New Machine Build Iron-Man Servo CNC System-Red Candy Running - Page 4


Page 4 of 4 FirstFirst 1234
Results 37 to 47 of 47

Thread: Iron-Man Servo CNC System-Red Candy Running

  1. #37
    Registered Iron-Man's Avatar
    Join Date
    Jan 2009
    Location
    United States
    Posts
    260
    Downloads
    0
    Uploads
    0

    Thumbs up Latest Updates

    I am just about finished, still a few tweaks to make. This mill was a pre-cnc ready model. It was converted to cnc using a Sherline Kit. If you are converting a pre-cnc model here is an excellent link to a video. It is in two parts; Sherline Mill CNC Conversion 1 - blip.tv - Motore di ricerca video Truveo .

    The servos are powerful and quiet. The only thing that you can hear is the spindle motor and cooling fans. Sorry about the rough images. I still need to set the correct number of steps in mach. This was a quick test, with calculated servo parameters and motor tuning. Covers on the servos were left off and lead screws were tightened just enough to test. I must locate more scrap materials for testing. In addition, the gap-pad material has worked excellent. The OPA 549s were cool to the touch, lots of surface area and forced air cooling.
    Enjoy,

    Iron-Man

    Attached Thumbnails Attached Thumbnails Iron-Man Servo CNC System-Red Candy Running-y-axis-tap-guide-jpg   Iron-Man Servo CNC System-Red Candy Running-x-axis-tap-guide-jpg   Iron-Man Servo CNC System-Red Candy Running-modified-mill-jpg   Iron-Man Servo CNC System-Red Candy Running-test-1-jpg  

    Iron-Man Servo CNC System-Red Candy Running-test-3a-jpg  


  2. #38
    Registered Iron-Man's Avatar
    Join Date
    Jan 2009
    Location
    United States
    Posts
    260
    Downloads
    0
    Uploads
    0

    Smile Calibration and Testing

    Here are a few pictures of calibration and testing of the servo system.
    Specs: Mach 3, 1/8 inch end mill. I did not have the correct end mill for the initial pocket test (2024 Al) and was not able to alter the initial settings in the demo version of Mach 3. This would have been a lot better with a engraving bit and higher RPM. After a few more test I will machine out a template for the I/O and power connectors to the CNC controller and powder coat them.

    Iron-Man

    Attached Thumbnails Attached Thumbnails Iron-Man Servo CNC System-Red Candy Running-calibration-1-jpg   Iron-Man Servo CNC System-Red Candy Running-calibration-2-jpg   Iron-Man Servo CNC System-Red Candy Running-first-pocket-2024-al-1a-jpg   Iron-Man Servo CNC System-Red Candy Running-first-pocket-2024-al-1b-jpg  

    Iron-Man Servo CNC System-Red Candy Running-engraving-test-calibration-jpg  


  3. #39
    Registered Iron-Man's Avatar
    Join Date
    Jan 2009
    Location
    United States
    Posts
    260
    Downloads
    0
    Uploads
    0

    Smile First CNC Milled Part

    First Iron-Man Servo CNC milled part. I rescaled the batman logo dxf file in Turbocad professional v12.5 mechanical edition, followed by a resetting of the (x,y,z) reference point. The part was then cleaned up with 600 grit sandpaper. I am not sure what the specs are on the Al as it was obtained from an electronic surplus store. The batman logo is 5.25" x 2.57".
    Specs: Mach 3, 1/8 end mill, feed 2 in/min. The cut seemed a bit gummy. I will try a faster feed rate next time.


    Iron-Man

    Attached Thumbnails Attached Thumbnails Iron-Man Servo CNC System-Red Candy Running-batman-1a-jpg   Iron-Man Servo CNC System-Red Candy Running-batman-1b-jpg   Iron-Man Servo CNC System-Red Candy Running-batman-1c-jpg   Iron-Man Servo CNC System-Red Candy Running-mach3-batman-jpg  

    Last edited by Iron-Man; 11-19-2010 at 12:23 PM. Reason: Additional info / dimensions.


  4. #40
    Registered Iron-Man's Avatar
    Join Date
    Jan 2009
    Location
    United States
    Posts
    260
    Downloads
    0
    Uploads
    0

    Default Circuit Boards ?

    Just wanted to get an idea of how many would be interested in Iron-Man Servo Amps. Would you prefer surface mount technology or through hole? Kit form or complete board? Also, how many would be interested in the servo reducers?, Kit, complete unit, drawings etc.

    Updates: I have switched over to EMC2.

    I will post video when I can.


    Iron-Man



  5. #41
    Gold Member
    Join Date
    Jul 2003
    Location
    Holmen, WI
    Posts
    1558
    Downloads
    2
    Uploads
    0

    Default

    Can I ask why?

    Quote Originally Posted by Iron-Man View Post

    Updates: I have switched over to EMC2.




  6. #42
    Registered Iron-Man's Avatar
    Join Date
    Jan 2009
    Location
    United States
    Posts
    260
    Downloads
    0
    Uploads
    0

    Default EMC2

    Quote Originally Posted by samco View Post
    Can I ask why?

