Shizouka An-s Build

We have been into a lot of the mill and had to figure things out for ourselves. A manual would be nice to answer questions when they come up. We are working on getting some backlash out of the X axis ballscrew and we didn't know if had double nuts on it or not. Turns out it does and I'm working on that now, but it would have been nice just to look at the parts manual to answer our question.

The spare parts are yours, just cover shipping. Off hand we have some circuit boards, the Geneva mechanism, 2 gear head motors, and other stuff I can't think of at the moment. I can take pics this weekend to show you what I have.

You can email the scans if you want. I'm alloyspecialties@yahoo.com
 
A little more progress today, got the spindle tach bracket done. One more step closer to being done.

. The tach input is from two 4mm proximity sensors that look at the gear teeth. When one is pointing at the gear tooth, the other is looking at the root. This gives an A/B signal to give both speed and direction to the computer. To the computer it will look just like an encoder.

See the full tach bracket build here http://www.hobby-machinist.com/threads/spindle-tach-prox-bracket.37664/

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JimS

Here is a pic of the tool changer controls.

20150620_092454.jpg
 
I have MME
(milling machine envy)

You're going to love this mill
 
Yes I'm sure I'll love it. Been over 10 years since I've owned a CNC. I run them all day at work and many times I've wished I had one at home to use.

I remember the day Jim and I went to look at the mill. I saw a large mill with NO control and the motors just had cut wires hanging from them.. To me it was a project that I had no hope of completing by myself, but Jim saw what it could be with a little (a lot) of work. Now we are so close to being finished.

I have the ball screw modified so we can use set screws to adjust the backlash and it's ready to install, but there was one metering valve for the way oil that was bad, and it won't be in until today sometime and it goes in under the ball screw, so have to finish the screw and the metering valve up tomorrow when I am at Jim's. The new coolant pump came in yesterday so I can get that wired in and mounted.

I'll post pics of any progress we make.
 
We got a lot more done this weekend on the mill. The table is back on and the oiling problem for the lead screw is taken care of. There was one metering valve in the valve block in the saddle with nothing connected to it and no way to oil the ball screw. I used some brake cleaner and got the valve unplugged and used some 1/8" copper tubing and made up a drip line that oils the screw. Jim looked at the PDF's of the factory manual JimS sent us said that's the way it was done from the factory, but for the life of me I can't understand why anyone would take it off and leave the screw un-lubricated. When I went to put the X axis motor back on I found some slop in the keyway on the ball screw. It would cause backlash so has to be taken care of. Tried drilling the flexible coupler it to put some set screws in to lock it to the shaft, but the coupler is hardened so that didn't work out. I found a new stainless one on fleabay and ordered it today.

We got the spindle motor back on with quite a bit of work. Used some all thread and compressed the spring on the motor pulley so we could drop it in place easier. Jim made a spacer up that held the pulleys apart and we just used pry bars to pop it off after the motor was in place. We used Jim's forklift to lift the motor to put in in place. ( EDIT: Pic added by Jim)

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Now a rant about Home Depot's 1/2" all thread. Drove 10 miles to get the rod (my second trip yesterday to Home Depot, went there instead of Ace because Harbor Fright is just a few blocks away and we needed a bearing spreader) and got back to Jim's and the rod was covered in such a thick galvanized coating that the nuts couldn't be screwed on. I tried chasing the threads with a die and no dice. What a royal pain, had to make a trip ( my second one yesterday) to Ace hardware for another piece of rod. Needles to say I'm not real high on Home Depot's quality control right now. Cost us precious time and me money.

After we got the motor on I wired up the VFD to the motor. Powered it up and Jim couldn't get the motor it to turn on. So we gave up for the day about 8 last night. Today Jim told me today he found a loose connection on the buss bar (amazingly it isn't something I did) and now the spindle is in his words " spindling" :) I've made a number of "errors" wiring things up and thankfully Jim had the patience to fix them.

No much more left to do now. Jim has a lot of programming to do, and I need to get a 3 way valve on for the mist coolant, ordered it today along with a few other parts from Automation Direct. We also need to get the power draw bar on and wired up and connected to air valve, and the K axis reader head on and wired in and get the X axis ball motor connector on when it comes in, and get the stepper motor on for the speed changer.

