CNC router build

	Attention: Dangerous machine ahead
	Use only at your own risk, and after proper instruction!

   

CNC Mill Release status: experimental [box doku]
Description
Author(s)	Tarwin
Last Version	v0.1

We want to use the big-ass CNC portal Thomas rescued from the trash to build a CNC router.

Goals

• Mill Aluminium!
• route PCBs
• be open for extensions, easy tool change

Hardware

Motor System

X & Y Motors

• Berger-Lahr VRDM3913 50LNBOO

Z Motor

• Berger-Lahr VRDM368 50LNBOB
  • brake needs 24V to loosen, works.

Motor controllers

• 3x JMC 3M860 -- Manual: File:3M860.pdf

Power supplies

• 3x 70V 400W from China

Motor cabeling

Z axis

• 1 = U
• 2 = V
• 3 = W
• 4 = NC
• 5 = break brown cable
• 6 = break white cable

X axis

• 1 = U
• 2 = V
• 3 = W
• 4 = NC
• 5 = NC
• 6 = NC

Endstops

X & Y

• Type unknown
• Seems to be an Solid-state Auto Switch, not just a Reed sensor, same pinout as the SMC

Z

• SMC D-F9H
  
  (datasheet) (Solid-state Auto Switch, works like a PNP transistor)
• Omron EE-SX870p Photomicrosensor (datasheet)

Electrical

• all endstops can be driven with 5 to 24V.
• Pinout is: brown: VCC / blue: GND / black: Signal
• Pinout on X: brown: VCC / green: GND / white: Signal
• all have a red led which goes out if they sense something
• Some input here

Endstop RJ45 connector

1. - Signal Z-
2. - Signal Z+
3. - VCC (5-24V) (Brown)
4. - Signal Y-
5. - GND (Orange)
6. - Signal Y+
7. - Signal X+
8. - Signal X-

List Left Sub D 25 Pol connector

1. - 1 Red Cable Driver X
2. - 2 Black Cable Driver X
3. - 3 Green Cable Driver X
4. - 4 Gray Cable Driver X
5. - 5 Red Cable Driver Y
6. - 6 Black Cable Driver Y
7. - 7 Green Cable Driver Y
8. - 8 Gray Cable Driver Y
9. - 9 Red Cable Driver Z
10. - 10 Black Cable Driver Z
11. - 11 Green Cable Driver Z
12. - 12 Gray Cable Driver Z
13. - 13 Free
14. - 14 Endstop Blue Cable RJ45=4 -> Signal Y-
15. - 15 Endstop Blue/White Cable RJ45=5 -> GND (Orange)
16. - 16 Endstop Orange Cable RJ45=2 -> Signal Z+
17. - 17 Endstop Orange/White Cable RJ45=1 ->Signal Z-
18. - 18 Endstop Green Cable RJ45=6 ->Signal Y+
19. - 19 Endstop Green/White Cable RJ45=3 ->VCC (5-24V)(Brown)
20. - 20 Endstop Brown Cable RJ45=8 -> Signal X+
21. - 21 Endstop Brown/White Cable RJ45=7 -> Signal X-
22. - 22 Free
23. - 23 Free
24. - 24 Free
25. - 25 Free

List Right Sub D 25 Pol connector

1. - 1 Not Halt Ader 1
2. - 2 Not Halt Ader 2
3. - 3
4. - 4
5. - 5
6. - 6
7. - 7
8. - 8
9. - 9
10. - 10
11. - 11
12. - 12 Bremse Ader 5
13. - 13 Bremse Ader 6
14. - 14
15. - 15
16. - 16
17. - 17
18. - 18
19. - 19
20. - 20
21. - 21
22. - 22
23. - 23
24. - 24
25. - 25

Handwheel

Bought from AliExpress, [page]

Pinout:

    1  GND
    2  +5V
    3  A+
    4  B+
    5  A-
    6  B-
    7  Emergency Stop (pin 1)
    8  Emergency Stop (pin 2)
    9  LED+
   10  LED-
   11  COM
   12  X
   13  Y
   14  Z
   15  4
   16  x1
   17  x10
   18  x100

Encoder Wheel

The wheel needs a +5V power supply, and outputs a slightly lower voltage on A+/B+/A-/B-. One step of the wheel goes through a full cycle. This is not a regular switch, so no connection can be measured.

Emergency Stop

This is a standart Mushroom Knot

Inside are 2 simple normally closed switch.

one is connected to the control unit to stop the program

the second one is connected with the power switch so if pressed the Power for motors and spindle will be switched off ( power for the control unit stay on)

Spindle

Connector Pins = Cable

1 = 1 2 = 2 3 = 3 4 = PE

Cable = controller side

Cable 1 = U Cable 2 = V Cable 3 = W PE Cable = E

LED

A red LED, 20mA standard current drive.

Selection Switches

These switches are connected through the "Enable" button on the left. No signal is received unless the button is pressed.

The X, Y, Z and 4 pins are connected to COM when the respective axis is selected, and the enable switch pressed.

The x1, x10 and x100 pins are connected to COM when the respective speed is selected, and the enable switch pressed.

Controller

-> CNC_router_controller

Manuals for CNC Controller:

• File:CNC Controller.pdf Handsteuerung
• File:CNC Controller use in Mach3 Mill and Pin-Out.pdf Description of Pins of the controller board and how to operate it within Mach3 Mill
• File:Controller Board Relay Output Wiring.pdf Information for connecting the spindle to a relay and the controller
• File:Wiring for Endstops and Emergency Stop.pdf How to wire the endstops and the emergency stop
• File:PCI-Parallel-setting.pdf windows settings for using the parallel port

Software

CNC_router_software_eval

Sub-projects

Fix up portal

• The portal needs to put together and fixed up
  • Put portal together, replace belt - done
  • identifiy / Test endstops - done
  • Build portal frame - in progress (Thomas E)
  • Try Z axis brake - done

Frame and table

• The X Axis is raised, the linear bearing runs far above the tool head. This implies a high center of gravity.
• Frame needs to be very stable
  • Old workbench?

First draft:

Tool head

• needs to be powerful (Aluminium) and precise (pcbs)
  • Find matching Spindle with driver and cooling - done
  • Bought this: 2.2kw wassergekühlte Frässpindel
  • This can be controlled manually on the inverter or over serial.
  • needs its own fuse and a fault current fuse (FI Schutzschalter)
  • Technical data:
    • 2.2kW / 8,000 - 24,000 RPM
    • ER20 spring collets (Spannbuchsen)
    • Driver: HY02D223B
    • water cooled

Software & Controller

• What will tell the drivers what to do? PC/parallel port, Mikrokontroller, old CNC hardware, ...
• Hardware? What do we need?
• Main page for this: CNC_router_software_eval

Pictures

Last picture of the portal before it ware put apart and brought to the space