    EMC2

    EMC is free software with open source code. Current versions of EMC are entirely licensed under the GNU General Public License and Lesser GNU General Public License (GPL and LGPL)
    • EMC provides:
      • several graphical user interfaces including one for touch screens
      • an interpreter for "G-code" (the RS-274 machine tool programming language)
      • a realtime motion planning system with look-ahead
      • operation of low-level machine electronics such as sensors and motor drives
      • an easy to use "breadboard" layer for quickly creating a unique configuration for your machine
      • a software PLC programmable with ladder diagrams
      • easy installation with .deb packages or a Live-CD


    It does not provide drawing (CAD - Computer Aided Design) or G-code generation from the drawing (CAM - Computer Automated Manufacturing) functions.
    • It can simultaneously move up to 9 axes and supports a variety of interfaces.
    • The control can operate true servos (analog or PWM) with the feedback loop closed by the EMC software at the computer, or open loop with "step-servos" or stepper motors.
    • Motion control features include: cutter radius and length compensation, path deviation limited to a specified tolerance, lathe threading, synchronized axis motion, adaptive feedrate, operator feed override, and constant velocity control.
    • Support for non-Cartesian motion systems is provided via custom kinematics modules. Available architectures include hexapods (Stewart platforms and similar concepts) and systems with rotary joints to provide motion such as PUMA or SCARA robots.
    • EMC runs on Linux using real time extensions. Support currently exists for version 2.4 and 2.6 Linux kernels with real time extensions applied by RT-Linux or RTAI patches.

    In summary, real time operating system, can control servo amps (+-10v) etc, encoders for closed loop and it is "FREE".

    Iron-Man



  7. #43
    Registered Iron-Man's Avatar
    Join Date
    Jan 2009
    Location
    United States
    Posts
    260
    Downloads
    0
    Uploads
    0

    Smile Video Finally

    Sorry for the long wait, but here is a video of the system. My video camera is not HD but it gets the job done. I decided to go with EMC2, but the system still works perfect with MACH3. I just need to purchase some end mills, bits and materials and start making parts.
    Future projects will include new servo drives based on TI DSPs and a conversion of a Denford Novaturn CNC lathe.

    [nomedia="http://www.youtube.com/watch?v=AopqlifEwmA"]YouTube - Iron Man Servo 03 26 2011 HQ NTSC[/nomedia]


    Hope you all enjoy.

    Iron-Man



  8. #44
    Registered
    Join Date
    Jan 2011
    Location
    USA
    Posts
    385
    Downloads
    0
    Uploads
    0

    Default

    Iron-Man that powder looks excellent. Did you ever get a good solution for your TO-220 insulation? I use a Mica insulator between the T0-220 packaging and heatsink with thermal paste on both sides of the Mica all fastened down with nylon screws nuts and bushings. I've never had a problem doing that and some of the components I do this with get to almost 200*F at times. My parts are ignition drivers and injector drivers in a MeagSquirt but they see a lot of power at the longer dwell cycles like WOT and I've never had one failure.

    How is EMC2 treating you? I'm going that route as well with EMC2 closing the servo loop.

    Jeremiah
    PM45 CNC Build in Progress


  9. #45
    Registered Iron-Man's Avatar
    Join Date
    Jan 2009
    Location
    United States
    Posts
    260
    Downloads
    0
    Uploads
    0

    Default TO-220 Insulation

    Quote Originally Posted by Maglin View Post
    Iron-Man that powder looks excellent. Did you ever get a good solution for your TO-220 insulation? I use a Mica insulator between the T0-220 packaging and heatsink with thermal paste on both sides of the Mica all fastened down with nylon screws nuts and bushings. I've never had a problem doing that and some of the components I do this with get to almost 200*F at times. My parts are ignition drivers and injector drivers in a MeagSquirt but they see a lot of power at the longer dwell cycles like WOT and I've never had one failure.

    How is EMC2 treating you? I'm going that route as well with EMC2 closing the servo loop.
    I did locate a great solution to the heatsink problem; Gap Pad 5000S35 Features ~ Thermal Materials, Thermal Solutions ~ The Bergquist Company

    This material has worked excellent. I will be switching over to a TI or IR devices for the power stage. The OPA549s are great, but I want to get away from the split power supply. EMC2 is great, although it has a higher learning curve. I will be looking at the MESA boards to close the loop.

    Iron-Man

    Attached Thumbnails Attached Thumbnails Iron-Man Servo CNC System-Red Candy Running-servo-amp-gp5000s35-jpg  


  10. #46
    Registered Iron-Man's Avatar
    Join Date
    Jan 2009
    Location
    United States
    Posts
    260
    Downloads
    0
    Uploads
    0

    Default Re: Iron-Man Servo CNC System-Red Candy Running

    There was never a problem in heating for the OPA 549 amps. All of the parts for the NovaTurn update were made on this Sherline mill using the Iron-Man Servo amps.
    Please see: http://www.cnczone.com/forums/bencht...61754-cnc.html


    Thanks,

    Iron-Man



  11. #47
    Registered
    Join Date
    Jan 2016
    Location
    United States
    Posts
    1
    Downloads
    0
    Uploads
    0

    Default Re: First CNC Milled Part

    Can someone post this Batman Logo DXF file so I can resize it in Ironcad?

    Thanks Chris



Page 4 of 4 FirstFirst 1234

Tags for this Thread

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  


About CNCzone.com

    We are the largest and most active discussion forum for manufacturing industry. The site is 100% free to join and use, so join today!

Follow us on


Our Brands

Iron-Man Servo CNC System-Red Candy Running

Iron-Man Servo CNC System-Red Candy Running