[matth]

I am starting a new build as I wanted to upgrade my existing machine with an ATC but I can not find enough downtime to make the modifications.
Because of this I am building a second machine and will then run them both in production.
The existing machine mostly does VCarving and struggles with cuts above 1000mm/Min due to vibrations in the structure destroying the fine detail (although it can make profile cuts at 5,000mm/Min):
Attachment 310764

With a view to going much faster on the VCarving I will build the new machine much heavier and with a lot more cross bracing for rigidity:
Attachment 310768

The spec of the new machine will be:
4'x2' cutting area with 24,000mm/Min rapids and 15,000mm/Min cutting speeds.

Hardware will be:
25mm, 20mm and 15mm Hiwin Rails for X, Y and Z.
Helical Rack and Pinion for the X and Y axis.
4mm Pitch THK Ballscrew for the Z (with Pneumatic counterbalance)

Frame will be 120mmX60mm RHS 5mm wall.
Gantry will be 180mmX90mm Heavy extrusion with uprights machined from solid aluminium billets.

Electronics and drive will be the same as my current machine:
2.2Kw 24,000RPM ATC spindle (ISO20)
Leadshine EL5 400W servos (dual on the X axis)
1:5 Planetary gearboxes for the R&P drive.
CSMIO from CS-Labs for the motion controller.

I already have the ATC and all the rails and R&P plus the gantry extrusion.
I will shortly be ordering the Servos and gearboxes. I will order the steel when I am ready to start with the build.

One of the pieces of aluminium to be machined for the gantry supports:
Attachment 310770
Parts for the Z axis including the ATC spindle
Attachment 310772
ISO20 Tool holders and holder forks:
Attachment 310774
Some test welding of the 120mmX60mm RHS:
Attachment 310776

[ger21]

On your current machine, have you tried closing the ends of the gantry tube, or internally bracing it? It can make a big difference in rigidity.

[matth]

The rigidity issues are in the frame not the gantry.
Once the z speed is pushed up it shows up flex in the frame.
The machine is running and earning money everyday so modifications are not easy and a second machine would be good. So building another and addressing the issues is a good course of action.

[ger21]

Leadshine EL5 400W servos (dual on the X axis)

How do you like these?
I'm planning on using them for my next machine.

[matth]

I fully rate them. I have had no problems with them at all and performance is great. The driver is very industrial and has all the IO you could want. I have four on the current machine and I am about to order another 5. 4 more for the new machine and 1 as a spare considering I'll have two production machines reliant on them (only because of the lead time from China rather than any reliability concerns).

Coupled with the CSMIO I think makes an excellent setup.
Attachment 310800

[ger21]

The CSMIO was my original plan, but I'll probably be moving to UCCNC for the smoother motion and better trajectory planner.

[manofmanyhats]

Attachment 310800[/QUOTE]
That is beautiful.

[matth]

Thank you. Next one should be even better!

[pippin88]

Matt, I'm surprised you have problems with your current machine, I thought it was quite a good design and was the inspiration for my build.
To improve your current machine, consider bolting on a horizontal brace between the bottoms of the legs, and bolting a middle leg to improve support in the middle of the travel.
Do you have any photos of the problem cuts?

I think a 4mm pitch screw could struggle to get to 15metres/min.

I'm not sure on the logic of your frame. You will get a stronger structure if you fabricate a grid of tubes (on one level, resulting in fully closed sections) rather than laying grids on top of each other. This would also allow you to reduce the gantry riser height.
(like this: http://www.cnczone.com/forums/diy-cn...ml#post1589816)

Watching with interest.
How much was the ATC spindle and from where?

[matth]

The current machine cuts perfectly and is doing a good job. But only up to a certain speed.
As I said the idea was to add the spindle to the current machine but I can't take it offline for that long hence the second machine.

The frame is stacked like it is for a couple of reasons. Firstly is a constraint in how big a piece I can accurately machine and weld. The top pieces that the table will sit on and the rails bolt to will be made up in one section then attached to the rest of the frame/base. The second is that the base can be wider by the amount that the gantry will need to be to give a bigger footprint for more stability.

