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Ok .... soo looong time since I've posted - a bit of health issues so going slow.... dissasembled everything, precision ground few parts, painted everything and started putting it together. Centering and leveling takes FOOOOREEEVEEER .... it took 3 days to square the Z relative to the X, make all of the linear guides paralel to each other, and fine tune the lead screws. Remains the Y axis to be adjusted but a small problem with the frame turned up - so a bit more heavy machining will be needed.
Because of some comments in the past here is how I tackled the problem of making the axis square to each one. I am using a machine grade square level and precision 90 degree angle.
And some "fine"positioning of the frame (this is just a test to see if I can achieve square angle or there is something wrong).
Finished the box full of air... After some testing it became clear that the inside was getting really hot due to the compressor - so I've added a fan to cool it down. Cheers
today i've rebuilt from scratc the oil pump for the spindle. The old one was dirty, and leaking oul all over the place. Also wanted a bigger volume container. By accident I found a real nice stainless steel container in the scrap yard so I went for it. After a full day of work this came to life . Cheers
long time no see. I've been working hard on the control panel and finally it is ready now. It has a USB keyboard emulator, modbus interface, complete standalone control over the machine (no PC needed) - for those little on the fly stuff, DROs..... This is a really big milestone for the project .... it took forever and I thought I would never finish it ..... Few more final touches and ready to connect to the machine and try to move the beast.
just before New year I finally got the spindle rotating with the final setup. Left it runing at different RPMs for about 10 hours. Seems to be working reliably.
First of all BIG thanks goes to Linas and Thomas W. for helping out with acquiring the high power parts.
The motor is controlled by a PID regulator. Feedback is with optical sensor and slotted wheel. Power supply is big old three phase transformer, rewound for the needed voltaga.
The biggest advantage of this setup is the ability to run at low RPM (currently min is 200) with very high torque. The down side is the complexity and the high currents (under very heavy loads up to 100A...) and the fact the motor is noisy due to the big amount of air forced through it and the brush mechanism at high RPMs.
The maximum RPM is about 4500. I've limited it to 4000. Above 4200 some disbalance issues appear with the homemade spindle.
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Big Mama CNC Mill
(this is just a test to see if I can achieve square angle or there is something wrong).
