So, almost a year since my last check in on this thread. I've been using the machine quite a bit and I've been super happy with it. I have made 30-40 different parts for a steam engine I'm helping a buddy build and it really does nice work.
A while back I posted about the work on this machine and the LUA code, so I figured I'd update that checklist:
- Rebuild spindle - DONE
- Install spindle motor, belt drive, and drawbar - DONE
- Remove old CNC components - DONE
- Install axis motors and mounts - DONE
- Install electrical cabinet - DONE
- Install limit/home switches - DONE
- Install wireway and cable routing - DONE
- Install touchscreen computer - DONE
- Migrate to Mach 4 - DONE
- Validate system functionality - DONE
- Performance characterization - DONE
- Mach 4 Pendant Configuration - DONE
- Mach 4 LUA Scripting & Servo drive serial communications
- Pneumatic drawbar release - DONE
- MPG functions - DONE
- Cycle start, hold, and stop buttons - Still haven't used these, the touchscreen computer is fine for what I do.
- Spindle Enable/Disable - Removed this, don't want it
- Spindle Orient - Removed this, don't want it
- De-ref all when disabled - DONE
- Auto Enable Soft Limits - DONE
- Power On cycle/Start-Up Menu Script - DONE
- Stop machine for faults and alarms - DONE
- Drive Serial Communications - DONE
- Spindle Load Meter - DONE
- Absolute Homing - DONE, slightly buggy, discussed below.
- Rigid Tapping - Code is there, but never scripted the G/M codes and never tried it
- Gear Hobbing - Code is there, but never scripted the G/M codes and never tried it
- Fix Cycle Timer - DONE
The Absolute homing script is the coolest thing I've added to this machine and I use it constantly. I do have one gripe. Sometimes, one of the axes fails to update with the number received from the drive, but marks itself as homed (rather than failing if the drive returns a bad serial packet, which does happen rarely and works). If I keep hitting the button 2-3 times, then all the axes will home correctly. I've been doing the lazy thing and just homing 4-5 times, but I really should investigate this issue.
The 5000 rpm spindle and load meter are awesome and I've had zero maintenance on it this entire time. The pneumatic drawbar is my favorite addition to the CNC and I am constantly using it.
The ballscrews and the flatness of the ways are the worst part on this machine. I think if I could get the machine ways ground or scraped and replace it with some nice double nut ground ballscrews, the machine would be much more accurate and rigid.
I've thought a lot about getting another larger CNC, but the truth is that for a lot of what I do, I would prefer a manual mill for quick setup and stock squaring. I mostly need a simple drill press setup or a facing cut and taking the time to boot the CNC or write a program isn't worth it. I may be moving soon, so adding a bridgeport to my shop will be on my mind.
Thanks again to everyone for following along with me on this thread!