CNC Upgrade and Fretboard program

[Diane Kauffmds]

YES! I'm back into building mode. I finished the machine in its entirety yesterday.

[Diane Kauffmds]

I've finished the x-axis, the last thing that needed upgrading. The original screw was an 8mm lead screw and the guide rods were 10mm. I've installed a 16mm ballscrew and 16mm guide rods. King Kong and 5 water buffaloes could stand on this machine and it wouldn't budge.

I've cleaned up the old hot glue places (use it to make sure the wires stay where I want them), put the wires where they need to be, and installed the new super precise collets into nuts.

It's done. There's nothing else to upgrade. I've finished the tedious fine details like wiring the limit switches and general clean up.

I've cut an R on the machine with amazing results. This font has tiny squares that are around 0.75mm, which are a part of the font. The collet makes all the difference in the world. The top photo doesn't have the square, because it was reduced to dust.

Both R's were cut using the same computer file and out of the exact same piece of shell ablam, with the same bit. The only difference is the use of the Technicks collet with a TIR rating of 0.0002"

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[Diane Kauffmds]

Hey guys,

I know it's been quite a while since I've posted. My husband had some very serious problems associated with his heart, which (hopefully) will stay resolved. Life's been a big roller coaster of late.

Well boys and girls, I ended up needing to upgrade the spindle motor, stepper drivers, and controller on the CNC. It started with the 600w spindle stalling while cutting an ebony bridge. I finally gave in to the inevitable; I needed a powerful spindle motor run from a VFD (Variable frequency drive). I prefer to run grbl based software, so it took me time to find a controller that had VFD support built-in. I found one hand-made by a man in Bulgaria.

So, I know have the wiring nightmare, which fortunately is under control now. I also realized that the old controller wasn't made for the bigger stepper motors. Now the machine flies without stalling, because I installed 3 stepper motor drivers.

I had a time finding a true 2hp (1.5kw) spindle motor. I knew enough to know that 8 amps doesn't equal 2hp. It takes 12 amps at 110v to produce 2hp at the spindle bit. I could have run a 220v outlet into the shop, but I've been playing plumber, electrician, HVAC, and carpenter for the past couple of months and honestly, I'm exhausted.

I found a G-PENNY branded 1.5kw, 110v, spindle that's 12amps. I opened the top when I got it and it's properly grounded (another problem found frequently). It's a MONSTER!

I had the same problem with VFD's; they're rated at 1.5kw, but only 8 amps. I could have bought the G-PENNY spindle with matching VFD, but I wanted a 2.2kw VFD. It's always better to size up, to ensure nothing develops heat when doing a lengthy job. So, I found a VFD which is made under several names (including G-PENNY), that's rated for up to 2.2kw 110v, 20 amp spindle.

I also replaced the 16mm ballscrew on the x-axis to a longer one. My x-axis is the shorter axis with the spindle.

Now my old gcode sender program doesn't like the new board, so I'm learning Universal Gcode Sender, a much better and more comprehensive program. The Vectric software communicates great with it.

Well, there is nothing else to upgrade on this machine. I'm still using 2 pieces of extrusion 2020 aluminum from my original desktop machine that I bought many moons ago. I keep them just because they're a reminder.

Yesterday I did "housekeeping". I got my e-stop wired in. I wired it into the USB cable live power wire, so that it cuts power and also disconnects the board, which is a really good and safe solution. I don't have an on/off switch for the board, so the e-stop functions as the switch. I calibrated the machine, enabled homing, and enabled soft limits. So The Beasty is running better than ever before. My usable cutting area is 25.3 x 10.3", more than enough for anything I need.

The driver wiring is a glorified mess of course, but they work great and I'll be experimenting with the microsteps. Right now, the machine seems to be dead-on accurate. I can usually hear when it's cutting anything. Not so with the new spindle. It simply goes through wood or shell like it's air. There's no vibration, no "cutting" noise.

The warmest my spindle has gotten in 3 hours of continuous running while running the initial break-in was a whopping 78° F. I was limited to 9000rpm on the old spindle. This one has a max of 24,000rpms

My test programs include a 1" square, a 1" circle, and an "R" cut out of 1.5mm thick shell, and the word "Roads". When I made the Vectric program for the R, I forgot to change it to cut "outside" of the line. As a result, it cut on the line. I thought it broke the R while milling it. I reprogrammed it properly and cut the R.

I found a piece of tape laying on the floor.. it had the original R stuck to it. It cut it perfectly. The R parts have a width of 1/3mm. I figured if the spindle can do that kind of fine work, then it's set up right and it's a very good spindle!

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[rcnewcomb]

Thanks for the update!

[Kevin Sjostrand]

Wow Diane you have been busy. I'm sorry about your husband's health issues.
It looks like your Beast is ready for the big test. Put a stack of wood on it and let it carve until you are left with a guitar. 😁

The R looks fantastic. I still have not progressed with my little machine and the new software, but I have built more instruments in the last 2 years than I did in the previous 5 so that is good.
Thanks for sharing about your new upgrade.

Kevin

[tippie53]

nicely done

[TEETERFAN]

Good to see ya back on the forum, Diane. sincerely hope your husband’s health is improving and things are a bit more normal. Dealing with medical issues is so challenging and emotionally exhausting. Look forward to seeing more of your interesting and informative postings!