X 750mm
1hp
12mm tool height
Headstock MT4
Tailstock MT2

So they say the best way to learn is to do. I and suspect most of you learn by puling something to bits and in the process of trying to put it back together add a few things here and there for kicks and giggles.

I managed to pick up this lathe on the cheap because a customer the supplier had puled the motor of it as a replacement for a customer, this suited me great as it was my intention to replace the standard 1hp 1ph (240v) motor with a 3ph motor and a vsd.

I brought this machine mostly because I really needed a lathe for general use in the shop, I love guns so brought it long (they do a 500mm version as well) with the intention of fitting barrels in her.

Picked up the lathe at 10am back home by 1pm had it in bits by 1:05pm




155
What an awesome project log, thank you very much for sharing, you have inspired me to get cracking with my machine.

I am going to attempt to hook my vsd up to mach using RS485 like you have, i have brought a USB to RS485 converter. Can you please explain the maths behind setting the  Max ADC count to 10000? any other info you have on making this happen would be appreciated.

Keep up the good work.

First off, Modbus in Mach3 ROCKS (they should sell it as an add on for $50.00)  

We are lucky that our BP412 has a 6000 RPM 10Hp Fanuc Spindle Motor.  The down side is it will take a LOT of power to just to run the Spindle and finding a VFD to run a 10Hp motor with single phase input power might be a challenge.  

We ended up using a SpeedStar PC-75 (yes the means 7.5Hp), they make a 10Hp one, but the power input requirements for 10Hp is 220VAC at 72Amps, even the 7.5HP has a max power draw of 54Amps (I only have 50Amps dedicated for the Machine, hoping to keep up under 40Amps).  Also the Spindle Motor is rated at 200VAC, so the VFD Parameters were adjusted to limit the output voltage to 200VDC.  This thing is a monster, as shown in the picture.

The VFD support 485 Modbus, so can set the target frequency and monitor the current speed and power draw of the spindle in real time and display it on our Mach3 Screen!  Getting the Mach3 Modbus working was fairly easy after watching the videos, but getting the VFD Speed integrated into the Mach3 system  was guess work i.e. “M6 T1 S3000” (Note: for now I only running the Spindle at a MAX of 3000 during this testing phase, we’ll crank it up as my confidence grows in the system)  The key things to get it integrated, is to the Max Speed in Pulley to 3000 RPMs and the MAX ADC Count (for our VFD, that means MAX output frequency 100.00Hz = 3000 RPMs)


Here is a test video of Mach3 Controlling the VFD while Monitoring Speed and Motor Amperage:

<a href="http://www.youtube.com/v/QUB8hFWrnfw&amp;hl=en&amp;fs=1&amp;rel=0&amp;color1=0x006699&amp;color2=0x54abd6&amp;border=1" target="_blank" rel="noopener noreferrer" class="bbc_link bbc_flash_disabled new_win">http://www.youtube.com/v/QUB8hFWrnfw&amp;hl=en&amp;fs=1&amp;rel=0&amp;color1=0x006699&amp;color2=0x54abd6&amp;border=1</a>

Below are Pictures of the VFD, Motor Plate and Mach3 Config Screens


156
Finished Screens / Re: CNC Cut to length Saw Screen and Wizards......
« on: October 30, 2010, 05:07:10 AM »
Great screen set, almost perfect for what I'm after a little feedback for you.

The display screen (top right) is almost useless as the tool path is a straight line, it is handy to see the z axis coming up and down however for diagnostics. If i may suggest making this section tall and skinny. with the space that has been created it would be great to have an indicator working its way down a  cutting list. this would make it so that people with no knowledge of Gcode could keep up with what is going on.

Would be very handy in the length wizard for a numerical pop up window to appear when entering length and amount data so that us touch screen users could run the entire session without the need for a keyboard or mouse.

Great job keep up the good work.



 

157
General Mach Discussion / Re: Can Mach do this? Bar feed
« on: October 29, 2010, 06:31:34 AM »
I just found popabears screen set here http://www.machsupport.com/forum/index.php/topic,4076.0.html
The screen set is designed for bar feeders that are roller driven so they never run out of travel lke a ball screw does.
It would be great to have this feature added to the screen set, unfortunately i do not currently posses such skills.

158
General Mach Discussion / Can Mach do this? Bar feed
« on: October 29, 2010, 06:12:42 AM »
Does anyone know how to get mach to do this?

I am building a bar feeder, I have a pneumatic clamp mounted on the end of a ball screw with a stepper (rear clamp), the ball screw is 800mm long, if i want the feeder to feed 400mm of bar i acivate the rear clamp (on) deactivate the main clamp (off) the dive the axis 400mm pushing the bar through when it reaches 400mm the main clamp engages, the rear clamp disengages and the stepper returns to home simple enough.

Now for you mach experts out there, what if i want 1000mm of bar? yes i can write soe code that runs 800mm through as a first cycle then an additional 200mm. What i am looking for it a real trick way of being able to enter the required length (1000mm) into a dedicated region on mach called bar length and have mach work out how many cycles it needs to run in order to achieve the desired length.

any help would be appreciated.

thx.

159
Well, a couple things you haven't mentioned that I use on my machine are coolant and vacuum. It's also a good idea to leave yourself a couple extra switches or buttons for future ideas.

 I never thought of putting a spindle control and Vacuum buttons on the front. good idea! My mill will be used for PCB milling and light rack panel engraving and small holes so I probably wont need a coolant but I was planning on putting some Solidstate relays inside for spindle control and vacuum control under software control but I could easily add 2 extras with front panel controls. great idea!

@Hood
 wow nice mill control! love that keyboard! Thanks for the suggestions. I guess i need to learn a bit more to understand what half those buttons would be for. But thanks for the tips It gives me direction to research. One thing i see that I love on the bottom picture is a meter that says spindle load! Ohh i love that idea. My spindle motor is a dremel tool and I could easily add a current meter and a speed control on the front panel.

Is it really that simple, put a ammeter on the spindle motor? what if its 3 phase?

160
If anyone needs a little more help with this see http://www.machsupport.com/forum/index.php/topic,15425.0.html

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