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Italian shed ornament - Nick's cnc router repower


NickJ
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12 minutes ago, NickJ said:

VFD - Settings confirmed as all wrong, but not terribly so, but with "better" numbers the external tach is now all wrong, while I didn't get my head around the external output settings that feed it, for now I'll let it be until I can get my hands on a hand held tach, unless someone has a fancypants way to work out the number of poles if its not on the nameplate? Currently set at 2 because thats what it was and it turns........

Managed to spin up all axes again and get each one to home on the limit switches, good learning here, setting home as zero throws errors cos it trips the switch, moving home position to a nominal offset cured that. Also found a few of the limit switches not quite in position, so fixed them too.

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All Green! If I was so keen, the controller would accept and run a program :)
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In reality this puts me servo tuning away from using the machine, in true procrastination form I dug into the pneumatics...

Spilling the wires and tubes out from the head I set up a test manifold to find out which solenoids worked and which were NFG.

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Expected result, more bits dumped in the bin

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Thankfully I was left with 7 operational 5/2 solenoids, a few other shuttle valves and a mountain of various fittings &hose, these were set up on a manifold and re-installed to work the tool change on the main spindle.

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All of this^ is now this:

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Not being one to leave a chance to test, a quick switchboard was thrown together linking the above solenoids

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In what I can only amount to a miracle, I somehow managed to get the polarity of the air lines correct allowing removal and insertion of a tool holder first time, while it was only manual, it gives me hope that if I can sit down with the ladder logic side, I should get tool changing on the functional list (Of course its not this easy, there are many interlock switches to monitor making sure everything is correct ie tool correctly loaded before 10,000rpm etc)
The tool change was also horrifically violent, must re-adjust the needle valves.

So, limit switches, homing and tool change. Time to sculpt?

No, theres still more distractions!

Enter the auto-greaser....

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I personally hate these things, experience tarred from older, mistreated farm machinery where blockages cause dry joints and days disappear in feeble attempts to unblock lines or work out which orifice plate goes to which port.

But, when they work, life is pretty darn peachy. 

Using the valves assembled for the above air tests, I soon found the pump wasn't building pressure, a quick loosening of fittings and air purge had that raised to a healthy 200bar grease pressure (safety glasses on)

Cracking the furthest distribution block I soon had grease pouring out then followed by a MDF/grease goo flowing from the linear rails and ball screws.

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While the flow is pretty uneven, i'll give it a few cycles a day in the hope everything will even out, worst case the lines can be swapped for nipples.

Ok, so large phallic engravings now or what?

Nope, in the adventure of chasing the grease lines I found the X axis drive cover was actually split and therefore working out the actual reduction ratio is possible. Cover off locates, well, more grease.

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Grabbing the nearest doggy bag the goo was disposed of and wiped up

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Fairly certain its just grease, the belt appears healthy but I might try locate a new one and replace it if the price is palatable.

And yes, this whole post has been a tease, I never managed to run a program, having a go at tuning the servos I realised I have no idea how to run the internal oscilloscope, back to the school of YouTube then I promise to cut something worthy.

In my limited 3 phase motor knowledge. I'd say it must be 2 pole to get some rpm.

6pole 920rpm

4pole 1440rpm

2pole 3000rpm

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15 minutes ago, rusty360 said:

In my limited 3 phase motor knowledge. I'd say it must be 2 pole to get some rpm.

6pole 920rpm

4pole 1440rpm

2pole 3000rpm

This is the nameplate:

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That aligns with our best guess of 2 pole.

4 pole would put everything out by a factor of two right?

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1 hour ago, ajg193 said:

I have a handheld soviet clockwork tach that is deadnuts accurate up to 10,000 rpm. Come over some time and grab it

Continuation of roadside sharns sounds like a good idea, i'll get in touch later this week.

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On 09/08/2022 at 20:29, NickJ said:

This is the nameplate:

1908202292_IMG_1313(1).jpeg.7f1d8d9728d7adfee5f58668a28317c8.jpeg

That aligns with our best guess of 2 pole.

4 pole would put everything out by a factor of two right?

Humm so 2pole motor at 200Hz be 12000rpm.

What's the max spindle speed?

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23 hours ago, rusty360 said:

Humm so 2pole motor at 200Hz be 12000rpm.

What's the max spindle speed?

According to the spec sheet for the machine 18,000 rpm, one explanation i’ve been given is 12,000rpm full load and 18,000rpm at reduced capacity.

 

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43 minutes ago, ajg193 said:

What's the backlash like? Is it pretty much ready to throw back into mass cabinet production?

Whats backlash? ;)
 

Spent the day digging further into the greasing issues, pretty sure its now getting everywhere, lots of black gunk spewing out onto the rails and its much, much quieter!

still have quite a list to do before full operation, but yeah, could start smashing out cabinets if the will to CAD them existed.

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