5'x3' Plasma Table Build

[arewehavingfun]

Well, I guess this is like stepping off the plane and pulling the chord, maybe not. It seems strange announcing what I would like to build. However, I would be a fool not to share my building experience with others. What I mean, is that all the information I possess about building a CNC plasma table has been directly received from sites like this, and so on and so forth. I’m so grateful that the internet exists and I'm able to prosper from others. With this all being said, I go forth.

The thought process on how I'm going to create a CNC plasma table has been addicting and time consuming to say the least. I am constantly going up and down on my build’s, "wish list". When all is done and said, I come to the same chilling fact that I have to build the CNC with the least amount of resources. However, the best resource I have is free, that's knowledge from folks like you. I welcome any and all opinions, also criticisms to say the least.

The plan is to have a three-foot by five-foot working CNC plasma table when finished. The main frame will be three inches by three inches square steel tubing. The gantry’s main beam will also be the same, respectfully. The rail system will, no doubt be a four inch width by a hundredth and eight-five thousands thick cold rolled piece of, well, I believe ten-eighteen mild steel at this moment. Carriage for the rails will be complemented by using products from “CNC Parts” company. Of course, this may change too, depending on how conservative I’m being that very day. I’m not trying to avoid the “Z” (zeeeeeee(trying to be funny)) item but, I might have something rolled up my sleeves on that subject, more to come. Electronics powering and driving this table will be 640 ounce steppers and such from Candcnc. Their Digital Torch Height Control II(DTHC II) board is a must for this guy.

I’m thinking this is a good start for now, more to come.

[arewehavingfun]

Someone asked me why I don't build it four-feet wide instead of three-feet? They also asked, which one was going to be the gantry? This was my response.

You know, you're right, the wine does certainly cloud the mind sometimes but, it's so fun. I can not tell you how many times I have bounced back and fourth, from three-feet to four-feet and so on. A lot, that has to do with this, is that I'm hopeful when I can get the business on track again, I will be able to create a five by ten foot table in lieu of the smaller one(I know,...I know). Your not even going to believe what I'm building the motor mount/drives out of. I'm not even going to tell you, in fear of being laughed at. If it's successful, I'll share it.

The logical choice was to make the shortest "arm" the gantry. This will be a three-inch by three-inch, one-hundred and twenty-five thousand thick piece of 6065 T5 aluminum. I’ll heat treat the aluminum and change it to “T6”. I know, I know, I’m cheap.

Anyone ever use the ABEC “9” bearings, instead of the “7”? It was just a thought as the nines are probably way overkill.

[arewehavingfun]

OK, I had the opportunity to use a FlowJet at an associates job yesterday, and for fun I created these parts on the fly. I basically, had twenty-minutes to create the file and about one-hour of machine use. I guessed on the bolt pattern spacing for the MEMA 23 steppers I had laying around. Boy, wouldn't that be great if these work.

I painted the parts with flat black and red paint from a spray can. Hmmm, this opens up a whole new thought process.

Here is a short HD video I made to share these parts with you. ...And yes, sound quality is horrible and so are some of the facts I mentioned, sorry.

Untitled on Vimeo
I meant .125" and not .185" on the spacer. Too much wine that night.

[arewehavingfun]

Here is an idea of some of the stuff I have so far. I also have the stock steel. I was able to purchase the square tubing for $42 for a twenty-four foot piece.

In the picture are part of the carriages. I got scrap steel for those for nothing. There are six-teen ABEC 7 bearings with bronze bearings for $13. The rest of the hardware was $7.42.

I'll post the "Z" axis picture when finished.

[arewehavingfun]

After much thought, and I mean "much thought", I have decided on purchasing the Everlast Power Plasma 60C single phase version. They do make a triple phase however, The single phase will enable me to locate my project in two different area's if the need arises.

Why did I chose Everlast? Well, primarily because of the strict budget I'm under to create this CNC plasma table. Secondly, I have discovered that the Everlast company is a very friendly company with an impressive level of customer service. Also, I was pleasantly surprised that the PP60C comes with the CNC plug and CNC style torch body. If your looking for an affordable plasma cutter for your project, you may want to check into them. Make sure you only buy from them when your ready to use the machine. They have a unrestricted 30 day warranty. From what I understand, is that if there is anything wrong with the machine, it will creep up within that thirty-days.

