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rung fu clone RF-45 ZX45 cnc conversion

Discussion in 'MACHINE BUILD LOGS' started by jumps4, Aug 22, 2012.

  1. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    This may be a little early to start this because i'm waiting for all the parts but here is what i have so far
    I thought this was going to be pretty easy but what I'm finding out is there are really a lot of different versions of this mill with all different z axis column lift configurations so I'm not going to have the luxury of using someone elses plans. Oh well just adds to the fun
    I have the mill and I took it apart after a 2 hour check out run, I have never used it it's new.
    I have my motors for the 4 axis and power supplies they are 4200 oz/in for z, 1600 oz/in for x and y, and an 800 oz/in for a rotary index. the power supplies (3)will be running 60 volt and the 4200's controller has it's own power supply.
    I'm still waiting for the ball screws, bearings, couplers and a 5 axis breakout board with relay.
    once I get the mechanical parts I can start on the motor mounts. these will be direct drive and that is why the motors are so big. the gear head on the mill weighs 300lbs and I wanted to use this mass to keep down vibration so I'm not going to use lift cylinders on the head.
    here are some pics of what I have so far and i will give my list of parts and cost when I get it all together
    I figure starting this now will help remind me to take pictures but I also going to be slow because of my health I cant lift anything or stand for very long, so I'll be waiting for my son and son-in-laws help for a lot of this
    steve
     
  2. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 milling machine cnc conversion

    these are not in any order but it shows what I'm up to
    steve

    DSCF0135.JPG DSCF0150.JPG DSCF0151.JPG DSCF0152.JPG DSCF0153.JPG DSCF0156.JPG DSCF0157.JPG DSCF0158.JPG DSCF0159.JPG DSCF0160.JPG DSCF0161.JPG DSCF0162.JPG DSCF0163.JPG DSCF0165.JPG DSCF0166.JPG DSCF0167.JPG DSCF0168.JPG DSCF0169.JPG DSCF0170.JPG DSCF0171.JPG DSCF0172.JPG DSCF0173.JPG DSCF0174.JPG DSCF0175.JPG DSCF0176.JPG DSCF0177.JPG DSCF0178.JPG DSCF0179.JPG
     
  3. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 milling machine cnc conversion

    i'm also waiting on another 4200 motor it got beat up on the junk from china
     
  4. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 milling machine cnc conversion

    parts list so far
    prices include shipping and tax if any
    wholesale tools zx45 mill including tax $1920.65 I picked it up local
    3 motors, driver, power supplies ebay#170796217146 $896.00
    2 10mm x 14mm shaft couplings ebay 251009617349 $17.98
    hand pump oiler ebay 170658580507 $49.95
    ballscrew kit with bearings ebay 290649528399 $410.00
    large shaft coupling 12mm x 19mm ebay 370594678819 $33.99
    5 axis breakout board w/relay ebay 290536178924 $26.99
    aviation plugs 10 total ebay 110925099663 $19.50
    shield wire 100' ebay 160632659191 $100.00
    estop and limits from cnc4pc.com $40.00
    I also purchased another motor set 3 axis to use for the 4th axis on this mill and to cnc my 9x20 lathe it's ebay #200740129338 i'm using 1/3 of the kit for this mill so that is 164.00 added to this cost. also this kit had 3- 60v 300watt power supplied not 1 as pictured. the company offered the different kit to me to save them import fees it was in cal.
    so total cost so far not including little items like wire connectors terminal strips ect is
    $3701.31
    here are pics

    2 couplings 10mm to 14mm ebay 251009617349.jpg 2 fans ebay 110756667561.jpg 5 axis breakout ebay 290536178924.jpg aviation plugs ebay 110925099663.jpg ballscrew brg set ebay 290649528399.jpg large coupling ebay 370594678819.jpg motors ebay 170796217146.jpg oiler ebay 170658580507.jpg sheild wire ebay 160632659191.jpg
     
    Last edited: Aug 23, 2012
  5. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 milling machine cnc conversion

    For the lighted power switch and circuit breaker for the control wiring I have found a new power strip cheap ($3.50) and I'm going to take the parts from it
    It is cheaper than trying to buy the parts local and the breaker is 15 amp. I'll post a pic when I take it apart. I'm also looking for a relay to turn on the power supplies since they are 6amp peak each and there is 4 of them. when I power this on all the motors are in braking mode 50% load so I wont want all that on the main power switch I'd prefer it to be on a relay.
    steve
     
  6. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 milling machine cnc conversion

    another note I'm adding a switch to turn off the 4th axis power supply unless its in use no need to have it running all the time
     
  7. hq308

    hq308 Australia Active User Active Member

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    Re: zx45 milling machine cnc conversion

    Look's like a good well thought out project so far Steve.

    Looking forward to watching you progress on this.
     
