[hub]

C5 already has a lead accuracy of .001" over 12" pr 0.008% over 1ft... I think you'll be fine!!!

Yes I agree, my parts turn out very good. Even bearing fits in AL! Just thought to improve "just in case because I can"... ...If it's easy, otherwise I'm fine as is.

[louieatienza]

Yes it's rotary. I was thinking of attaching it to a wheel with rubber coating against the base / Z column.. With some gearing to have it rotate enough for precise enough mapping.
Just my idea so far, not sure how well it would work.

I thonk also if you gear down rhen you're at the mercy of rhe accuracy of the gearset you use, which may skew your readings.

I remember seeing some magnetic encoder on eBay that used regular magnetic tape, pretty high resolution might work for this...

[hub]

I thonk also if you gear down rhen you're at the mercy of rhe accuracy of the gearset you use, which may skew your readings.

I remember seeing some magnetic encoder on eBay that used regular magnetic tape, pretty high resolution might work for this...

It would work better for sure. Just trying to achieve it with what I have, if possible. Also, the machine is accurate enough, so I can't justify extra expenses on this, since it's not a problem really

[hub]

Now that the machine is more rigid, climb milling works better than conventional (for wood). It was the opposite before...
I now have limit sensors on Y-, Y+, X+.. They are at the extreme ends and will signal E-Stop. I'll install a limit sensor override, since now I have to manually turn the screw to enable again.
Never thought I would say this, but the rapids are a bit too fast... Woosh and it's traveled half a meter.. I think I'll change the resolution from 0.002mm to 0.001mm, It would then go at 6000mm/min max.
When doing small movements the other day, the machine was "jumping", so I tried to lower acceleration, it made it worse so I increased acceleration to 5000 and no more jumping around.
A bit against logic...but it works for me.

[hub]

Spent some time designing today...

Thought these extra supports might help make it more rigid:







I also did re-design the Z-axis assy. Added L-steel to make it more rigid. And I think these "pre-load" adjustment screws will help those open bearings to be more rigid (?):



If it works, I'll do it for the X & Y too...

[hub]

I installed a limit switch over-ride button to my control panel. Since they E-stop the machine, I wanted a way to disable E-stop and jog back using the control. Works fine.
Had a minor crash a few days ago (before I installed limit switches), so I re-aligned the machine just in case. Took 3 hours..
Also re-measured back-lash. It's about 0.01mm on Z & X. Y has 0.012mm.

The new 4th axis is still under construction.

[nlancaster]

If you are using Mach3 you can set an "automatically override" option that overrides until you are off the limit switch.

[hub]

If you are using Mach3 you can set an "automatically override" option that overrides until you are off the limit switch.

Thanks,
Yes true, but my limits are hard-wired to e-stop ("nothing" to do with Mach3). At least for now. They are at the very ends of the axes. Just before hard stop.
Normally it wouldn't go near the limits, but if it does for some reason (mistake) it will E-Stop (which will cause the servos to stop at max current as fast as possible, and spindle too).

[hub]

Did some more fine alignment. On large parts some measurements were a tiny bit off, so I attached the dial indicator to check what's wrong..
The Y axis was "bowed" outward in the middle by ~0.2mm, ends were fine. I made a AL support and adjusted the axes straight and tightened the support.
Aligning everything to 0.00mm takes a lot of time...
There is also a ~0.2mm difference in Z (in X direction) over 700mm. Not a lot but will have to adjust it tomorrow I hope.

Just want the base frame as straight/square as possible in all directions. It's very close now, but not good enough yet.

[hub]

Spent hours and hours trying to align everything perfectly. Got very close, but not perfect... The extrusions aren't precision, so I took an average of the dial ind. values. They were about +- 0.07mm.
I'll have to be happy with that, and make some sort of table plate on top that I can sand/grind it straight. I don't want to grind the extrusions...

During jogging the Z axis timing pulley started to slip, It only had two tiny M4 set screws. So I drilled 3 new holes & tapped to M6, Pretty good now (I hope.....)

[hub]

Made a board out of a pretty rigid flooring board (for making floors in houses). Similar to MDF.
Cut it out & drilled etc, and painted back side & sides & installed M8 nuts from the bottom. I'll then bolt it to my table and face mill it for a straight surface.
Will probably end up painting a few layers & grinding the top surface.

