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rock4xfab
07-01-2010, 11:29 PM
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"

http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/PlasmaTable001.jpg

I removed my 3/16" top from my blanchard ground table so I could be realy anal and get everything square and true
http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/PlasmaTable002.jpg

My table is that much out on the floor so close enough
http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/PlasmaTable009.jpg

rock4xfab
07-01-2010, 11:32 PM
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.

http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/PlasmaTable012.jpg

http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/PlasmaTable015.jpg

http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/PlasmaTable017.jpg

lukewarm
07-02-2010, 02:56 AM
Amazing quality work! Can't wait to see it up and running, cheers!

vcooney
07-02-2010, 04:24 AM
Nice welds, keep us posted.

Vince

rock4xfab
07-02-2010, 11:45 AM
Nice welds, keep us posted.

Vince

Thank you, Welding is my main source of income along with the machining.. Generaly under a helmet of 14 hrs a day. So you either get good or get out. LOL

rock4xfab
07-02-2010, 11:50 AM
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

http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/Palsmagantryparts001.jpg

http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/Palsmagantryparts002.jpg

http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/Palsmagantryparts003.jpg
And for those that like pretty welds here is a teaser
http://i10.photobucket.com/albums/a102/rockfab/General%20fab/IMG_1055.jpg

http://i10.photobucket.com/albums/a102/rockfab/General%20fab/IMG_1232.jpg

AndiKid
07-18-2010, 12:36 PM
Hey, your table build looks very nice and impressively professional. Do you have any further pictures and information on your build?

Best regards

Andreas

rock4xfab
07-22-2010, 02:53 PM
Hey, your table build looks very nice and impressively professional. Do you have any further pictures and information on your build?

Best regards

Andreas

I have been super busy but I have a few updates I will post up later tonight... All my electronics have shown up, and the rails are mounted and I have the gantry trued up... I still have to source the E-track and then disasemble for powder coat and build my water table...

AndiKid
07-25-2010, 07:03 AM
Hey Rock,

that sounds good and it would be really great if you could find the time. I think me and many others would appreciate it very much.

rock4xfab
07-26-2010, 12:39 PM
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




http://i10.photobucket.com/albums/a102/rockfab/Palsmagantryparts008.jpg

http://i10.photobucket.com/albums/a102/rockfab/Palsmagantryparts011.jpg

http://i10.photobucket.com/albums/a102/rockfab/Palsmagantryparts014.jpg

Hard to see but inside the rail is the 3/16" drilled and tapped plate that the rails are bolted into.
http://i10.photobucket.com/albums/a102/rockfab/Palsmagantryparts009.jpg

Scotts Elle
07-31-2010, 10:57 AM
http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/Palsmagantryparts001.jpg

http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/Palsmagantryparts002.jpg


Awesome build. Alot of attention to detail here. 2 questions:

What did you use to cut your steel. Those are very clean cuts! Cold saw?, Band saw?

Can I ask where you bought this gantry kit? Link?

rock4xfab
07-31-2010, 01:08 PM
Awesome build. Alot of attention to detail here. 2 questions:

What did you use to cut your steel. Those are very clean cuts! Cold saw?, Band saw?

Can I ask where you bought this gantry kit? Link?

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
08-14-2010, 11:57 PM
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- Improved Mach 3 Axis Calibration

rock4xfab
08-17-2010, 05:22 PM
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
08-18-2010, 08:06 PM
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.

http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/CM51Circuitboard.gif

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
http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/PlasmaCUtterelectronics016.jpg

-Raw Arc connection
http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/PlasmaCUtterelectronics017.jpg

+ Raw Arc connection
http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/PlasmaCUtterelectronics018.jpg

Location for DTHC Card
http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/PlasmaCUtterelectronics013.jpg

Card mounted on stand off mounting plate
http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/PlasmaCUtterelectronics011.jpg

http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/PlasmaCUtterelectronics012.jpg

http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/PlasmaCUtterelectronics024.jpg

http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/PlasmaCUtterelectronics035.jpg

rock4xfab
08-19-2010, 02:52 AM
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...

http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/PlasmaCUtterelectronics037.jpg

http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/PlasmaCUtterelectronics038.jpg

And the torch on command light

http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/PlasmaCUtterelectronics040.jpg

rock4xfab
08-20-2010, 12:11 PM
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.


http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/PlasmaCUttertableandsides003.jpg

inside shot where the slats will interlock
http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/PlasmaCUttertableandsides002.jpg

http://i10.photobucket.com/albums/a102/rockfab/50x60%20Plasma%20Table%20build/PlasmaCUttertableandsides001.jpg

GAWnCA
09-07-2010, 03:40 PM
Nice work and table. Will it be heavy enough for the rapid movements? What do you figure the total table will cost, less the plasma cutter? Will be be using a straight plasma torch head?

I'd like to build one of these.

Erick Davidson
09-07-2010, 05:27 PM
Thanks for posting the DTHC connections inside your Thermal Dynamics plasma. That is just the information I was looking for. Sweet build, very clean!
Cheers, Erick

rock4xfab
09-08-2010, 11:34 AM
Nice work and table. Will it be heavy enough for the rapid movements? What do you figure the total table will cost, less the plasma cutter? Will be be using a straight plasma torch head?

I'd like to build one of these.

As for weight by the time it is done with the water table installed I dont believe it will be an issue. Price break down

CandCNC Dragon cut blade Runner $1640.
Precision Plasma 3x4 with gear drive and the better Ball screw for Z Axis
$2350.00

Mach license $160.00
Mechanical torch for my cutmaster 51 $535.00

And as of right now I have about $200. in materail, screws, and connectors

I would guess another $200-$300 in powder coat and castors.

All said and done I will probably be just over $5000.00

Now I didnt need to get the mechanical torch.. I wanted it. This way I can still use my plasma for a hand unit when needed.
I did not have to put home and limit switched on it, but I did.
I dont have to have it powder coated but I will.
I could have bought a base line system from CandCNC for half.
I could have also purchased one of the 2x2 kits from Precision plasma. but I wanted soemthing a little more commercial.

So if you had a plasma cutter already you could get away for alot less. I just chose to get all the xtras up front. and nicle and dime the small stuff

rock4xfab
09-08-2010, 11:36 AM
Thanks for posting the DTHC connections inside your Thermal Dynamics plasma. That is just the information I was looking for. Sweet build, very clean!
Cheers, Erick

No problem... I looked along time and never did find what I was looking for, and figured I am not the only guy that bought a TD cutmaster. So I hope that helps sombebody that does the same.

GAWnCA
09-10-2010, 09:02 AM
Thanks Rock for that information. It's not in my immediate future but is something I’d like to have within a year. I would like to buy one of those gear drive units for another project I have planned.

edrawe
03-24-2011, 01:46 AM
Are the rails alum? If so is that a steel piece that the bearing rides?
I wonder how there put together.