[kazimierzduch]

Hello everyone! I would like to show off with my custom-made CNC controller and subject it to your criticism. It is based on Gecko G540 module and purposed for driving a 3-axis milling machine with moving table or gantry, or other similar machines. Here is the specification:



Driver for motors: Geckodrive - Gecko G540
- 4-axis driver for 3,5 A max bipolar steppers
- integrated peripherals driver
- microstepping (10-step)

PC interface: Warp9 Tech Design - Ethernet SmoothStepper (no LPT port needed, communication through ethernet)
- eliminated problems with LPT and Windows "timing" issues
- huge possibilities for system upgrade (two spare LPT-alike ports left)

Computer: Lenovo 3000 C200 laptop
- WInXP SP2 (licensed)
- Mach3 (licensed)
- preconfigured system, Mach3 + plugins, SmoothStepper

Bipolar stepper motors (3 motors, 4th one possible):
- Type: NEMA23 - R57BYGH4331 (200 steps/rev)
- Current/Phase: 3,5 A max
- Motor shaft: 1/4"
- high quality motor cables

Power supplies:
- 48 V - 7,0 A (for Gecko driver motors)
- 12 V - 1,3 A (for fans and relays)
- 5 V - 3,0 A (for SmoothStepper)
- dedicated laptop power supply
- all voltages available on DIN rail connectors

2 relay blocks (for spindle, coolant etc.):
- every block is a 3PDT relay (TE Connectivity - PT370012) in DIN rail module, with flyback diode
- max 400 V AC - for 250 V AC max 10 A
--- "PC type" IN and OUT slots on panel (by-pass, fused)
- max 300 V DC - for 30 V DC max 5 A
--- "microphone type" IN and OUT slots on panel (by-pass, two poles)

Input and output connectors:
- 6 NC type "limit" switches: X++, X--, Y++, Y--, Z++, Z--
--- connected in series, "MIC type" connectors on panel
- 3 NC type "home" switches: X home, Y home, Z home
--- connected in series, "MIC type" connectors on panel
- 2 NO type digital inputs (for tool length probe etc.)
- 1 analog output 0-10 V (PWM for VFD spindle)

Other:
- mains switch with fuse, E-STOP button
- 4 fans (connected by WAGO quick connectors)
- cables organized on DIN rail WAGO connectors for easy maintenance and modification

Mechanics:
- structural aluminum profiles enclosure frame
- 2mm powder coated steel walls, fixed in profile seals
- stainless steel mounting plate
- easy access to internals without tools
- detachable transportation handles (can be used as standoffs when used vertically)
- dimensions (without handles and connectors): 540 mm x 400 mm x 135 mm
- weight (without laptop and motors): approximately 16 kg

Total project cost (including Mach3 license and own used laptop, excluding man-hours): approximately 6500 PLN / 1850 USD / 1550 EUR

[kazimierzduch]

And here are the photos of the device:

[PeterTheWolf]

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This looks great ... This is exactly what I want to make for the replacement of the my existing drives/control/steppers on the Taig CNC mill I purchased used running MACH3.

Are you willing to share information / Help someone like myself who is very electronically challenged?
In fact, much of the research I have done in the past few weeks is pointing me to the purchase many of the main components you have used.
I would really appreciate being able to learn from what you have already done in making this controller base.

Thanks ... and very well done.

PeteW.

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[kazimierzduch]

Hi Peter,
Thank you for your appreciation. And yes, I can help you with some guidance within the field of similar drivers. There are some things I have learned and if I were supposed to design a similar driver I would make some things a slightly different way. I will PM you with the details.
In touch.

[3dmike]

Hi can yo provid a wiring diagram please.

Mike

[joeavaerage]

Hi,
you have made a beautiful job but why stick with Mach3? All development ceased on it six years ago, so you have a new control
box with new parts and yet its controlled by software that's out of date?

The ESS has a Mach4 plugin....try it.

Craig

[kazimierzduch]

Hi,
you have made a beautiful job but why stick with Mach3? All development ceased on it six years ago, so you have a new control
box with new parts and yet its controlled by software that's out of date?

The ESS has a Mach4 plugin....try it.

Craig

Well, when I decided to go with this project, Mach3 was still popular here in Poland, and in fact it still is.

BTW. Personally, I'd like to have a software similar to Tormach's PathPilot, or even better - something similar to Datron's soft, which will be suitable to support our mid-end home made machines with Ethernet interfaces.

[kazimierzduch]

Honestly, I have never drawn the full diagram. There were only my notes taken by hand on some parts which needed to be organized before assembly.

[kazimierzduch]

Hi can yo provid a wiring diagram please.

Mike

Honestly, I have never drawn the full diagram. There were only my notes taken by hand on some parts which needed to be organized before assembly.