  8. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 milling machine cnc conversion

    thank you david
    after sleeping on this last night I have decided to make this all 220v. this will require me to run a dedicated "4" wire 220 circuit from my breaker box to another breaker panel with seperate breakers for the mill, power supplies and 110 circuits. there will be parts like the cooling fans and ac relay circuit that will still be 110v so I will require a ground circuit (white wire )and an equipment ground circuit (green wire). there is too high of an amp load to have the mill and the power supplies,drivers and motors all on one 110v circuit. plus In the future I'm intending to change this 2hp single phase motor to a 3hp 3 phase motor and vfd for speed control, so the 220 will already be there for that. and there will be a coolant pump also. looks like my son and son-in-law will be digging a ditch for the new wire to the house :thinking: I'll draw this all up from the main home load center out and include it with the control circuit drawings.
    steve
     
  9. brucer

    brucer Active User Active Member

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    Re: zx45 milling machine cnc conversion

    when do you plan on granite epoxying the base?
     
  10. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 milling machine cnc conversion

    I have given that some thought but not yet.
    I'm intending on putting the y axis motor on the rear for more room up front and I will be working on the base a lot. dont want it too heavy yet. I cant lift anything so I will be waiting for my son to help me out. also on a lot of the conversions I see they leave the y and z axis ballscrew ends loose. I dont want the screw to whip so I'll be mounting both ends thats going to take careful alignment.
    steve
     
  11. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 milling machine cnc conversion

    I'm also planning on mounting the z and y axis motors directly to the column and base and place the coupling and bearing mounts inside for a cleaner look. this is all still in the planning stage because the slow "junk" from china has not brought all my parts yet
    steve
     
  12. 7HC

    7HC Active User Active Member

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    Re: zx45 milling machine cnc conversion

    Following this with interest.
    Looks like the mill will only be 50% of the cost of the whole project.

    M
     
  13. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 milling machine cnc conversion

    this type of mill comes from a lot of different companies but there are so many different versions thats why no one is marketing a cnc kit I'm sure. if you look there are many z axis versions with the crank on the left or right
    the wholesale tools version is 2/3 the cost of everyone else and upon disassembly I dont have a clue why. it is very nice and beefy the z axis screw that came with it was 1-1/4" and x y were 1" with adjustable nuts for endplay. some of the companies are asking over $3000.00 for the same type of mill not including shipping.
    also they are 1-1/2 hp this came as a 2hp I'm very happy with the purchase
    I intend to leave the quill feed on the mill, It will make a fast and easy way to rezero the z after a tool change witout making all the tool offsets. I'll just starts with the quill down about an inch and locked. then when i change tools I'll adjust the quill to rezero not reset mach3 z to zero
    steve
     
  14. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 mill cnc conversion

    still waiting on parts but here is the rear electronics panel drawing for the g-code I did today
    steve

    rearpaneldrawing.jpg
     
    Last edited: Aug 28, 2012
  15. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 milling machine cnc conversion

    I got a little of one of the electrical panels done today and everything seems to be fitting ok
    the enclosure is open on the sides on the bottom and there will be 12x12 air filter in the bottom. air flow will go from bottom to top and exit 2 120v fans, three of the motor drivers were mounted the lowest so they will not be absorbing heat off of the 4 power supplies. the 5 volt assisted breakout board is going to be mounted in the rear upper panel so the cables from the pc can be connected from outside. In the pics i show 2 relays and a transformer (12v) these were in my first plans but i have decided to go with 5v controlled solidstate relays to eliminate some of the wiring and stray emf from the transformer. the fourth axis will have a switch on the front panel to shut off the power when not in use. the power supplies for the 1600 oz/im motors and the 880 oz/in are 60v and the controller for the 4200 oz/in outputs 80v.
    still waiting on switches, circuit breakers, relays, and my ballscrews and bearing so I havent started on motor mounts yet.
    steve

    DIGI0035.JPG DIGI0036.JPG DIGI0037.JPG DIGI0038.JPG
     
  16. dustooff

    dustooff Australia Active Member Active Member

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    Re: zx45 milling machine cnc conversion

    Hi Steve,
    seeing first pics of your mill, I thought 'wunder if he's gunna epoxy it?'

    If you haven't seen it already Bob W. has good examples...
    http://cnccookbook.com/CCMillEpoxyFill.htm

    with the beefy steppers you're hooking up to the end of those screws,
    you'll need all the rigidity you can get.

    regards
    Andrew
     
  17. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 milling machine cnc conversion

    yes andrew i intend to epoxy fill but i also want to install the coupling and bearings inside the z column and base for a cleaner look so epoxy is much later. I also want the y motor on the back. there is a lot to design still.
    steve
     
  18. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 milling machine cnc conversion

    my aviation connectors came today and they sent a free gift...
    microscopic momentary button switches? still no ballscrews yet but they replied after another week and said they are on the way again. I dont think they stock anything I think they order them when you purchase. I will be buying the ballscrews from someone else for the 9x20 lathe conversion i'm doing after this mill.
    steve

    DSCF0186.JPG
     
  19. 7HC

    7HC Active User Active Member

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    Re: zx45 milling machine cnc conversion

    They look like microphone cable and panel connectors; you've certainly got a lot of them!

