CNC
Broke Beamer
I have just had a interesting development with the HB2 router. Most of my readers realize I push my inventions to the limit, actually breaking things from time to time. The Proxxon lathe is but one example. Not saying that I plan to break things but how else do I know where the break points are?
This one is a bit curious as what I broke this time was one, actually both of the helical beam clamp-on shaft couplings for the dual drive Y axis. One of the couplings totally failed (broke in two pieces) so that really caught my attention. The other had a clicking sound. Actually both had the clicking sound but I was not sure what the reason was. Now I know.
The dual drive was the hardest to get fine tuned (alignment and sticking spots) and suffered some abuse. No not the large mallet I joked about in another report. There were many times when I stalled the steppers trying to go too fast. It is pretty hard on the works when one motor stops and the other keeps going. I was also getting aggressive with short ramp times and was certainly slamming the couplings on several other occasions. Top speed at 4000 SPI on 5 TPI screws is 150 IPM. I’ll probably run my rapids at 100-125.
But Hey! That’s what it is all about when you make your own. No manufacturer to blame. I love it!
The HB2 is much larger and heavier than the Taig mill I have been playing with for years. There is more mass in motion. Therefore I have to pay more attention to Newton’s laws of physics. The hard Part is the MACH3 stepper tune up instructions say to set the motor speed and ramp times until they sound… Continue reading
HB2 First Project
HB2 has been brought to full functioning life with sounds not much unlike a trim router. I am kind of alluding here to a new baby cries when first born.
I am not one to choose an easy project for the very first run. What you see here is the Aztec calendar with a lot of detail. I set the design up in Vectric Aspire V2 and sized it for a 12 inch diameter. The process is known as V-Carving.
I used a 90 degree V-Carve bit. I discovered I should have used a 60 or perhaps 45 degree V-Carve bit. I would have deeper cuts and wouldn’t have had the dropout in several areas due to board warpage.
But all in all, not too shabby for a first run. I and HB2 can only get better. Enjoy the pictures.
See Video -> V-Carve Action
It’s the Details
I have ordered a few more parts for the HB2. That sentence may be written many more times as I continue to detail the HB2 build.
This time it is some cable carriers or sometimes called cable chains. They are flexible linked sections of wiring conduit that contains the wiring that is forced to flex as the X/Y axis moves. They really clean up the jumble of system wiring and keep it out of the way.
This constant movement also requires special wiring that can withstand all the flexing. Ordinary wire will fail in several different ways from the constant flex. I have used only this special purpose flexable type wiring in the HB2 design. A little more expensive but the “right stuff” for use in a cable chain.
More about this after I get it all installed. ~ Dan’l
Music To My Ears
My wife is a professional piano teacher but I am swooning over another kind of music. That other kind of music has four speakers and three channels.
What I am hinting at is the HB2 has come alive and is singing it’s stepper pulses. Anyone familiar with stepper motors knows what I am talking about. The steppers actually sing in the audio range as the pulses are being fed to them. The HB2 has four motors (speakers) and three channels (X, Y, Z).
The PS2 Power supply is complete and working as good if not better than expected. I made up all four XLR 5 pin plugs and they are a perfect match to the stepper motor cable I am using. I haven’t done the finish wiring at the motors yet as I plan to test for awhile.
I’ll get some pictures tomorrow and post here. Maybe a video too. I also need to do a write up for the web site. For today I just wanted to mark this milestone that the HB2 is now self powered. I could actually do some cutting if I come up with a hold down.
Dan’l
UPDATE 3/8/09: Pictures of the PS2 are now in the THMS website. Look under SITE TOOLS and What’s New for this entry: 03/08/09 – HB2 Construction Section 6, The PS2 Controller/Power Supply. At last the HB2 gets the power and brains to move on its own!
More HB2PS2
Click on pictures for a large view.
I got a lot of work done on the PS2 Power Supply / Controller this week end. Slight layout change form the first picture a few days ago. I turned the transformer around and put the full bridge diodes on the other side. There was too much going on around the capacitor
I fired it up and got some DC voltage readings (see picture). The transformer is 10 Amps at 24 volts A/C. With full wave rectification and the capacitor it charges up to peak voltage DC. I haven’t powered the board yet as I need a 10 amp fuse. Otherwise it is ready to go.