Greenhorn question..getting started

[Kozmonyet]

The last project was 12 years ago with a Kollmorgen (roughly 5 horse, 5000 RPM) servo set-up for a single axis forming machine...Since then, I've forgotton more than I learned so though it was better to start asking questions than dive in head first. (I remember just enough to make a mess of things).

So, here's the scenerio: Everything I've heard about geckos is good and the price is right so I'm leaning that way on a project.

I need to start the plans for a wire forming machine that will need 6 axis movement. Fortunately (for my sanity), all of the axes will move independantly of the others and moves will not be complex...Move A, when that's done, Move B, etc. Only one motor will need to move at a time.

4 of these axes don't really need much torque and are simple machine moves. 2 will need pretty darned good torque to do the actual forming motion. Positioning of all the motors is not too tight...I dont need to get fancy with zero backlash gearing or even ballscrews. I'll probably just get the same motors for all the axis drives rather than have a kludge of different sizes.

Having used both steppers and servos with encoders, I prefer to stick to a closed loop system if it doesn't run the costs and complexity up too much. Losing steps could be a really bad thing as this machine has to run without being watched.

It's a bit of a skunkworks project so I'd like to keep the budget down.

With regards to software driving the thing, it'll be designed for repetative moves..same thing day in and out. Traditionally, it's done mechanically but I want the option of doing some "tweaks" on the fly (bend a little more or less) and the ability to change the bending form slightly as the product develops.

I need some beginning guidence to narrow down choices so I can move on with the rest of design.

1) Suggestion on the right gecko drive and/or controller combo that'll give enough amps for..(guessing about 500 oz/in of torque)? Suggestion for motors (brand, type, source) without breaking the budget?

2) Suggestion for control/programming software to do simple moves for all 6 axis drives (remembering the KISS thing)?

Yes, there is a LOT of information left out. I'd rather play ignorant and see if any good ideas come of it than start putting limits on at this point. I think there's enough info but happy to provide more if needed.

Thanks for the help and ideas!

Koz

[Garyy]

Hello How did your wire former turn out
I am looking to build one and can use some advise.
Gary