    M
     
  20. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 milling machine cnc conversion

    there are 3 4 and 5 pin and they were $2 each set in lots of 10
    they are for my shielded cable to the motors, limit switches, tach , coolant and spindle control. the relays for the spindle power and coolant pump are going to be in the enclosure under the mill so i'll use them for the low voltage control
    I'm going to cnc my 9x20 lathe also so i'll use them
    I'm starting to buy bulk lol switches 10 to a pack 3 packs different colors lighted
    I have no use for the tiny button switches though I should mail them to bob (rbeckett ) he does a lot of electronic stuff
    steve
     
  21. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 milling machine cnc conversion

    I just scored a case of really nice surge and lightning protectors ( lightning ya right )
    6 of them for $20.00 new in the case. so there are all the circuit breakers, switches i need and line protection with noise filtering can not buy the parts on ebay for that!
    i'll be stripping them out tomorrow and milling out the rear power panel on the sherline cnc. the fans also arrived today so that can be built and installed in the enclosure. I'm finally getting started with part of this projectsteve

    DSCF0189.JPG DSCF0190.JPG DSCF0191.JPG
     
  22. 7HC

    7HC Active User Active Member

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    Re: zx45 milling machine cnc conversion

    Free micro switches with the connnectors, and now you get a free pair of dogs with the surge protectors; you are doing well! ;)

    M
     
  23. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 milling machine cnc conversion

    they are everywhere i go
    steve
     
  24. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 milling machine cnc conversion

    this morning I measured my new parts that just came in for the rear panel and of course the were not the same as the manufacturers drawings so I did another drawing of the rear panel and I finally went to the shop to make something with my mill. the little sherline has not been used for months and I had to replace the power supply and driver board when i got home after vacation because of lightning hitting the shed. i had cleaned and adjusted everything after the new parts but i never used it. just a note if you have one of these little machines dont make my repeated mistake and adjust all the backlash out of everything. when the machine warms up after a while everything expands and will lock up the little steppers. I was lucky this time it did it while making a transition move and i caught it. so leave a couple thousands for expansion. my sherline is modified to have a 6x9 work space and thats not big enough for this panel so i split the drawing in 2 and generated the g-codes for each side in d2nc.
    here are some pics. the panel came out nice and everything fits first try.
    steve

    DIGI0039.JPG DIGI0040.JPG DIGI0041.JPG DIGI0042.JPG DIGI0043.JPG DIGI0044.JPG DIGI0045.JPG DIGI0046.JPG DIGI0048.JPG DIGI0049.JPG DIGI0050.JPG DIGI0051.JPG DIGI0052.JPG DIGI0054.JPG DIGI0055.JPG DIGI0056.JPG
     
  25. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 milling machine cnc conversion

    I have not been saving g-code files for this project (probably should) but if anyone wants them i do have all the dxf files
    If you look at the forth pic down closely you might notice a big mistake compared to the others. I typed in .950 for the depth instead of .095 since i really didnt want that cut into the table i changed it...
    :shush:
    steve
     
    Last edited: Aug 31, 2012
  26. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 milling machine cnc conversion

    I got all the parts installed into the rear panel today and i did the cad drawing and g-code for the front panel i should be cutting it out tomorrow. there are only 4 switches on the front panel so it's nothing really but it's my last piece of metal that size. I had to quit today my back was killing me!
    i'm still waiting on solidstate relays so the ac wiring is on hold but i'm going to set up a wiring board tomorrow so i can wire everything outside of the enclosure then install it. the space is too cramped inside to do it.
    steve

    DIGI0059.JPG DIGI0060.JPG DSCF0193.JPG
     
  27. brucer

    brucer Active User Active Member

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    Re: zx45 milling machine cnc conversion

    looks real good so far jumps...

    looks like you've got everything you'll need for the build.. Are you still waiting on ballscrews?
     
  28. 7HC

    7HC Active User Active Member

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    Re: zx45 milling machine cnc conversion

    I know that feeling! :(

    The panel looks really good, all it needs now is an engraving of your avatar in the lower right corner. :)

    M
     
  29. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 milling machine cnc conversion

    yes brucer i am still waiting for the ball screws and bearings but i have a lot of wiring to do and i still have to cut out the enclosure.

    7 i had it all set to cut out and forgot i was going to engrave. it was clamped and taped to the plywood backer and that is not flat enough for engraving so I'll label it some other way. I have started wiring now.
     
  30. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    Re: zx45 milling machine cnc conversion

    this morning i split the front panel drawing into 2 sections so it would fit the sherline mill and made the g-code. then I machined the front panel and installed the switches
    I screwed the 3 panels down to a piece of plywood stretched out the right distances apart and started doing the low voltage wiring. so far i have wired the 4 controllers to the breakout board and the power supplies to the controllers. then i routed the motor wires to the rear panel plugs.
    i will have all the low voltage wiring done tomorrow morning for the enclosure then i'm waiting for parts again.
    steve

    DIGI0061.JPG DIGI0062.JPG DIGI0063.JPG DIGI0064.JPG DIGI0065.JPG
     

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