5 axis control system need suggestions

[pab]

Hello
I am very new to CNC control system and need to buy a machine controller for a 5 axis cnc router that I am just finish building.
I am not looking for a high end solution but more moderate cost effective option with good technology and open control system.
I have been told to look for a controller that has simultaneous interpolation on all axes and has high block process speeds and look ahead capability.

My plan is to cut larger shapes and contour machining of plugs for Fiberglas moulds and vacuum forming moulds etc. and anything else that comes in the door.

The router is designed to cut at 400 inches per minute. I will start with the machine operating as 3 axis, and in the future go to 5 axis. This router has 10mm pitch ballscrews 30mm dia. on xyz axes. The xy moving table is 4ft by 5 ft and 30 in Z axis.
It will have a 9hp spindle motor probably Colombo. I have OneCNC XR Cad/Cam that would be generating the tool paths in g code.


I have heard about the Mach2 cnc controller and am considering using it. Is their other controls I should look at?


I am not clear on how to put together the control system and could use a little advice.

Could you give me an idea of what the components I would need to purchase. Possibly the names of the better quality components and those that may save me head aches down the road and be easy to install and get operational?

I was planning to use AC brushless servo motors and drives as I heard they work well and presently considering Baldor motors with their Digital FlexDrive2 motor amplifiers. I am open to other suggestions and cost effective approaches. I have heard of gecko but if they are DC servo how would they preform compared to the AC brushless?

I realize I have a lot of questions but I sure would appreciate some good advice.
Thanks
Peter

[ger21]

Mach2 sends step and direction signals to the drives. Do those FlexDrive amps accept step and direction? And Mach2 can't do closed loop with the encoders. That is usually handles by the Gecko's. Rutex also makes servo drives, and are coming out with a DC brushless drive. No AC, however. I believe most Mach2 users use either Geckos or Rutex. http://www.rutex.com

[ger21]

Here's a controller you might want to look at. http://cnccontrols.com/

[pab]

Gerry
Thanks for the input.
Yes the Flex Drives do accept pulse and direct. I was wondering if the AC brushless servo iare a better choice as I hear DC servos being mentioned quite often.

In reply to your other suggestion I have looked at camsoft but I am not sure I want to go that way.
Thanks again.
Peter

[ger21]

THe majority of home built machines use Geckos or Rutex because of 1) They work good, and 2) They're cheap. I'm sure those FlexDrives are probably close to 10x the price of a Gecko. I have no idea how AC servos compare to DC. You should ask in the Servo forum.

As for the Camsoft, I can see how it's easier to lean toward Mach2 ($150) versus $2000 to $5000.

[Scott_bob]

Originally Posted by pab "I need to buy a machine controller for a 5 axis cnc router that I am just finish building... I have been told to look for a controller that has simultaneous interpolation on all axes and has high block process speeds and look ahead capability... The router is designed to cut at 400 inches per minute. I will start with the machine operating as 3 axis, and in the future go to 5 axis... I have OneCNC XR Cad/Cam that would be generating the tool paths in g code... I am not clear on how to put together the control system and could use a little advice. Could you give me an idea of what the components I would need to purchase. Possibly the names of the better quality components and those that may save me head aches down the road... Thanks Peter

Peter,

My advise. Do not settle for undemonstrated 5 axis simultanious control. Also, if you really want to do motion at 400 IPM then you are not talking about an inexpensive control. So, be ready to spend enough to get what you're after. The kind of machining that I imagine you'll want to do should definetly be up in that range IMO.
The most helpful team that I have worked with is:
http://www.numeryx.com/cnc/index.htm

Advice galore... If you need a lot of help, you'll need to find the right people for your project. If you're interested, I have documented here @cnczone.com a lot of the performance and payback ROI for this control...

Just remember, you get what you pay for,

[epatsellis]

Scott, have you looked at Mach2? you'd be surprised at how far pc-based s&d controls have come, Peter you can download the current version and run it as a demo, limited to 25khz pulse stream and 1000 lines of code, try it and decide for yourself. there is also a discussion group on yahoo groups that will amaze you at the depth of knowledge and responsiveness to requests.

erie