I'm sure I'm forgetting something but we will take care of it when it comes up. Jim said we may be making some ships next weekend, that's if all the parts come in.

Today I scored a 1954 Craftsman drill press for $50.

http://www.hobby-machinist.com/threads/picked-up-a-craftsman-drill-press-today.37782/#post-323118

As I said in the thread on the way home with it I told my girlfriend I now have a project to work on at home. She said you need a home project? You work four 10's and spend 2 days a week at Jim's working on your mill and you need a project for your only day off at home? I just laughed.

I don't sit still with nothing to do very well at all even on my "only" day off. She has never been with someone like me before :)


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We got a lot accomplished this weekend. More wiring done for the power draw bar, and Jim has it working under the computer and now has to write a Galil program to run the tool changer. When we went to put the power draw bar (a black and decker 1/2" impact wrench) the return spring was missing. I looked for several hours to find a spring that would work but no luck. So we came up with a multi spring setup. Jim machined recesses to retain the springs. He cut 8 recesses, but we only needed 4 to have enough spring pressure to return the draw bar to the up position. I also worked out an oil line for the Z axis ball screw. There was no provision to oil it at all. I have no idea how it ran like that, but it' taken care of now.

The VFD is on and working, but it goes over current when stopping the motor. When I bought the mill there was a stove burner included to use as a resistor, but it's just too difficult to mount it. So I ordered more conventional one from china for $28. The new motor shaft coupler came in for X axis, and after a little modification it's on and working.

I got the speed changer stepper motor mounted on the new plate Jim made for it. We had to modify a sprocket to fit, but it's on and looks good.

There is a lot of programming to do and get Mach working with the Galil. As far as mechanical things to do I need to wire up the K axis reader head, and get the speed changer stepper motor connections done. We also need to get the limit switches on the the speed changer, but need to get the stepper motor working to see where to mount the switches.

I'm sure I'm forgetting something that needs to be done, but we are close. I can almost see chips flying off it :)

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...


There is a lot of programming to do and get Mach working with the Galil...

I'm probably the only other Galil bit head around here, but I'd sure like to see the detail on the Galil programming.

Karl
 
Carl, here is what I have so far. Needs a lot of cleanup and I need write the tool changer FULL AUTO code. Then the Speed Change code.

