New Precision Plasma Build 3x4

[rock4xfab]

Since this is a Percision Plasma Build I have moved this here Hopefully a Mod will Remove the other thread.

3x4 Plasma table build..

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Hey Guys new here... Machinist Fabricator...
Just started my build of a Precision Plasma gantry system, with a Bladerunner Dragon cut . Here is what I have so far..

Table material ordered and Delivered
Gantry system ordered and delivered
Still waiting on Stuff from Tom at CandCNC

Specs
BladeRunner AIO Controller with 4 Drives (4 axis)
576W 48V12A Power Supply
4ea 300 oz-in 3.5A Hybrid Stepper motors - optimized for the BladeRunner
THC Sensor Card & cable
DTHC Expansion Module - Installed
Full Cable Set
DTHC
I upgraded my system to the 5th axis and 620oz motors
Dragon-Cut 620-5


ROTARY (5 MOTOR) DRAGON CUT w/Rotary Wizard and TubeSlicer(tm) Basic
5ea 620 oz-in motors


Here is the pictures of the table build. so far pc's cut to
4) 56"
2) 48"
4) 44"
4) 7.5"
4) 26"


I removed my 3/16" top from my blanchard ground table so I could be realy anal and get everything square and true



My table is that much out on the floor so close enough

[rock4xfab]

Sides done and bottom square migd in. It took awhile to square it up by myself but it is dead on. The 2x3 you see clamped is to hold the side upright and to help keep them from warping in or out ward. What is not in the picture was the big ass Machinist angle plate that was clamped in the mix also.







Some stuff most of you have already seen.. If I get a free moment this afternoon I will try and post my Table drawings...

V-Rail and rack along with pulleys and Ugraded Z-axis
The z-axis is a finer acme 5 turns to and inch vs. 10 turns

[rock4xfab]

OK here is what I have done so far...and some may have been overkill. but I have equipment to perform the tasks..

I set my table sides up in the mill and drilled them for the rails... Now it was recommneded to use .063 wall tube and drill tap for .25 srcews.. I used .083wall tube and I drilled my top tubes for .4 hole. Then drilled and tapped a pc of 3/6" plate 3.15" or 80mm on center to use .3125 button head SS screws all 15 holes.
I then mounted the gantry rails, to the frame, squared them and set the V-rollers, I think .7 on one side and .9 on the other. Not exactly center but the adjustment lets the gantry foat, and I have full contact on the gear rack.

I then mounted all the motors and belt drives ( actualy a couple times) I put the carage in front of the horse and had to dissasemble and redue. I drilled all the 620oz motors out to .1875 to allow the supplied screrws to be used. After all the motors were hooked up I started looking at the next step. Cable routing and e track... I just ordered My cabel track from Mcmaster on fri, it should be here Tuesday. Once I have that I will bend up some aluminum channel I am using .040 but it wll be dimple holed and flared to give rigidity...

Anyway here are a few photos..

Also for those using the presicion plasma gantry kit( non bolt together..)
Hole spacing on the rails is 3.15 or 80mm total holes for the 3x4 kit is 15 per rail.
Hole diameter .35

Also thank you to unixadm for giving me the Part numbers he used for the Cable track
I ordered 2-6 foot pcs and will make them fit my use.
1 4409T513 2 Each Open Hinged Cable And Hose Carrier, 0.98"h X 1.50"w Interior Size,2.17"bend Radius,6'l
2 4556T562 2 Pairs Mounting Bracket For Cable And Hose Carrier, Open, For 0.98"h X 1.50"w







Hard to see but inside the rail is the 3/16" drilled and tapped plate that the rails are bolted into.



I cut all my steel with a Band saw,.030 Long and trued it in my VMC machining center.

The Gantry Kit is from Ron at Precision plasma...All my electronics are from Tom @CandCNC.com I went with the Dragon cut 5 axis as I will be adding the Rotory head by prescion plasma, at some point.

http://www.precisionplasmallc.com/

[rock4xfab]

A little update, I purchased another computer strictly for Mach 3.. It is a Dell 520 2.66 GHZ 80gHD and 1G of memory and it is using the on board video for now I have a another card for it. I loaded mach and All the CandCNC files to the computer last night and began tuning the motors today. I found a nice little video on tuning the motors that takes all the math out of the equation... You don't need to know all the pitch and pinion Blah blah blah...

