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  1. #1
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    Design & Build of Frankenrouter

    Evening all - I have started designing Frankenrouter. It will use up some (hopefully all) of the bits and pieces I have accumulated while building a few machines. Frankie will be 2900mm long and 700mm wide. So its a "long" half sheet machine. Haven't decided on the Z height yet. It will be made from ply and aluminium. Some parts will be ply laminated with aluminium. The gantry maybe cast CSA cement. Early days. So I have blocked out some geometry and details in CAD. Will develop it over the next few weeks... The mantra is make everything myself, spend as less $$$ as possible. I need a long machine for making future gantry moulds. I have been very impressed by the stiffness of the high rail mdf base I made for BrevisHD/YaG on another thread. Since its long I thought it would go up against a wall quite well, use the high rail at the back and a low rail at the front for easy loading of material.... Will use round rails as these are cheaper and I'd like to see what they are about. The Z axis will be square rail as I have that. Plus depending on the length of the gantry I may have square for that. It will be driven by 10:1 N17 steppers using 10mm AT belts from another router I have. The z will be a ballscrew I have.. So I'm breaking down a router called Brevis-3 and mashing it up with surplus parts to create Frankenrouter. Will have to wait for a lightning storm to enliven it... Peter

  2. #2
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    Re: Design & Build of Frankenrouter

    Hi All - I have been thinking about building parts from laminated ply and aluminium. This would give me geometry flexibility and the ability to mill in various features that an AL tube lacks. So I modelled an AL tube 120x120x5 by 1000mm long and loaded it in combined bending and torsion. I also modelled a ply version and a ply Al laminated version to compare with same outer dims. The AL tube is the stiffest and lightest but the hybrid is 80% the efficiency of the al tube. That's close enough for this purpose. I can either epoxy the aluminium on the outside of the beams or recess it in so the parts are smooth on the outside. Will figure that later. Peter

  3. #3
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    Re: Design & Build of Frankenrouter

    Hi All - I was wondering which way to orient the wall webs. l So I made a quite model. Intuitively I would say vertical and that's what it worked out with. Having them vertical is about twice as stiff as having them horizontal. ie have the webs in the plane of the bending... Peter
    Attached Thumbnails Attached Thumbnails shear beam.jpg  

  4. #4
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    Re: Design & Build of Frankenrouter

    Evening all - I have started chucking in the parts I have. I have to measure up a couple of the square rails from Brevis. Its the machine I'm breaking down. I have taken the electronics from Brevis2 and migrated them to YaG the router I'm building at the moment. The other parts go to Frankie. Coming along, need to sort the 2400mm length, maybe have to have a 3m base to get the 2440mm envelope... Peter

  5. #5
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    Re: Design & Build of Frankenrouter

    Hi All - I have wondered if I should go with aluminium ribs or stay with ply. I'll have to cost that out to decide. I made the ribs a bit taller so I can install the motor "inside" the structure. I'm thinking the saddle to be cast CSA, the z axis plate to be laminated aluminium / ply and the gantry to be ply plated with AL... I have put the 20mm square rails on the z and will measure the other rails I have to see if they are long enough for the gantry. Now I'll have to tune up the envelope and then I can detail it. Peter

    YaG will be building the parts, hopefully get it moving this week... - Peter

  6. #6
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    Re: Design & Build of Frankenrouter

    Evening All - I've decide to stay with the 2400mm total overall length and optimise around a sheet size. So it will be 2400mm length and 700-750mm deep. Will do some more work on the model now YaG is running. Plus we now have a border bubble so materials are easier to get, Yeh! Peter

  7. #7
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    Re: Design & Build of Frankenrouter

    Do you think it is nessecarry with dual drive on the long axis with 700-750mm depth ?

  8. #8
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    Re: Design & Build of Frankenrouter

    Yes Buoyen - I do. Sounds like a marriage.. Peter

  9. #9
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    Re: Design & Build of Frankenrouter

    Morning All - YaG is now fully commissioned and running around the shed. So I can get serious designing Frankie. I'll muster all the surplus parts so I can see whats what. Peter

  10. #10
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    Re: Design & Build of Frankenrouter

    Afternoon - I started mustering parts and while some epoxy was curing started breaking down Brevis#1 and Brevis#2. It hard to pull apart a perfectly functioning machine. I've been putting it off but now Yag/Scoot is running I don't need Brevis. Took less then 1.5hrs to strip it. Took a few days on and off to build it... So B1 will be sent to the paint shop for sandblast and epoxy paint. Then it will be rebuilt with a reinforced saddle and new antibacklash Z nut. Then it will be sold. I thought about migrating the electronics to Frankie but will start that from scratch I'm going to aim at a high voltage system. B2 I'm going to box as a mechanical kit set and try to sell that too. Need the room in the workshop for the new routers including Frankenrouter. Brevis#1 was designed as a demo machine that can be carted around the timber & machinery shows, but they don't exist now. B#2 was built to trial gearboxes and some electronics, all done now... So now back to the drawing board to develop Frankenrouter more.. Peter

    Break Down 1 - B#2 with its motors removed. These will go to Frankie
    Break Down 2 - B#1 starting the pull down
    Brevis 1 - Prior to pull down with new Z nut and saddle, UC100 etc
    Brevis 2 - B#2 prior to pull down with some surplus parts for Frankie
    fully stripped down - B#1 in pieces, sad but the rust was really annoying and I was loosing sleep over it Interesting all the screws in the timber were rusting in the embedded area even some of the zinc plated ones...

  11. #11
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    Re: Design & Build of Frankenrouter

    Hi All - I have done some more work on Frankie. It will be 2400mm long and 700mm wide. The base will be aluminium ply laminate. The rest we shall see. I do have concerns with the cranked gantry but we shall get it along a bit further...Peter

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