The spindle cost about £2000 delivered from China with a matching VFD and 12 toolholders. The man problem with adding it to the current machine is that new Sunfar VFD has to be hardwired to the CSMIO whereas the current Hyanyang is using a plugin and all the Pnuematic actuators that need to be wired in. Meaning a lot of modification to the control cabinet and all the associated time that it entails.

[matth]

Nice build by the way Pippin. I will not be using epoxy though. My plan is to mill the sides of the RHS that the rails bolt to.

[matth]

Servos and gearboxes now ordered. I'll post up some pics once they arrive.

[Eddard_Stark]

Are you the guy that had DMM servos originally and replaced them with the Leadshine EL5? If so, I have seen several of your vids; nice machine.

I have been eyeing the EL5's for a prospective project; do you mind telling us what you paid for them?

Can you provide a link or further clarification to your vendor in China? I buy plenty of stuff from Chinese vendors on Ebay, but I have been wary of buying something really important like an ATC spindle or servos. For one thing I am wary of receiving counterfeit merchandise in the case of the EL5's.

[matth]

Yes that's me, the DDM kit is sat in a box at the back of one of me sheds somewhere.

The first lot of 4 servo and drive kits I bought cost around £1200 with express delivery plus import charges. The lot I have just ordered was for 5 sets plus 3 1:5 low backlash planetary gearboxes designed to suit the Leadshine servos and that lot was £2000 inc express delivery plus import charges.
I buy from Aliexpress which offers buyer protection but I have never had a problem with Chinese suppliers in general and the seller of the servo kit has always been very responsive and helpful.

[matth]

Here's a link to the Ali store:

LiJiao control product - Small Orders Online Store, Hot Selling drive service,drive webcam,drive interface and more on Aliexpress.com | Alibaba Group

Always ask for best pricing, you will always get some level of discount.

[Eddard_Stark]

Thx. I have done some shopping on AliExpress and had a good experience; looks like I will be doing more in the future.

[matth]

Motors arrived yesterday. Two day shipping from Hong Kong to my door. Can't complain about that.

Fitted the low backlash 5:1 planetary gearboxes, 2 for the X axis and one for the Y. The Z will be direct drive and then I have one spare servo set for my two machines.

Attachment 312988

[trnsfrmr33]

Hi matth, I've been looking all over for a reliable ATC spindle... looks like you got one (from China) and it works?! Wondering if you mind sharing the link to where you got it from? Apologies if I somehow missed the link if you already shared.

thx!

[matth]

Hi matth, I've been looking all over for a reliable ATC spindle... looks like you got one (from China) and it works?! Wondering if you mind sharing the link to where you got it from? Apologies if I somehow missed the link if you already shared.

thx!

Well time will tell as I'm not using it yet but it seems well made.

2.2 Kw 24000 rpm 220V ATC Spindle Motor for Woodworking Water cooled, ISO20 Collet spindle ATC-in Machine Tool Spindle from Industry & Business on Aliexpress.com | Alibaba Group

I bought the 24KRPM version but there is a 30KRPM unit as well. Ignore the price, I got a sizable discount when I purchased tool holders and VFD along with the spindle.

[iforeman]

Hi Matth

I am situated in Ireland, and I stumbled across your post regarding your new machine."Heavy steel build, ATC, R&P, Servos". I am in the process of ordering the stuff for me to build 2 machines and I am extremely interested on you experiences regarding your ATC spindle.

I have a quote that I am ready to place the order on for a GDL80-20-24Z-2.2 2.2 kw 24000 rpm ATC Spindle @ $1500 FOB. This looks like it is similar to you spindle.

So I was hoping you could answer some questions for me please-

What are your experiences to date with your spindle, are you happy with it?
Did you get the ISO20 Tool holders and holder fork with your spindle or was that a separate order?
If it was separate would you mind sharing the details please?
Do you think $1500 for the spindle (excluding shipping and VFD) is a reasonable cost?

Any other additional detail or info you have would be greatly appreciated.