'SHZ2
#AUTO
CN1
CEA=0
CEB=0
CEC=2
CEG=3;'MPG AXIS
MTA=1
MTB=-1
MTC=1
MTE=2;'TC STEPPER
MTG=1
SH A;'X AXIS
'MO A
SH B;'Y AXIS
SH C;'Z AXIS
SH D;'A AXIS
SH E;'E AXIS TC
MO G;'SPEED CONTROL STEPPER
KPA=8
KPB=6
KPC=6
KDA=96
KDB=96
KDC=64
OFA=0.035
OFB=0
OFC=0.007
TLA=5
TLB=5
TLC=5
TLD=5
SPA=12700
SPB=12700
SPC=6000
SPE=1500
ACA=1000000
ACB=1000000
ACC=1000000
ACD=1000000
ACE=100000
DCA=1000000
DCB=1000000
DCC=1000000
DCD=1000000
DCE=100000
OP0
CB44;'OPEN TOOL CLAMP
WT 200
SB44;'TURN OFF TOOL CLAMP OPEN SOL
BKSPON=0;'SPINDLE BRK ON BIT
MPGSCL=25.4;'MPG INITIALSET
MPGPOS=0
MPGDPX=0;'0 IS SET BIT
MPGDPY=0;'0 IS SET BIT
MPGDPZ=0;'0 IS SET BIT
MPGDPA=0;'0 IS SET BIT
TCHM=0
TCPXCT=0
TCJOG=0
TOOLNUM=0
TOOLCNT=0
TOOLNEXT=0
SPDLRUN=0
BLINKER=0
BLINKCNT=0
#A
CN 1;'RESET LIMIT SWITCH CONFIG IN CASE MACH CHANGES THEM
'HOME TC
IF(TCHM=0)&(@IN[5]=0)
'HOME Z AXIS
SPC=6000
FE C
BGC
SHE
WT 500
IF(@IN[28]=0);'MAKE SURE TOOL CLAMP IS OPEN
JGE=1500
BGE
WT 1000
AI -30
AI -31
AI 31
AI -31
AI 31
AI -31
AI 31
AI -31
SPE=100
AI 31
AI-31
STE
TCHM=1
TOOLNUM=24
SPE=1500
AME
ENDIF;'IF(@IN[28]=0)
WT 100
DPE=0
DEE=0
DPC=0
DEC=0
SPC=12700
ENDIF
IF(@IN[5]=1);TCHM=0;ENDIF
'TC MANUAL
IF(@IN[24]=0)
IF(@IN[21]=0);CB44;WT200;SB44;ENDIF;'CLAMP OPEN
IF(@IN[20]=0);CB43;WT200;SB43;ENDIF;'CLAMP CLOSE
IF(@IN[18]=0);CB41;WT200;SB41;ENDIF;'ARM TO SPINDLE
IF(@IN[23]=0);CB42;WT200;SB42;ENDIF;'ARM TO TOOL
IF(@IN[22]=0)&(TCJOG=0);JGE=-1500;BGE;TCJOG=1;ENDIF
IF(@IN[19]=0)&(TCJOG=0);JGE=1500;BGE;TCJOG=1;ENDIF
IF(@IN[22]=1)&(@IN[19]=1)&(TCJOG=1)
AI-31
STE
WT 20
AME
IPE=-30
TCJOG=0
ENDIF
ENDIF;'IF(@IN[24]=0)
IF(@IN[16]=0);CB48;ENDIF;'MANUAL SPINDLE BRAKE ON
IF(@IN[16]=1)&(BKSPON=0);SB48;ENDIF;'MANUAL SPINDLE BRAKE OFF
'MPG
IF(@IN[37]=0);MPGSCL=2.54;ENDIF;'MPG SCALE =0.001
IF(@IN[38]=0);MPGSCL=25.4;ENDIF;'MPG SCALE =0.01
IF(@IN[39]=0);MPGSCL=254;ENDIF;'MPG SCALE =0.1
'MPG X
IF(@IN[4]=0)&(@IN[5]=0)
IF(@IN[33]=0)
MPGPOS=(_TPG*MPGSCL)
IF(MPGPOS<>0);IPA=MPGPOS;ENDIF
AMA
ACA=256000
DCA=256000
SPA=12700
ENDIF;'MPG X
'MPG Y
IF(@IN[34]=0)
MPGPOS=(_TPG*MPGSCL)
IF(MPGPOS<>0);IPB=MPGPOS;ENDIF
AMB
SPB=12700
ACB=256000
DCB=256000
ENDIF;'MPG Y
'MPG Z
IF(@IN[35]=0)
MPGPOS=(_TPG*MPGSCL)
ACC=256000
DCC=256000
SPC=12700
IF((_HMC=1)&(MPGPOS<0))
IF(MPGPOS<>0);IPC=MPGPOS;ENDIF
ENDIF
IF(_HMC=0)
IF(MPGPOS<>0);IPC=MPGPOS;ENDIF
ENDIF
AMC
ENDIF;'MPGZ
'IF(@IN[36]=0)
'IF(MPGPOS<>0);'IPD=MPGPOS;'ENDIF
