Need advise on 5-axis manipulator controls

[jmanz6]

I have been reading about all the great CNC software applications and I am using Mach3 in my personal CNC conversion project. However, I am also working on a problem at work that might be of interest here. We refurbish industrial x-ray equipment and have started to get in systems with parts manipulators run by either stepper motors or servo motors. Normally we would replace these motors with normal 90VDC motors and use our standard control setup for manual operation. I have decided to make some of our products more appealing I would like to use the steppers or servos for control. I would like the customers to be able to program motions into the manipulator or use a manual jog to move without programming. Most of the CNC type stuff requires people to know G-code or have a drawing. Most of my potential customers don't know G-code or have reference drawings. They are doing a real-time x-ray inspection of the parts and either need to manipulator to go to predetermined posistions or be able to move manually to see defects. Most x-ray operators are not highly trained so training them on G-code is out of the question. I'm thinking of more of a robot position type interface. They could move to a position, save it and go to the next for programming. There are systems n the field that do this but most have proprietary software. We are not an OEM so I would need an aftermarket solution for this. Preferably something I could brand similar to an OEM. Does anyone know of something that would work? I'm open to ideas. I have contacted a couple different companies but most are only focused on CNC type controls that it would get too complicated for my customers to use.

[mxtras]

I need to look into a few things, but I think I might have at least a suggestion.

Is this a low budget project, a one time deal or will a similar system be needed over and over again?

What are the expected annual volume?

What's your budget $ range per unit?

Scott

[jmanz6]

Scott,
Is this a low budget project
I wouldn't call it "low budget" but I would like to keep from spending thousands of dollars as these machines are used and refurbished by us. Our best margin is on the resale of these machines so keeping costs down is a good thing. However, when I look at what it costs to have one of my techs find the right motors, build the motion control, buy the controllers (KBIC 120) and the integration there is room for a good system to be done.

a one time deal or will a similar system be needed over and over again
As far as how many will be done, it's dependent on what types of used cabinets we get in. Some are pretty old and do not require the use of automated controls. Others are newer (80's and 90's) and have some sort of old automated motor controls that are either not working correctly or are no longer supported. I figure we would be doing at least 2-3/year. I have 2 in right now. One is almost finished being converted to manual only operation, but there is another one that is a 3 axis system that appears to have 50V servo motors. I might be willing to try something on that one as a trial for a new control. It currently has a BEC POS900 as the control for the motors, but we have no information on it nor do we have any knowledge on how to program it.

What's your budget $ range per unit?
My budget per unit is variable but as I stated above I would like to keep it as low as possible. Realistically I think if I can get to around $2000 or so per unit I would be happy. But, I don't know what this type of system might cost either. I know when I spoke to Camsoft it was more, but it also did a lot of things that I didn't need and I got the feeling it wasn't really what I wanted.

I am attaching a pic of what a typical manipulator looks like. This one is a manual only running 90VDC motors, but we do get them in like this with either steppers or servos.

[jmanz6]

Since I am not sure what something would cost for this type of application I need some ideas. I'm sure I set my numbers too low, but I'm cheap. I would like a realistic cost of what I am looking for. Just keep in mind that normally the machines with steppers or servos will already have power supplies, drives, and motors. I am looking for new control software to use on a new PC. Wiring changes and some drive changes might be fine, but I'm not looking for all new parts down to the motors unless I really need it.

[Switcher]

I know you don't want the end user working with g-code.

Do you think maybe your machines could work with Mach3?

If they could, maybe you could create your own custom screens, & only include simple (see attached photo) on screen buttons.

You might have to buy a license for each machine? You could still create a generic program, then when you get in the next machine just edit the program to each specific machine (example: X can only travel this far).

If that would work, you would get your money back from each Mach3 license, many times over.

The end user never needs to know they are working with a cnc control.

Just an idea...


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[jmanz6]

That would probably work. I didn't know I could do that with Mach 3. I have Mach on my PC for another CNC project at home. I am still learning it and how to get my motor drivers to work with it. I don't know VB but I should be able to make some simple buttons and such, I hope. Is it pretty easy or at least not rocket science to do this? I've never tried or even know where to start to do this with Mach. Any insight would be good. Thanks Jason

[Switcher]

I havn't created a custom screen myself, I have seen a bunch of folks here on the zone & Mach3 site, build custom screens.

Here is a video that will give some info about the Mach3/Screen4.

Screen4 is what is used to create custom screens for Mach3.

The cool thing is you won't have to spend a penny unless you can make it work for you.



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[Switcher]

Here is the "Mach Screen Forum".

Lots of info.

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[Switcher]

A sample of someones custom screen here.

That page loads kinda slow, should have some photos on it.




This one looks very good, I like the direction arrows for the jog/axis.



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[jmanz6]

I think that might work. I will do some research and play with it. If I can get a design that works and figure out how to make it do what I want I think that will fit the bill. The price is surely right. Even a full license of Mach is worth it if it will work. Thanks for the help.

If anyone else has any ideas please keep them coming. I'm open to other options too. I like having more than one way to do things. I'm so glad I found this place.