[hub]

Installed the table board, face milled, sealed it, sanded, sealed.. It's ok .Will leave it for a week or two to settle & twist and re-do face milling etc.
Machined the last AL bearing block for the Y axis. Installing all of them tomorrow I hope.
Then the X... and Z....

[hub]

Installed the AL bearing blocks for the left Y axis. Noticed the timing belt pulley had worn and was loose 2 of 4 set screws..It was a somewhat flimsy connection so not a surprise really. So I started to make a good/better new connection for the Y slave axis. Hopefully will be all done tomorrow..

[hub]

Some updates.. The Y axis now has new timing belt connection, much better than the old. The faced MDF plate has now "rested" for a few days, letting it warp/bend etc. Measured it, highest to lowest point is 0.1mm so far. Less than I expected.
Will face & seal it again if it stays constant. (Will upgrade to a metal one when I get some extra cash..)

Attachment 280192

Has 4 connectors for some clamps:
Attachment 280194

Slots to fit the AL T slots below:
Attachment 280196

Also some extra connector holes for misc. clamping. (All holes have steel nuts inserted from below).

Attachment 280198

The plastic & tape is just a temp dust shield..

[hub]

Re-milled the table plate & sealed.. It's good now. Will see if stays good over time...
Made some Gcode in CAM for a few parts for the X & Z-axis. As a compromise, the plates will be MDF/AL/steel hybrid (for now) until I can afford some rigid AL/steel plates etc.
Not ideal but I hope it works for a while...

[hub]

Need some ideas/help/advice...:.

When the machine has been powered off for (about) 16 hours or more; then, when I connect power the RCCB (residual-current circuit breaker) cuts off all power including most of the building.
I then switch the RCCB on again (with machine "plugged in") & power turns on just fine..

- The RCCB is in the main switchboard of the building.
- Units behind the "problem connection" (all powered on at once:
1.5kW Servo Drive, 2 x 400W servo drives, 48V PSU, 24V PSU, 5V PSU, bunch of sensors & optos, BOB etc

I'm guessing the high current spike at power on triggers it when the drivers caps are completely empty(discharged) & charges all at the same time. ?
I'm thinking of maybe delays of some sort to power on units one after the another... Advice on a better/simpler solution?

[wizard]

Need some ideas/help/advice...:.

When the machine has been powered off for (about) 16 hours or more; then, when I connect power the RCCB (residual-current circuit breaker) cuts off all power including most of the building.
I then switch the RCCB on again (with machine "plugged in") & power turns on just fine..

Does the breaker also have a current rating?

- The RCCB is in the main switchboard of the building.

I'm assuming this is a rather large breaker thus has a high current trip point. If that is the case inrush current probably isn't the problem thus you are likely getting a trip due to leakage.

- Units behind the "problem connection" (all powered on at once:
1.5kW Servo Drive, 2 x 400W servo drives, 48V PSU, 24V PSU, 5V PSU, bunch of sensors & optos, BOB etc

I'd try to isolate the unit causing the trip. Power up the system with some of the supplies disconnected to see what happens. There is a the possibility that one of the power supplies has leakage to ground.

I'm guessing the high current spike at power on triggers it when the drivers caps are completely empty(discharged) & charges all at the same time. ?

Not for your main panel breaker if I understand you correctly. That should be rated fairly large. I'm thinking in terms of wiring in the USA and what we refer to as the main breaker.

I'm thinking of maybe delays of some sort to power on units one after the another... Advice on a better/simpler solution?

That would work if inrush is a problem. I'm just having problem imagining tripping the main breaker via inrush to a small machine like this.

[hub]

Thank you for the reply

The breaker is:
ABB Vikavirtasuojakytkimet - Vikavirtasuojakytkimet (Moduulikojeet)
Yes, it's the main panel breaker.

I don't think it has a current rating, except for the 40A/400V..

I'm pretty sure it's leakage that's triggering it.. but somehow caused by drivers powered off for a "long" time, just my best guess though..

I'll try your isolating suggestion, just will take some time since the 16h+ wait in between.

Thanks again wizard,
Hub

[alan_3301]

Is there not a breaker for the circuit your machine is on?

[hub]

Is there not a breaker for the circuit your machine is on?

If you mean a RCCB then no. I guess that could be a solution, to add a dedicated one to the machine, easy to test as I have an extra somewhere if I can find it..
I only have an automatic fuse on the machine side.

Also, my VFD has a separate connection, it's not powered on with the rest. (It's connected to the same phase though).