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  1. #1
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    Aug 2010
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    583

    New upgrades to the ole Mikini. Servos!

    After having a bunch of studdering issues and losing position with my stepper motors I decided to fix it with 750w DMM servos. Along with a host of other upgrades.

    First I had to upgrade the power distribution panel
    Attachment 423288

    Then I had to build the servo control cabinet
    Attachment 423290

    I mounted it to the side of the Mikini
    Attachment 423292

    I had to drill and tap for more armored conduit runs
    Attachment 423294

    I then mounted the motors (having to do some cutting on the way covers since the servos are longer)
    Attachment 423296
    Attachment 423298
    Attachment 423300
    Attachment 423302
    warmachinellc.com

  2. #2
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    Re: New upgrades to the ole Mikini. Servos!

    I designed some new way cover extensions and am having them made from stainless steel
    Attachment 423304
    Attachment 423306
    Attachment 423308
    Attachment 423310

    Then I rearranged the rear cabinet after removing the stepper drivers
    Attachment 423312

    I replaced the three proximity switches on the X axis that all quit working (because they are the only ones mounted upside down, need to seal them with silicone to keep coolant out)
    Attachment 423314

    Built a new Rex84 Ver2.0 to get the drive fault working for fear of the powerful servos breaking stuff if the spindle stalls
    Attachment 423316

    Made some mods to Mach3 with brains to get the servo drive faults to trigger an e-stop
    Attachment 423318

    Ultimately this was again a seamless upgrade as all of the Mikini front panel controls work exactly the same as before, as well as the Mach3 controls.
    warmachinellc.com

  3. #3
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    Re: New upgrades to the ole Mikini. Servos!

    Made a bunch of changes and upgrades to the Mach screen set I use. Most notably a rapid feed override, distance to go DRO, G90/G91 toggle, and work offset toggle.
    Attachment 423320

    Made a drawer slide system to more easily slide out the coolant tank for access
    Attachment 423322
    Attachment 423324
    Attachment 423326
    Attachment 423328
    Attachment 423330

    Before and after pics of scraping the crappy peeling paint and repainting it (still ongoing). I also replaced all of the armored conduit and fittings (which were falling apart)
    Attachment 423332
    Click image for larger version. 

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    warmachinellc.com

  4. #4
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    May 2016
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    155

    Re: New upgrades to the ole Mikini. Servos!

    Awesome. Nice job on the overhaul.

    Especially as I have 4x DMM 750's waiting to get stuffed in my 1610L pretty shortly. I'm upgrading the controller & spindle (againg) at the same time so it'll be a total retrofit.

    The blue coils at the top of your electrical enclosure... line reactors? You find them necessary, or are just going by the 'optional' in the DMM manual and seemed like a good idea?

    Also, the green breakout boards for the servos... source? They look handy.

  5. #5
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    Re: New upgrades to the ole Mikini. Servos!

    Quote Originally Posted by spumco View Post
    Awesome. Nice job on the overhaul.

    Especially as I have 4x DMM 750's waiting to get stuffed in my 1610L pretty shortly. I'm upgrading the controller & spindle (againg) at the same time so it'll be a total retrofit.

    The blue coils at the top of your electrical enclosure... line reactors? You find them necessary, or are just going by the 'optional' in the DMM manual and seemed like a good idea?

    Also, the green breakout boards for the servos... source? They look handy.
    Thanks! Nice! What spindle are you upgrading too? BT30? What controller?

    Yes those are line reactors, I spoke with DMM throughout the entire build process and they recommended line reactors.

    I have two breakout board types I'm using there. One type are 2x8 pin header breakout boards so I can use the the same cables that connected to the previous stepper drivers to the Mikini front panel. The other type are just DB25 breakout boards. I found them both on Amazon. I think I just found the cheapest ones. I also bought some DIN rail mounts so I could just mount them to DIN rails. I actually have the DMM breakout board but was unable to get the Mikini DIR signals to work correctly to change the motor direction. So ultimately I just built my own breakout using four DB25 breakout boards.

    DB25 breakout boards: https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

    2x8 pin header breakout boards: https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

    Extra DIN rail mounts (if needed): https://www.amazon.com/Sysly-Mountin...9S7KDRD1VX8KZN
    warmachinellc.com

  6. #6
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    Re: New upgrades to the ole Mikini. Servos!

    doubletap
    warmachinellc.com

  7. #7
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    May 2016
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    155

    Re: New upgrades to the ole Mikini. Servos!

    Thanks for the details. DMM gave me a good diagram to connect to my BOB - they're good folks to deal with.

    Spindle is a 10k BT30 bought from Skyfire. I have to pull the head and bore it out as it's 90mm vs the 80mm R8 that's in there now. I'm tired of TTS pullout, and I want an ATC.

    Spindle motor is a Parker servo with one of their Gemini drives. Ebay find, pretty cheap - biggest servo they make that stil runs on single phase 220v. I have a BlackMax induction motor on there now and it's fine, but way too heavy and large.

    Since I'm pulling the head, I also plan to pull the column and experiment with epoxy granite fill, but more importantly I'm adding a plate to the back of the column to box it in. If there's one bad mechanical design it's the open-back column. Floppy as a noodle - boxing it with some 1/4" or 3/8" plate should stiffen things up quite a bit.

    And while the column is off I may try to reverse the Z-ball screw and stick the Z servo on top. Mine is a fairly early model with no opening in the base - if I don't reverse the ballscrew I'll have to cut a hole through the base so the DMM can hang down lower.

    I'm currently running UCCNC, having gutted the electronics a couple years ago. Original steppers, drive and toroid remain, but that's it. New version will still use UCCNC, but with way more I/O and a 24V-only control system. No more 5/12/24 mess in the same machine.

    And thanks for the tip on the DB25 boards.

    Source for the line reactors? Those look pretty compact & tidy.

  8. #8
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    Re: New upgrades to the ole Mikini. Servos!

    Nice a BT30 will be my next upgrade if I don't jump to a new machine by then. I also have a 2hp Black Max spindle motor and wish it had a tad more power. If I upgrade that may be with a 3-4 hp servo.

    I've also thought about the epoxy granite fill. On the next round of maintenance I may completely disassemble the machine and have everything powder coated and I may do the epoxy granite fill.

    The cast iron base is fairly easy to cut through with a hole saw and a sawzall. I had to do that in a few places to get things to fit.

    The line reactors I just found on ebay. They are quite big and heavy and rated for 12A each.
    warmachinellc.com

  9. #9
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    May 2016
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    Re: New upgrades to the ole Mikini. Servos!

    Thanks, I'll start trolling for reactors. Yours just look smaller than most of the footed ones I've mounted for various VFD projects.

    I've only stalled my 2hp spindle once with a really aggressive cut in aluminum. More HP would be nice, but the flexing and chatter from the column flopping around is driving me crazy. The rails and screws that came on these machines are amazingly accurate (for what it is), but the open-back column is a noodle.

    And I suspect the base where the column mounts may also be flexing a bit locally where the bolt holes are. We'll see once I fill it up and box it in.

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