Build Thread- Tsugami spl cnc conversion using DSPMC/ip controller

[TOTALLYRC]

I am using the same control box on mmy lathe as on my mill since I really like it and I had analog input servo amps in stock.

The x has .003 backlash and the Z Has about .005 I am going to work on reducing the baclash on both axis as I progress but for now I am wiring up the control box, putting together the computer and adding the limit switches.

A couple of things.

1. I will be putting the Z limit on a slider so I can set the limit switch near the chuck depending on the job I am working on.

2. I will be making a nice control panel and possibly getting a touch screen computer, depending on how the money goes.

3.I will be looking to add an air operated cylinder to the collet closer so I can just push a button and have the collet open and close. It will allow for a bar feeder to be added later.


Pics to follow.

Mike

[TOTALLYRC]

Here are some pictures of where I am at today.

I have removed all of the parts that were needed for maual operation, but are not needed for CNC. They are available for purchase if anyone is interested.

On the electronics side I have 2 AMC brushless servo amps and a 50v power supply. Since the lathe only has about 15" in the z, I would like to get at least 50ipm and preferably 100ipm.

For the BOB power, I scored a Phoenix contact 24v, 2.5 amp power supply for the I/O. To power the dspmc/ip and the 5v needed for the bob control power I had a combined 12v/5v potrable hard drive power supply.

The control cabinet, terminal strips, and the fuse holders are all dumpster finds.

The jumble of orange wires coming from the drives is just temporary wiring to make sure the drives power up and come out of fault status. I will need to use a few relays to get the enable and fault signals from the drives to the dspmc.

I have 2 40 amp solid state relays to turn on the coolant and something else. I know they are massive overkill, but they work great on my other machines and I bought them real cheap last year.

I currently have a RPC(rotary phase converter) ready to power the spindle motor, but I am saving my pennies to get a Hitachi sj200 vfd since the one on my mill works so well.

The VFD will go inside the factory electrical cabinet. I am considering putting all of the controls inside the factory cabinet, but I will do it only after everything is wired up and tested.

Please feel free to ask question, offer suggestions, or just general comments.

For those of you who want more insight into my choice of controller and its capabilites, see my mill build log here.

BTC-1 retro fit using DSPMC/IP controller.


Mike

[TOTALLYRC]

I forgot to attach the pictures.

The control cabinet is sideways in the picture but the dspmc should be at the top.


Mike

[TOTALLYRC]

I was able to get some more work done in between bouts of yard work.

Both the x and z pulleys are bored to size and the x was counter bored to clear the bearing adjustment housing.

When I find the factory nuts I will put them back on. The Z pulley is on a tapered shaft. I set the lathe for a 1 deg taper and it fits really nice.

Mike

[TOTALLYRC]

I was able to grab my wife's old desktop and my son's old monitor and get them installed and talking to the dspmc.

I also installed the latest lockdown version of Mach3 and setup a lathe profile.

If I keep this up, I will be finished in less than a year.

Mike

[TOTALLYRC]

I placed my order for amt 102 capacitive encoders and the line driver cables.
This way I have a lot less soldering to do.

The encoders have nice adjustable resolution and since the dspmc will handle high pulse rates 2mhz, I will go with higher than 500(2000in quad) encoders.
With just the change of settings on the encoders, and a change in the steps per inch, I can really test out the capabilities of the encoders, the dspmc and the lathe itself.

I am looking thru the pile-o-motors to see what I can use or more likely will order something from ebay today. I would love to go with brushless motors since the drives will run them, but I don't want/can't spend a fortune this month.

More updates to follow as they happen.

Mike

[TOTALLYRC]

The encoders came in in 2 days and they look like they will do the job nicely.

I am still pursuing motors but haven't come up with any ones just yet.

I have been side tracked by the latest additions to the shop.

A nice Monarch 11" "C" with an actuall swing of 14.5", which came with a bunch of goodies, a conventional surface grinder with magnetic chuck, and a Greenard #3 arbour press. I think I will need to expand the building soon.

Mike

[TOTALLYRC]

Just a quick update to let you know I am still working on it. Seeing as how it has been almost 4 months since the last update.

I have several different motors that I picked up and will be starting back on it this weekend since it is raining and is expected to rain all day and possibly tomorrow.

Any body have any questions or comments? It gets lonely here all by myself.

[Milton SWFL]

Have that same lathe, hope to someday to cnc it.

What are your plans for turret?

Milton in SW fl.

[TOTALLYRC]

Originally Posted by Milton SWFL Have that same lathe, hope to someday to cnc it. What are your plans for turret? Milton in SW fl.

I will start out by doing the turret manually but I will probably drive it with a servo or stepper when the rest of the machine is done.
Let me know when you start yours and we can swap notes.

In this economy it is hard to believe but I have been swamped with part time work, mandatory overtime at the primary job, and a few machining orders.
I will take it though as not working sucks.
That is why this is taking a lot longer than expected.

Mike

[pofo]

Mike,

How did the DSPMC work out?

[TOTALLYRC]

Originally Posted by pofo Mike, How did the DSPMC work out?

Hi POFO,
Well the dspmc is working great on the mill but I still have not had the time to get the lathe up and running. The latest excuse is that I spent the long Thanksgiving weekend (4 days) moving in a nice Monarch CK12 lathe and a surface grinder into the shop. Not to mention working on the honey do list. Since I had to remove my Atlas lathe in order to fit the two new machines my time has been taken up with getting the 3 phase converter setup and wired. This way I can use the new lathe to make some parts for the Tsugami conversion.

The overtime monster has aslo been attaking me again. It is hard to pass on the OT in this economy. Besides the extra money will come in handy when I need to buy more toling and stuff.

I will be posting some updates when more work actually happens.

I will have some time in the shop over the holidays and since the Monarch is just about wired, I should be able to get some time on the Tsugami and the BTC-1.
I have just updated the firmware on the mill to a test version that Rufi is working on. It contains all of the updates to this point. A nice change is that the machine will now home and back off of the homing switchses as opposed to just stopping on them.

The lathe htreading from what I undersand is working well but I will testing that out as soon as the lathe is up and running.

As always, feel free to ask questions, I have this sickness and like to answer them, even if I am wrong.


Mike