X3 build - Kflop/Snapamp, Keling servos, AC servo spindle drive, cncfusion kit...

[Al_The_Man]

I think you may have sold me!.
Of course once this feature is captured down pat, then other features of threading come into play which is the ability to program single edge cutting as you would by advancing the tool in a manual lathe by setting the compound rest to 29° , this results in advancing the tool in at the correct angle for each pass and only using one cutting edge, this would be done on a CNC operation by moving the sync point by so much relative to the last sync point, the trigonometric calculation for the degree of advance would depend on the amount of infeed.
BTW, do you know of any Dynomotion users that have developed or using these solutions?
Al.

[TomKerekes]

I think you may have sold me!.
Of course once this feature is captured down pat, then other features of threading come into play which is the ability to program single edge cutting as you would by advancing the tool in a manual lathe by setting the compound rest to 29° , this results in advancing the tool in at the correct angle for each pass and only using one cutting edge, this would be done on a CNC operation by moving the sync point by so much relative to the last sync point, the trigonometric calculation for the degree of advance would depend on the amount of infeed.
BTW, do you know of any Dynomotion users that have developed or using these solutions?
Al.

Hi Al,

Yes that was just an example. I'm not a threading expert but basically once the basic "Spindle-Sync'ed-Coordinated-Motion" is implemented in the Controller then the rest just becomes a matter of GCode programming. In Mach3 a single threading pass is performed with G32. Then you can use the threading wizards to create various multi-pass, tool advance angle, spring-passes, tapers, etc... There is an option to either use G76 or keep it all multiple G32 codes.

yantr3d is one user. I recall he even showed me a weird cone shaped spiral thread thing he made, but I can't find the photo right now.

Regards
TK

[Al_The_Man]

=TomKerekes;964122]Hi Al,

This is exactly how it works with our KFLOP. But we find no need for a marker pulse. The encoder position is enough to know where the marker pulse would occur. There would be a problem if you lose power (and encoder) between cutting passes on a thread. If that were an issue we could "home" the encoder to an absolute marker pulse on power up, but so far that has never been an issue.

Regards
TK

Tom, I hate to belabour the point, but I have read/re-read your MC/Bus analogy and see how you merge the Z smoothly with the spindle at the (hopefully) right ratio, but if not using the marker to re-sync then wouldn't the continuous Spindle encoder value have to be used as the constant value in order for the Z to know the exact entry point of the SP angular position?
Hopefully I explained myself sufficiently.
Al.

[TomKerekes]

if not using the marker to re-sync then wouldn't the continuous Spindle encoder value have to be used as the constant value in order for the Z to know the exact entry point of the SP angular position?
Al.

Well we effectively have a "simulated" marker value. In our configuration the user must tell us the number of encoder counts-per-rev of the spindle. We then arbitrarily define encoder position zero and every multiple of the counts-per-rev to be the "marker" position. So basically before each threading pass begins the system will dwell waiting until the next encoder counts-per-rev multiple (bus) comes by.

TK
Dynomotion | Motion Control Boards

[yantra3d]

First off, many thanks to cjdavis and SFL for the kind words, etc... I am very happy that I am able to share anything with the community after gaining so much knowledge and insight from all of you here. Of course I had ZERO experience with machining or cnc when I found this site and so everyone's contribution here has been most valuable to me. If it weren't for guys like Al_the_Man then I would have likely burned down my shop and never made it to this stage! So, thank you guys!!!

Hey Al, I have successfully cut threads on a taper using the mach lathe threading wizard as Tom mentioned.... in both 404 SS and 6061 Al. The threads were approximately 4.5tpi on a 18 degree pitch and a total length of approximately 3/4". I have done about a dozen or so of these parts and they all came out well without any hiccups. Hope that helps!

[Al_The_Man]

Very impressive, but way too clean!?
I intend trying a system using Kflop/Kanalog, but would hope to develop the DM HMI rather than use Mach.
Some of the software I am waiting for has been help up in the Canada post strike back-log!!
Al.

[sagreen]

Here are the installed limit switch mounting enclosures and triggers for all 3 axis (see pics below). The X axis is a bit exposed however it will be well hidden by the tooling plate once it is mounted on the table. Both of the X axis triggers are designed to move along the front table slot for adjustability. The reason for this is so that I can set the limit position for the addition of a 4th axis rotary table (likely to be a CNC'd 5C collet indexer).

The Z axis limit switch triggers will also be adjustable. The lower trigger adjustability will be convenient for setting the lower travel extent depending on wether the vise is mounted to the tooling plate or not. The upper limit trigger will be adjustable according to the gas strut setting (high or low). In the post above you can see the two gas strut pivot mount positions that will allow a lower setting for normal use and a higher setting for the occassional clearance needed for milling taller parts on the mill. These are just simple round magnets I picked up on sale at LMS that were cut down to size and they work pretty well for this app since they are quickly adjustable and have an infinite range of movement for dialing them in without any restraint.


These switches are wired for NC operation and are tied into a relay that interrupts the servo motor circuit for all 3 axis. the 24V limit switch circuit is also wired into the AC servo drive's enable input which drives the spindle.

pic#1: X axis limit switch:



pic#2: X axis limit switch trigger:



pic#3: Y axis limit switch and (+) trigger:



pic#4: Y axis limit switch triggers positioning:



pic#5: Z axis limit switch:



pic#5: Z axis limit switch trigger (moveable magnetic disc):

Any chance you could post the DXF files for the limit switch covers and the stops?

Thanks,
Scott...

[magnetos2010]

Nice work, I have a x2 , like you a start it but never complete the project :giggle:

Cheers.



Sent from my Mouse 3G

[yantra3d]

Hey Scott, sure.... just pm me and I'll direct you to the files.

Thanks magnetos2010! Don't give up... you'll get there.

[sagreen]

Yantra, sent you PM some time back for the DXF files for the switch covers and triggers. Can you send please?

Scott...

[Analias]

Yantra - I tried to send a PM to ask for the files, but your inbox is full. Could I get a copy of files?

If anyone got a copy, and there are no restrictions on them, could they send me a PM with the files?

-Freeman

[scott wiggins]

Tried to send you a pm to request the files but your box is full. I too would like to get the files.

Scott