I used a .0005" indicator and a rod that I milled to a specific length. In my case it is 33.506" long. With the known and the travel along with Machs Cal button I am now holding .0015" across the 33.506" I performed the same for the Z axis only using a set of 1,2,3, blocks.

Tomorrow I will look at installing home switches, and limit switches.. And if time permits start mounting E track permanently

Here is the link to the video that I used
YouTube- [nomedia="http://www.youtube.com/watch?v=XkO5tc-jSxw&feature=related"]YouTube- Improved Mach 3 Axis Calibration[/nomedia]

Well I finally got all the info for the Cut-master 51... To tie in the DTHC.
I will be uploading some pics later showing the tie in points to that machine, to help anyone else out in the future. I just stopped at the electronics store to pick up some DB 9 connectors and few misc. parts.. Anyway pics later of the progress and tie ins.

[rock4xfab]

OK here is the board points to pick up the switch and Raw Arc Volts for the thermal dynamics CUTMASTER 51.

I still have to wire in the DB 9 connector into the shell of the plasma cutter, that will be tonights chore then I can put the palsma cutter back together.


Terminal E-27+ raw arc Volts E24 -Raw arc Volts
Terminal E 23 and E25 torch switch
The CM51 does not have OK to move so you need to use a CSR, tied to the CandCNC DTHC board.

Here are some photo's of tie in and the location I mounted the DTHC card
Torch connection's


-Raw Arc connection


+Raw Arc Connection


Location for DTHC Card


Card mounted on stand off mounting plate

[rock4xfab]

Ok its been a long night but I have the DB9 connector mounted on the face of the plasma cutter, and all the final test's completed... So a few pics, and then get some stel on the table to do the final THC tests...





And the torch on command light

[rock4xfab]

Well I got the base under the table, height may change. Also got the sides made up this morning for it.. The caps will go on all 4 sides.. the slats for the tabe will interlock into them once complete.
The table will be powdercoated black and I will do the sides in a contrasting color..

You can see the holes in the side plate. I will be center punching and installing riv nuts into the tube so they will bolt on with SS button heads.

Nix the Riv nuts, I ended up just drilling and tapping the Square tube..



inside shot where the slats will interlock

[fatal-exception]

Nice job, machine is looking real sweet. Nice welds too. Just a shame that it will look like it's 100 years old in the first week of using it... Are you putting a water table on it?

Paul

[rock4xfab]

Nice job, machine is looking real sweet. Nice welds too. Just a shame that it will look like it's 100 years old in the first week of using it... Are you putting a water table on it?

Paul

I am in the middle of the water table build now but have been super swamped with welding work and machining so it is on hold. The table will be powder coated after everything is done in the assembly and checked. I like to do things once not multiples.. So I am working on the water table and where my
5th axis is going to mount for the rotory. I just finished home and limit placement on the table this weekend... Soo on to the next step.

[rock4xfab]

Well I got all 4 sides mocked up all holes drilled and tapped, along with making up my home and limit switch brackets For X. I still have to mount the Y home and limit along with run the wires and figure out the insallation of the cable track.

[rock4xfab]

No pics but I did get all of the limits and home switches installed along with the Y axis tray for holding the Cable track formed on the press brake. I just have to mount it. I have to leave town next week and when I get back I should have the water tabel formed and ready to install. Then break it all down for powder coat.. BTW I got my hands on a pc of 4x8 Stainless to bend the water table up. Thanks to a freind scraping 2500# of it...

[rock4xfab]

Sorry for such a long delay guys... I had a lung collaps in September and it has put me out of the game for some time. Anyway my health is back and I have made more progress on the table.. Here are some more photos.

The top obveuosly is modular, (explains why the legs are not painted)
E-track is run cable pulled, water pan done, drain mounted, Home and Limit switches mounted, SOme pain and a little powder coat..

Hoping to be running By next week



Start of the Slats



Blade Runner Controler mounted






Bracket for E-track I dimple dies the hole to clearance the Bearing for the motor