Here is a video I found on the Torchmate youtube channel. They are using the PP60C from Everlast. I'm not sure if that is the single or triple phase model they are using. BTW, a little tid bit, did you know that Lincoln Electric bought Torchmate.
http://www.youtube.com/watch?v=45Up0-aj6QI]Everlast 60c Plasma Cutter on Torchmate 2x2 CNC cutting 3/16" mild steel - YouTube

Electronics was a very simple decision. I can't imagine a better company to buy from than CandCNC. I will certainly purchase their BladeRunner Dragon-Cut CNC Plasma Controller. After much thought I think I'm going to purchase the smaller 300- series steppers as a plasma cutter has no torque. Any thoughts on that?

[jimcolt]

It is nice to see another build thread from you. The video looks great....would be nice to see some cutting specs for the plasma shown? Do you know where we can get the specs regarding speeds, amperage, cut height and pierce heights on the full range of materials it can cut?

The Torchmate machines are nice, I happen to have a 2 x 4 Torchmate with their AVHC height control....and a 45 Amp plasma from Hypertherm mounted. I use it to pierce and cut from thin gauge to 1/2" thick....I can do a decent job cutting thicker if I edge start....however with 45 amps I am limited to piercing 1/2"....so that the torch consumables do not get damaged from blowback.

You should consider with your build (from my experience installing plasma systems that use either a capacitive or inductive based torch start mecanism) to ensure that the computer, as well as all motor drive cabling is shielded, and with the shield drains connected to an earth driven ground rod. While inductive and capacitive starting systems have been available on plasma systems for many years, and they do not tend to produce as much RF electrical noise.....they still have the propensity of producing electrical noise that can affect the cnc and drive components...trust me!

Everlast does produce some systems with blowback start technology....like all of the Hypertherm air plasma systems. These types of plasma's will operate without additional machine shielding/grounding steps that usually are necessary with other designs. My experience is with installing Thermal Dynamics capacitive start systems as well as Hypertherm's two industrial plasma's (HD4070 and HT4400) that use an inductive based start circuit.

Best regards, and lets see some of the mechanics of your machine build!

Jim Colt Hypertherm

[arewehavingfun]

Thanks for your reply Jim.

Yes, the shielding was one of the first items I have thought of. For you Jim, I'll make sure I take extra video's for all to see when I install the PP60C. Everlast has also offered to work with me on any issues I might come up with.

I should have more pics coming soon of the material I'm using. That's one of the problems with working within a budget and that is that the "finish line" is constantly changing. And remember, I'm designing and building the carriages for my table. I'll keep this open source so if anyone is crazy enough to do what I'm doing, more power to them.

[arewehavingfun]

The journey continues with making a CNC plasma table on a super tight budget. I found some used steel that will work perfectly for my gantry and frame. I went to the good old steel yard and found some used posts sitting in the corner of the lot. I was able to purchase the material for 30 cents a pound which roughly estimated a little less than $3 dollars a piece. The place was kind enough to let me return my previous purchase of new steel. The fact that I purchased almost $50 in additional hardware for another project, I’m sure had something to do with it.

The pieces are five feet by two inch square. They are a little thicker than I wanted but, a third of the weight will be eliminated with lightening holes. I have changed the table size too, again. Table size will now be a working area of, four feet by four feet respectfully.

I am going to prime and paint them. Color will be an Everlast green or a cherry red. I guess that will determine on how I’m feeling that day, when I purchase the paint.

Currently, I’m at $29.42 for hardware costs. I will be purchasing rails and gear tracks next.

More to come.

[arewehavingfun]

Hey folks,

Still here, just got back from a trip to New York.

Have super news!

-Joe
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[I Lean]

Hey folks,

Still here, just got back from a trip to New York.

Have super news!

-Joe
__________________

....and?

[arewehavingfun]

....and?

Hi Carl,
Well, I just got back from the East coast with good news about an account I got. Mainly just wanted everyone to know I was still around, working on my "budget" table.

The wine was flowing a little too much last night.