'AMD
'ENDIF;'MPG A
DPG=0
DEG=0
MPGPOS=0
ELSE
DPG=0
DEG=0
ENDIF;'IF(@IN[4]=0
'END MPG
'MANUAL SPINDLE
IF(SPDLRUN=0)&(@IN[6]=0)&(@IN[8]=1);SPDLRUN=1;SB3;ENDIF
IF(SPDLRUN=0)&(@IN[6]=0)&(@IN[8]=0);SPDLRUN=2;SB2;ENDIF
IF(SPDLRUN=2)&(@IN[8]=1);CB2;WT10;SB3;SPDLRUN=1;ENDIF
IF(SPDLRUN=1)&(@IN[8]=0);CB3;WT10;SB2;SPDLRUN=2;ENDIF
IF(@IN[7]=0);CB2;CB3;SPDLRUN=0;ENDIF
IF(@IN[8]=0);OB 9, BLINKER;ENDIF
IF(@IN[8]=1);SB9;ENDIF
IF(SPDLRUN=0);SB10;CB11;ENDIF
IF(SPDLRUN>0);SB11;CB10;ENDIF
'POWER DB MANUAL
IF(@IN[17]=1)&(@IN[24]=0);'IF TC IN MANUAL
IF(@IN[16]=0);'BRAKE SW ON
CB48;'SPINDLE BRAKE ON
IF(@IN[15]=0);CB45;WT100;SB6;WT 20;SB5;SB7;ENDIF; 'RUN REV TOOL OUT
IF(@IN[14]=0);CB45;WT100;SB5;SB8;ENDIF;'RUN FOR TOOL IN
IF(@IN[14]=1)&(@IN[15]=1);SB45;CB7;CB8;CB5;WT 20;CB6;ENDIF;'PDB OFF
ENDIF
IF(@IN[16]=1)|(@IN[24]=1);SB48;SB45;CB5;CB6;CB7;CB8;ENDIF;'TURN EVERYTING OFF
ENDIF
'BLINK
BLINKCNT=BLINKCNT+1
IF(BLINKCNT>49);BLINKER=1;ENDIF
IF(BLINKCNT>99);BLINKER=0;BLINKCNT=0;ENDIF
WT 10
JP#A
EN
#TCW
T1=TOOLNUM-TOOLNEXT
T2=TOOLNEXT-TOOLNUM
IF(T1<0);T1=T1+24;ENDIF
IF(T2<0);T2=T2+24;ENDIF
IF(T1>T2);JP#TCCW;ENDIF
JGE=1500
BGE
#CWLOOP
AI -31
AI 31
AI -31
AI 31
AI -31
AI 31
AI -31
IF(TOOLNUM=(TOOLNEXT+1));SPE=200;ENDIF
AI 31
AI-31
TOOLNUM=TOOLNUM-1
IF(TOOLNUM=0);TOOLNUM=24;ENDIF
JP#CWLOOP,(TOOLNUM<>TOOLNEXT)
MG TOOLNUM
IPE=-30
STE
MG TOOLNUM
EN
#TCCW
'TOOLNUM=0
'TOOLCNT=0
SPE=1500
IPE=-(T2*1050)
AME
JGE=-200
BGE
AI-31
AI31
STE
AME
JGE=100
BGE
AI-31
STE
AME
TOOLNUM=TOOLNEXT
MG TOOLNUM
EN
#PWRDB;'TEST CODE
WT10
'IN 15 FOR TOOL IN SW 1=OFF
'IN 14 REV TOOL OUT SW 1=OFF
'IN 16 BRAKE SW 1=OFF
'OUT 5 DB RUN SB5=RUN
'OUT 6 DB FOR/REV 0=FOR SB6=REV
'OUT 7 TOOL IN LAMP SB7=ON
'OUT 8 TOOL OUT LAMP SB7=ON
'OUT 45 PDB SOL CB45=ON
'OUT 48 SPINDLE BRAKE SOL CB48=ON
IF(@IN[17]=1)
IF(@IN[16]=0)&(@IN[24]=0);'BRAKE SW ON AND TC MANUAL
CB48;'SPINDLE BRAKE ON
IF(@IN[15]=0);CB45;WT100;SB6;WT 20;SB5;SB7;ENDIF; 'RUN REV TOOL OUT
IF(@IN[14]=0);CB45;WT100;SB5;SB8;ENDIF;'RUN FOR TOOL IN
IF(@IN[14]=1)&(@IN[15]=1);SB45;CB7;CB8;CB5;WT 20;CB6;ENDIF;'PDB OFF
ENDIF
IF(@IN[16]=1)|(@IN[24]=1);SB48;SB45;CB5;CB6;CB7;CB8;ENDIF;'TURN EVERYTING OFF
ENDIF
JP #PWRDB
EN
 
Cool stuff here. I've not done the PLC type programming in Galil. No need with my control, looks to be a great route to go under Mach. have you ran out of I/O yet?

Karl
 
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