Upgrading My Cnc Machine

Do a search for a Dell 3050 micro desktop, I just installed one like it on a machine a couple of weeks ago. Fits in the palm of your hand.

I would use the original operator panel enclosure, then just buy a piece of aluminum to replace the the existing panel. Or of you need bigger for the screen then head for your local sheet metal shop and have an enclosure bent up. It doesn't have to be a NEMA 4, a NEMA 1 would be fine.
 
Jim,
I was thinking of that solution but for some reason I thought the panel needed to be a Nema 12. I just happen to have some aluminum sheet around and a couple of metal brakes so I'll see what I can come up with. May even be able to use some of my existing buttons and other pieces, but I don't think there are any pots in the mix so I'll have to find some of those and a flat screen to mount in the panel front. Any idea where I can find one of those?
 
Any idea where I can find one of those?

I normally just go to Best Buy or Frys for monitors. You can generally pick up a 21 or 23 inch for about $120. I like big monitors because my old eyes don't work as well as they used to.;) Just make sure the monitor has a more or less flat border around the screen, that way you can use double sided tape to mount it in the panel. Make sure it supports 1920 x 1080 resolution.

The only pot you should need is for the VFD. Check the specs on your VFD, but normally 2 - 5 K, 1 Watt, linear taper is what you want. These are the ones I normally use http://www.automationdirect.com/adc...dicators/22mm_Metal/Potentiometers/ECX2300-5K
 
Jim, your idea was genius. After taking a better look at the control box, I realized it was a much better console than I could build or order so I got to work stripping out the internals. Got it down to the bare cast aluminum frame and it is a pretty impressive piece, as the pics will show.
After stripping all the metal off the cabinet except the bottom, I formed new pieces out of .063 aluminum sheet for the front, the infill pieces for the step where the tape unit used to be, and the back. Should be perfect for the new flat screen, computer, and other assorted pieces I need to house in there. Also, plenty of room for buttons, switches, and other items as needed.
Couldn't fit a 21 or 22" monitor in the cabinet as it was only 19 5/8" inside measurement. 19" monitor is as big as I can go for now. ;)

Anyone need a slightly used tape drive unit? CNC Control console 001.JPG CNC Control console 002.JPG CNC Control console 003.JPG CNC Control console 004.JPG CNC Control console 005.JPG CNC Control console 006.JPG

After I get all the holes punched and pieces mounted, including the monitor, it will all come apart again and get painted, probably a machine gray or something boring like that.

Bob
 
Looking good, nice sheet metal work! That enclosure has a pretty substantial frame in it.
 
CNC parts.jpg
I finally got almost all of my components here in my grubby hands and ready to start installing parts. I need to buy cables to connect from my 20105 daughter board to the servo drives and from the DMC 2143 board to the controls as needed. Looking at the Galil site, the necessary cables are ridiculously expensive. Is there a reason for this? Is there something different or special about these cables or would any 15 pin, 25 pin, and 37 pin cable work in this instance with #26 wire guage conductors?

I found the pin out configurations on the Galil website so I should be able to start wiring it up once I get the cables I need and mount the equipment in the control box and the operator station.

Thanks,
Bob
 
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Thanks Jim,
Ordered the breakout boards today. Now need to order some MTW wire. What size do you prefer for this control wiring? I was thinking 16 guage MTW ?

Bob
 
16ga should be fine. For low energy stuff like encoders and wiring to the inputs, I normally use multi-conductor cables around 22 - 28 ga, the max current on those is just a few mili-amps.
 
So I now have almost everything I need to start the install. Started removing some of the incidental wiring that came with the old controls and installed a new feed cable to handle the 30 Amp 120/240V feed to the machine with a twist lock receptacle on the end. Even found a matching twist lock receptacle in my box-O-parts so that part is taken care of once I pull a new circuit in my shop.

Planning on removing the reversing contactors this week and replacing them with the VFD and wire it in. Then the tough part starts. The wiring for the controls at the quill motor and other controls (coolant, air flow, oiler, etc...) are almost impossible to follow in the small control box and gutter. I need to keep most of these items running after the upgrade so I need to identify them. It will take a bit of time to determine all of their functions and what is necessary to keep them functioning with the new control scheme. Wish me luck with this....

Then, the wiring of the controls begins once I find room for the control board to mount and install the computer, screen, power receptacles, and other cables needed in the operator interface cabinet and mount it.

The existing flex conduit used on this unit is stiff and cracking from age. Most sealtight flex really doesn't lend itself to being moved around a lot and tends to break or split after a short time. I am hoping to find some of the super soft and flexible stuff I sometimes find on machine tools- especially asian tools so I can install the cables from the interface cabinet to the controls cabinet and still move the interface console around when necessary without stressing the flex. Anyone know where I can find some of this super flexible in either 1/2" or 3/4" size?

Thanks,
Bob
 
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