Build Thread 'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo - Page 5


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Thread: 'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo

  1. #81
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    Default Re: Cutter Suggestions

    Quote Originally Posted by louieatienza View Post
    Buy them as you need them, and buy spares of each one to minimize downtime. Compression spirals for panels; the faster your machine can cut and the more HP your spindle has, the more flutes you can use. I like Onsrud tools. Insert V tooling from Amana is great, since you get two edges from each insert, and they can be honed in a pinch if needed. You also don't have to remove the tool to change the insert which is a good thing should one break or go dull in the middle of a job.

    I'd hold off on 3D cutting tools until you really need them, because some 3D jobs will require a tapered ball endmill, and some can use a larger core box or ball nose bit.
    Yeah we held off on buying a combo set, we just got a few 1/4" Onsrud Carbide single flute cutters and a 3 Edged 60deg Carbide sign cutting bit from LeeValley to do some test V carve signs for now. I'm sure 3d work will be in the near future but I'll look more into the Amana insert ones too.



  2. #82
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    Default Re: 'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo

    Some pictures of spindle mounted...

    Attached Thumbnails Attached Thumbnails 'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo-101-large-jpg   'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo-102-large-jpg   'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo-103-large-jpg  


  3. #83
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    Default Z Axis Drag Chains

    We added a drag chain to the Z axis, we didn’t know how much cable was going to need to make it to the front of the Z so we ordered two drag chains of the same length, the left drag chain is mounted to the black electrical box on the top of the Z shelf, the right drag chain is mounted onto a bracket that will be supporting the various air filters and regulators.

    The drag chain is 4.7”x1.4” with 5” bend radius from McMaster Carr, we couldn’t find this size in the length we needed from Amazon or Ebay in order to fit the large diameter of the Spindle VFD cable. We are currently running the signal cables in on the left length and the VFD cables and air hoses in the other to try and eliminate as much noise as possible.

    We fabricated a bracket out of angle iron and painted it black that bolts onto the top of the two pneumatic cylinders of the two slides on either side of the spindle. These stay fixed relative to the z plate that goes up and down. The end result is a clean and impressive looking cable management system.

    Attached Thumbnails Attached Thumbnails 'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo-1-large-jpg   'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo-2-large-jpg   'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo-3-large-jpg   'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo-4-large-jpg  

    'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo-5-large-jpg   'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo-6-large-jpg   'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo-7-large-jpg  


  4. #84
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    Default ATC Spindle Control Set Up

    The Spindle uses 4 Conductor AWG10 for the 3 phases of power and ground, 5 conductors of AWG18 for fans, thermal switches and grounds and 9 conductor AWG22 for tool change sensors, push button lights and grounds. (All 18 wires needed to be shielded to eliminate interference and be 50 ft long = $$$. Do not under estimate how much you will spend on shielded and un shielded cable alone for big machines.) They then terminated into 2 military type connectors at the spindle and are screwed into place for solid connection during operation. See picture attached.

    The ATC function brings a whole new level of complexity in terms of pneumatics to cool and to control the tool change operation. The way this spindle works is it requires two filtered air streams, one that runs a 60 psi steady stream of air (low volume) into the top of the spindle and pushed through the bearing and exhausted out the bottom of the collet area to help cool internally as wells as to keep any dust out for contamination free operation.

    The second stream supplies 100PSI of air to a series of safety solenoid switches and eventually to the draw bar. In order to perform a tool change operation 3 conditions have to be met prior to the draw bar releasing the tool collet ( 3 normally closed air valve solenoids in series, all have to be activated in order for air to travel to the draw bar) :

    1- Adequate pressure at the draw bar (We don’t want the tool to try and release if the air is not supplied to it.
    2- The Spindle must not be rotating. ( Ejecting a cutter from the spindle at 24000RPM is bad)
    3- The tool change button must be held down. (we don’t want it to release when it’s not told to be)

    In order to make sure that the 3 conditions are adequately met for tool change function to be operated.

    1. We have 4 adjustable pressure switches located at the back of the Z shelf, two are used to make sure that supply pressure from the compressor is between a min and max range. As long as the pressure is acceptable; an OK signal is sent to the first solenoid to open.

    2. In order to make sure that the spindle is not moving we use an output signal from the Hitachi VFD that sends a high signal when the VFD is sending 0 Hz signal to the spindle. (I.e. the VFD is not moving the spindle.) As soon as the VFD starts moving the spindle above 0 Hz the signal goes low and that air solenoid closes preventing pressure from getting through to the draw bar.

    3. The third condition is satisfied with the green push button on the spindle which activates the tool change function. We hooked up this signal from the spindle to a relay in the electrical cabinet, this relay send out 2 signals; the first goes to the third air solenoid to open it and allow air to pass. The second signal goes to the Hitachi VFD as an input. The VFD takes this input as a permission to start input, meaning as long as this signal is high into the VFD it can’t start no matter what.

    At the same time we took the 0 Hz signal from the 2nd condition above to a relay that determines if power is sent to the Tool change button switch and the button light on the spindle. So now, not only will the spindle not start if the button is pushed, the button will not light up or function unless the spindle is stationary which is handy to have when you can’t see the cutter under the dust shroud or if the button was accidentally bumped during operation it adds another level of safety.

    Both air streams have a 5 micron contaminant filter (Silver one in pics) leading into a 0.1 micron de-oiler filter (black one) to keep the internal air supply as clean as possible. (Both were from Mcmaster Carrr) the air supply then splits into 2 regulators to drop the pressure down to 60 and 100PSI.

    And now the typical disclaimer, this is how we did it, I’m not suggesting this is how anyone else do it. It seems like the professionals don’t like to share how they do it because they make their income with service calls. So take any advice in this thread as a suggestion and use at your own risk.

    Attached Thumbnails Attached Thumbnails 'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo-dsc02236-large-jpg   'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo-dsc02234-large-jpg   'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo-dsc02238-large-jpg   'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo-dsc02240-large-jpg  

    'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo-dsc03552-large-jpg  


  5. #85
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    Default Re: 'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo

    Can you please post some videos of this beast running? Wow!!!



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'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo

'Project Overkill' 4 Axis Heavy Duty 5'x10' Servo