New Machine Build- 4X8 Router. Getting somewhere.

[flash319]

Well I started building and collecting parts about 1.5 - 2 years ago. Most of the stuff is from Ebay. So getting deals you have to wait. I am getting down to just a few more things to get but I keep changing my mind as to the best way to go about things. It always looks different when not in CAD.

So here is my description.

All THK rails, 4 bearings on the Z and 4 on the Y.
500 Watt Emerson servo motor driving a ballscrew 2:1 with 5mm lead.
1hp Allen Bradley servo through a 5:1 gear box for Y axis on soon to get rack gear.

I have two 25mm wide AT10 timing belts that I was planning on using for the X axis (8 feetish). These would be driven with a 2hp servo to a drive shaft that runs the belts but am worried that the weight of the gantry will be to much for the belts.

I plan on running the gantry on 20mm round linear bearings. I am now thinking or running two steppers, one on either side running on rack and pinion gear sets. What are your thoughts?





Here I am holding up the AB motor where the rack is going to go. Any thoughts or problems with this?

[eloid]

check out this build....
some great idea to use...

5' x 10' NEW ROUTER BUILD

[oldhack]

Flash
wher did you get your thk rails from.
Im going to need 20ft myself.
Im doing a 5x10 table for 4x8 materials. I thought maybe thk rails would be better than v groove.

[flash319]

I got the rail from a scrap machine at work and the smaller stuff from flea-bay. 20ft will cost a lot. That is why I not using it for the x axis. Instead using 20mm shafting. I think it is the cheapest way to go.

[flash319]

Well I got my head working using EMC. Now I am on to the long axis. I have changed my design so I have to cut my main frame up a bit to make it narrower. As you can I put the main axis inside the rails but this is proving to be very difficult to work with like this.
I am going to put it on top instead.



Here is a movie of the axis moving.

[harryn]

Hi, I usually read the router build logs, so I missed your fine start on a machine.

As far as suggestions, I have a few, but they are just that - suggestions.

I have seen some systems where the Y gantry rides on bearings that are "raised" above the table to a fixed height, which eliminates the need for the potentially wobbly side supports. I like that approach, but it does make loading potentially harder.

I agree with your decision to move the bearings to the top.

As far as your 25mm wide AT-10 belts - those are usually pretty robust. That is how I am hoping to drive my router. Do you happen to know the brand or if they are steel vs other reinforced?

I will tell you this in all seriousness. If you decide to change over to a different drive method, I will happily buy you out of the entire 25mm AT-10 parts set, lock, stock, and barrel. That is my next big parts purchase, possibly coming up soon - just let me know.

Take care,

HarryN

[flash319]

Thanks for the suggestions. I had this grand idea that putting the axis inside the rails would eliminate side movement, which it would but at the expense of being very hard to put together and also work on after the fact. i think I am helping myself out by changing it. I am going to start with the easiest way then fix problems as they come.

Well you are in luck my friend. I am going to be using gear racks instead of the belts with a stepper on each side. The belts are Brecoflex belts. They are in a loop that is about 8ft from one end to the other if they were on pullys. They had hooks glued on the back but I cut them all off (see pic). I got them off ebay so I am not sure what they were used for but they are in very good condition. They have steel wire running in them. I don't have pullys or anything just the belts. You can see the belts in the one picture laying on the table in the first post.

Shoot me an offer.

[flash319]

So this is going very slowly but life is like that.

I got the table welded back narrower so that I can move the x rails to the top. I have them sitting on top right now and am just making some jigs for holding the rail in a straight line so I can weld the end holders on square. I will post some pics tomorrow.

I am not sure if I should weld the rack to the side of the table or bolt it. I am not spring loading the pinions so I am leaning toward bolting so that I can adjust the backlash. Any opinions?

I still have the belts if anyone wants them. $175 for both plus shipping. They are AT25's and they loop around about a 7-8 foot distance depending on pully size.

[flash319]

Here are some pics.

[flash319]

Update:
Got my bearings mounted on the rails and one side rack mounted and set up. Just have the other rack to do.
I bolted the one side bearing rod with supports but I think I am going to weld the other side. It is a pain to drill up through the 1/4 inch tube and get them in the right spot. The gantry slides up and down the rails very nice so I think if I weld the other side I am good. If I have to take the shaft off at some time I will have to grind it but I don't think that will happen any time soon.

I just got my two Gecko 201x drives yesterday. Man they came fast and I am in Canada. Nice job Gecko inc. Took like 3 days. Sweet. I was surprised at how small they are. I have mounted them to heat sinks and then mounted both into an old power supply case. I will take some pics tomorrow. I might have the whole thing moving this weekend. Whats it been like 2 years since I started..............

[Jesse B]

Looks great so far

[flash319]

So here are the Geckos in the power supply housing. (don't mind the toe )




I am going to add this fan to the top. I also need to get some thermal past for the geckos to heat sink junction



These are the power supplies I built from old 24V power supplies. I took all the guts out and just used the caps and transformers. Added rectifiers and I am getting 46V DC out of them. I will see how that goes. They were rated or 7 amps at 24 so I think the transformers will be enough for the 5 amp motors.


Here is inside the cabinet. I still need to mount the Geckos and the power supplies to the back plate.


This is a blurry pic of the whole machine. The rail to the left is bolted to the 3x3 but I am going to weld the other side. I need to figure out some kind of hanging track for the cables.



This is the rack bolted to the frame. I can rock it back and forth and looks to be very little to no backlash. I hope it stays like that but I doubt it. I may have to change the pinion out for a split style. Once I get everything working I will feel better about spending any more money on it That is 20mm rail.