Build Thread- SuperX3

[Crevice Reamer]

Good job Dean! You ARE now off to a good start.

If your CNCFusion kit has not shipped yet, be sure to email Michael that you want the CR Special G540 pulleys with your kit. Otherwise your 906 may be too weak. If you already HAVE the kit, I'm sure Michael will exchange them for you.

I just noticed that in a prior post, Jeff lauded the G540s spindle speed control abilities. Since you have the (Superior in all other respects) SX3, you cannot take advantage of this. You CAN, however set your spindle speed manually once, and then turn the spindle on and off through Mach3. No speed control but almost as good.

CR.

[Quazar]

Originally Posted by Crevice Reamer Good job Dean! You ARE now off to a good start. If your CNCFusion kit has not shipped yet, be sure to email Michael that you want the CR Special G540 pulleys with your kit. Otherwise your 906 may be too weak. If you already HAVE the kit, I'm sure Michael will exchange them for you.

I already have the kit, but I am hoping the gas strut I mounted on the head will help reduce the load on the motor enough to make it work well. I can always change the pulley later if needed.

Originally Posted by Crevice Reamer I just noticed that in a prior post, Jeff lauded the G540s spindle speed control abilities. Since you have the (Superior in all other respects) SX3, you cannot take advantage of this.

Actually, I am working on a spindle speed controller for the SX3. The front panel controls use a pretty simple protocol to communicate with the BLDC motor driver. This protocol sends the current RPM (±10RPM) and takes button presses as inputs. My controller will monitor the VFD signal from the G540 and the RPM readings from the BLDC controller, and will generate button presses to adjust the RPM as needed. This will pretty much be the last part of my conversion, though, so it'll be a while before I have that up and running.

Cheers,
- Dean

[Crevice Reamer]

Not a bad speed control idea. I've thought about doing this with relays and multiple signals from program to simulate button pushes, but have not done so yet.

Can't wait to see what you come up with.

CR.

[Quazar]

Ok, after a bit of a detour for a "honey-do" project, I'm back on my CNC conversion. I've finished my electronics box and it seems to work OK. Tomorrow I'll hook it all up on the benchtop to see if I can get EMC2 to run the steppers.

Here are a few pics.



This box includes the power supply, G540 driver, breakouts for all the limit switches, Cooling fan (with inlet filter), and an E-Stop circuit that will integrate with the E-Stop in the SX3.

The red brackets on the back are to properly hold the G540 in place. The enclosure I used had a rectangular cutout that was not exactly the right size but was pretty close. These brackets help it fit tightly. They are red because that is the color that was loaded in the powder coating gun at the time and I didn't think it was worth the effort of cleaning it to change colors just for these two small parts. Besides, the red adds a splash of color an an otherwise fairly monochrome back panel

Cheers,
- Dean

[skullworks]

Nifty!

[compunerdy]

I am doing a C4 lathe conversion so I will be interested to see what you come up with as far as controlling the motor.

Tim

[BobWarfield]

Love the enclosure. Very nicely done.

Cheers,

BW

[Quazar]

Thanks for the kind words folks!

I've successfully run all three axes with the motors loose on the bench. The power+driver box seems to be working well and the steppers run smoothly.

My next step is to tear down my SX3 and build it back up with the CNCFusion kit installed. I plan to clean and generally improve the condition of the mill as I go. I'll flatten the gib strips, and replace them with these if needed. I'm using CR's fine site as a guide.

compunerdy, I'll certainly keep your build in mind as I make my speed controller. I'll probably have some spare boards made and make them available (assuming they work ).

Cheers,
- Dean

[Crevice Reamer]

Originally Posted by Quazar Thanks for the kind words folks! I've successfully run all three axes with the motors loose on the bench. The power+driver box seems to be working well and the steppers run smoothly. My next step is to tear down my SX3 and build it back up with the CNCFusion kit installed. I plan to clean and generally improve the condition of the mill as I go. I'll flatten the gib strips, and replace them with these if needed. I'm using CR's fine site as a guide. compunerdy, I'll certainly keep your build in mind as I make my speed controller. I'll probably have some spare boards made and make them available (assuming they work ). Cheers, - Dean

Thanks, Dean!

Be careful, that LMS gib set is for an X3. I think the Z gib might be different in an SX3. Better ask Chris to be sure.

CR.

[Quazar]

Originally Posted by Crevice Reamer Be careful, that LMS gib set is for an X3. I think the Z gib might be different in an SX3. Better ask Chris to be sure.

I realized that shortly after I posted - that was a link I grabbed from another thread a while back. Must have been a (non-Super)X3 thread and I just didn't notice. I'll check with Chris if I need new Gibs, but from reading other threads it sounds like the factory gibs are often in pretty sad shape.

Any thoughts on upgraded spindle bearings? My spindle has way too much runout and I'd like to replace the bearings while I've got it all apart. I found this thread, but it sounds like nobody has found a drop-in replacement for the upper bearing.

Cheers,
- Dean

[Jeff Davis]

Dean,

Guess I got lucky with my gibs. Mine were nice and straight / flat . Granted they are made from mystery metal and I would prefer brass ones but mine worked just fine.

Nice work on the control box, I am trying to identify what the box is from. It almost looks like an old Scope housing.

Glad to hear everything for the most part is going well!

Jeff Davis

[Quazar]

Originally Posted by Jeff Davis Guess I got lucky with my gibs. Mine were nice and straight / flat . Granted they are made from mystery metal and I would prefer brass ones but mine worked just fine.

Good to hear. I'll have mine out in a few days and will know what I'm facing then.

Originally Posted by Jeff Davis Nice work on the control box, I am trying to identify what the box is from. It almost looks like an old Scope housing.

I really liked the retro-chic of this case. It is a Bud Industries "Portacab" enclosure. It is designed for tube-era style construction. If you ever took apart a tube radio or TV you'll know what I mean. It is intended to have an aluminum chassis slide in through the front, which is why it has a 2" x 6½" cutout in the back (the chassis would block this cutout and expose whatever connectors were needed).

I wanted to find some old-school round meters too, but no luck finding a matched pair in the right range.

Originally Posted by Jeff Davis Glad to hear everything for the most part is going well!

Me too! Progress is gradual, but I'm taking my time and (hopefully) not making too many mistakes. My next bug hurdle will be drilling & tapping a bunch of holes for the limit switches. Crossing my fingers that a bit or tap doesn't snap off...

Cheers,
- Dean