Router opportunity with a few unknowns

[D_moll]

Hi all,

I have a crazy opportunity to get myself an 4000x2000mm ATC router.
It does have some issues but at a price per kg it's more than a bargain!

The specs are:
Dimensions: 4500x2500mm (working area 4200x2000x200mm)
Spindle: HSD ES 330A 4.5kW Air cooled ATC ISO30
VFD: Omron (Yaskawa V1000 3phase)
Servo drive: Omron (Yaskawa SGDH 08AE-S-OY + NS100)
Servo motor: Yaskawa SGMAH-08AAA61D-0Y, 750W, 200V, 3000rpm
Servo gearbox: Wittenstein alpha LP 070-M01-10, 1:10
Control unit: Osai 10/510
Rack and pinion: helical approx 20mm wide, not sure about exact dimensions
Linear rails: PMI-AMT 25 table, PMI-AMT 20 gantry, not sure but i presume 15 or 20 on the Z axis
Tools: Linear ATC 12 positions ISO30
Vacuum: 2X Becker 5.5kW pumps, 4 vacuum zones (electronic actuation of individual zones)
Air/Mist coolant: electronic actuation
Automatic tool measuring mounted on table frame
All accessories are 24V

Construction is very robust, i don't have exact numbers but I would say table is made of 150x180mm steel RHS, table braces 100x100mm steel RHS, gantry is around 280x250mm steel RHS. Not sure about wall thickness, but it's quite thick.

The main issue is control unit. It's Osai 10/510 and its on it's last legs.

I Have 99% decided on UC300ETH-5LPT + UCBB breakout board + 2xIDC26-IDC26 cables + free UCCNC license key. For 212€ that is hard to beat. Other options were Acorn and Masso but they are at least 3X in price.
I do have concerns about number of relays that I'll need
Is there an option to run servos with modbus? and what would be the advantage vs pulse/dir?
Essentially I need to replace the control unit and rewire everything, I'm not sure if that is possible and to what extent.

The bonus is that machine schematics are lost (I'm trying to obtain a copy as that would make things much easier)

Any experience? advice? comments?

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[ger21]

I Have 99% decided on UC300ETH-5LPT + UCBB breakout board + 2xIDC26-IDC26 cables + free UCCNC license key. For 212€ that is hard to beat. Other options were Acorn and Masso but they are at least 3X in price.

I wouldn't be trying to save $500 on what sounds like a $100K machine. Just saying. And I'm a UCCNC user.

No, you can't run servos with Modbus.
Do those drives accept Step/Dir control?

[D_moll]

I wouldn't be trying to save $500 on what sounds like a $100K machine. Just saying. And I'm a UCCNC user.

No, you can't run servos with Modbus.
Do those drives accept Step/Dir control?

Well, it was a 100K machine back in 2009! which is why i'm so excited to get it at scrap metal price.
I did find a few examples of people running old SGDH drives with step/dir and as far as I can tell it's just a matter of configuring drive to run of those instead of modbus. The NS100 is obsolete as it's used for modbus connection between drives and for returning values to control unit.
I'm planning to have a dedicated computer for this CNC anyway so what would be the benefit of Masso or Acorn compared to UC300ETH?
They all have very similar capabilities, and all use their own software. The reason I'm leaning towards UC300ETH is their user base and forums, a lot of my doubts have already been solved by someone.

What would you suggest for a controller?

[breezy1849]

MASSO, but then I’m biased to MASSO.


Sent from my iPad using Tapatalk

[ger21]

What would you suggest for a controller?

My preference is UCCNC, which is what I use.

[D_moll]

As I mentioned they all have very similar capabilities which are far beyond what I really need, so it comes to small subtle preferences that everyone would rank different.

I managed to find most of my doubts already resolved and I like how UCCNC works and looks

connecting SGDH yaskawa drives:
https://www.cnczone.com/forums/servo...57229-cnc.html
This is the same series only smaller, it takes sigmawin to change the parameters and re-tune the motors

Connecting V1000 VFD is covered so many times, for connecting and reading current rpm over modbus/usb

I found the exact tool change procedure macro on a cncdrive forum that also uses fixed tool length probe, so it's just a matter of changing some coordinates and pin numbers

This machine will require A LOT of work, it was very poorly maintained and it will take a fair bit of parts to get it perfect.
First thing is the linear bearings, Z axis is good, on gantry they would need cleaning and lubrication, but on the table they are beyond repair and need to be replaced. Pneumatic system has never been touched. Rack and pinion on the table is also a big question.
Essentially I plan to take everything apart, test, repair/replace and reassemble, while it's in pieces it would be good to put a fresh coat of paint on everything.

[dazp1976]

The UC300eth, ucbb, are great bits of kit.
Although 300 could do with more inputs afaic.

[D_moll]

As the OP said, the opportunity was too good to be passed, so I did it...
From the current perspective it's not so bad, but at the time machine looked very bad (hence the price).
The overall neglect, dirt, grime, coupled with few controller issues made it obsolete in the company.
But, i knew that deep down, it was still a good machine


So I took a better look at all the components, and it was all very solid (expensive) components that can work for many years more...

[D_moll]

Anyway, few more images from back in 2022...


So the electronics even though old, are still in decent shape, and very neatly put together (I do have all schematics of the machine)...

[D_moll]

Anyway...
The main thing was neglect, and that shows on the outside (even though all components were there, some panels were taken off, and the machine was used as a table when not in use)...

[D_moll]

there was paint and silicone all over machine, but that's just cosmetic...

[D_moll]

And a few concerning mechanical issues...

[D_moll]

Now that's all great, but it's a big machine, where are you going to put it???
Errr... I have... A shed???

[D_moll]

And so it begins...
A small excavator and the shed was no more, and the everything was prepared for foundations, and the main slab...

[D_moll]

3 trucks of concrete for foundations and 2 trucks for the slab, we were getting somewhere.... (and a sh... load of rebar steel at covid prices)

[D_moll]

And just as I was building walls... the new machine came to factory and the old one had to go! NOW!

[D_moll]

Anyway... This meant that I had a machine and I was building a workshop around it! Not the most conventional was but nothing about this is...


And since it will be some time before finishing walls and roof, i covered it...

[D_moll]

Eventually the roof came so it was starting to look like workshop...

[D_moll]

And just like that, the roof was done...



Now to close the openings and on with electrical installation...
I have to transfer photos, but the machine is currently operational...
anyway, to be continued....

[RaderSidetrack]

Anyway... This meant that I had a machine and I was building a workshop around it! Not the most conventional was but nothing about this is...

That approach certainly make it easy to fit the machine through the doorway -- just have the crane on the truck place the machine where you want it!

Nice work!