3 axis router build

[Eric Baack]

Some more work on the timing belt and replaced some spacers with 424 lb/inch die springs to make sure it conforms to the track Got my Y-axis acme nut bolted down and this thing is pretty solid! I little flex in the gantry sides but I'll work on that with some bracing.

[David King]

Lovely looking idler arm there.

Will you need one of those spinning laser level thingies to get it all aligned?

Where do you think the sway in the gantry is coming from?

[Eric Baack]

I think it is actually coming from the lack of a plate that I just haven't made yet. It's in the design, just haven't gotten to that one yet. The cross pieces that tie the gantry together under the table aren't fixed from flexing yet.

I have access to a laser level if I choose to use it. My father in law has a LOT of tools

[Eric Baack]

the lead screws are installed on all 3 axis and the router should arrive on saturday. I got a dewalt variable speed router replacement motor (1.75 HP) that should work nicely. It's compact and should be light weight.

I've run all 3 axis now by hand though the belt tensioner needs a bit of work, If I held that down it turned fairly easily by hand using a wrench on the input shaft or a drill with a socket adapter. (I put a 1/4-20 bolt into the end of the shaft but need to lock it with a roll pin yet)

I'm excited to try it out on a couple of pieces!!

[David King]

You could have a giant etchosketch that runs with joysticks connected to portable drills.

[Eric Baack]

now that would be sweet!!

I do have an old drill that I was considering tearing apart to use as a power feed on the X-axis....

[David King]

A joystick with pwm speed controls for 2 axis would be very easy to implement if that's what you actually wanted.

[Eric Baack]

I changed the idler pulley arms to something adjustable and bolted in place. It turns pretty well by hand now. A few pieces to make yet and I can cut some stuff!!!





Here's a little video of it.

http://youtu.be/av5NOR4HyO0

[Eric Baack]

Thread revival! I scored 2 stepper motors and 3 motor drivers for free from work as they were going to be thrown away even though they worked fine on the machine that they came off of. So I bought a third motor and have a break out board on the way. I have an old computer that will be the controller so I just have a few brackets to make.

Here are a couple of the motors installed. I need to make couplers and the z-axis bracket yet. The Z-axis lead screw needs to be shortened and I'll probably turn the end down to 3/8" so I can put a bit smaller of a coupler on.

[Jamie Unden]

WOW! Didn't they have any bigger motors?

A note of caution about the DeWalt router. I had that exact model in my CNC and the bearing went out. Being a cheap bastard I ordered the parts and tried to put them in myself. Big mistake. I wound up bending the shaft and pitching the whole mess. The top bearing is held in place by the plastic case! I bought a Porter-Cable single-speed and it fit right in the bracket.

[Eric Baack]

Noted!

I'll run this one as long as it works and maybe replace it with something better eventually.

The price was right on the motors! I did check the specs on them and they should run 100-150 inches per minute pretty easily I think. I bought a nema 23 motor for the z-axis. That screw turns pretty easily.

[David King]

The round body steppers go back a ways. Modern square motors will take up a lot less room and often run faster on the same voltage. What are you doing for a power supply?

[Eric Baack]

I have 115V input motor drivers that were used with the motors on the machine that they came out of. They are actually 5 phase motors.

I might also get some linear bearings at some point and replace the skate bearings and angle aluminum. There's a bit of galling on the rails but not enough to keep it from running smoothly yet. I do need to rig up some wipers and a dust collection system to keep that clean.

[Jason Rodgers]

Pretty screwy little machine you got there.

All this stuff blows my mind. Cool.

[Eric Baack]

Here are a few shots of the control enclosure in process. The power for the router and vacuum will be run through a relay and the e-stop in series so I can shut those off quickly and can leave it turned off until needed. I'll have a LED indicator to show e-stop status hard-wired to the NC side. Light on = power on.

The inputs will go through a cat-5 cable and to the limit switches that way so I can disconnect it easily for servicing the electrical.

[Eric Baack]

It's looking even more like spaghetti!

I have to do a bit of cable management on this thing.....

[David King]

It all looks good to me.

[Eric Baack]

Got it buttoned up tonight. I have to test it out but the fan turned on and all 3 drives lit up like they were suppose to. Now I need to do a bit of work on the machine to get it ready.

The LED on the lid is a bit dim. I wonder if it isn't getting the full 110V or if the current is a bit low for it. It does shut off when I hit the e-stop though, so that is good. I'll have to hook up the computer to see if I can get the outlet to turn on.

[Eric Baack]

Got the enclosure up on the wall and the computer is out in the garage. I've got some major cleaning to do! There are several cross braces to put in yet and I still need to get the spoil-board in. Then there's wiring. I have a .050" thick piece of ABS that is 2" wide and several feet long that I'm going to use for a cable drag along the x-axis. The Z axis will have a piece of reinforced 3/8" OD push to connect tube that I will zip tie the wires to. With 3 kids 5 and under there's not a ton of time to work on this thing!

[Eric Baack]

So I hooked the control box up quick. Wiring still needs to be finished but I was able to run a few jogs with the hand controller. Kinda cool!!!!

http://youtu.be/pGpP4QFyQg4