Good news & glad to see you’re all right !
Cool…. & cool …Robert ;)

Glad everyone got through it OK! :)

I hear you used your belt to tie yourself to the mechmate to stop yourself blowing away :)

It's good that the cyclone did not follow its predicted path, but my thoughts are with those where it did hit.
Good to hear you're OK.

From the low human casualties, would I be correct in assuming that your buildings are typically constructed of brick & mortar?

Hi Gerald

The construction is a real mix.
The first and most traditional construction method is an iron roof with single skin VJ pine board or fibro cement on high set stumps.
These are lightweight and provide good ventilation even to the underfloor area.
A lot of these homes have then been enclosed underneath with concrete block work to provide extra living space.
Their are fundamental flaws with building tie down all the way from the bottom plates to the roof battens.
These homes are very subject to racking and will literally fall apart under a dynamic wind load. Uplift forces can also be enormous, literally sucking a roof off the structure.
Even homes at 27 deg South latitude in Brisbane homes of this type are commonly pushed out of square by moderate wind load.

Newer homes are constructed far more solidly and tend to be either slab on ground brick structures or properly braced and tied down lightweight high set homes.
Beach front homes may be reasonably expensive homes however further inland dwellings tend to be far more simple.
We have had significant review of building practices in the light of previous cyclones and have in place a rating system based on potential wind rating.
All new homes in the effected area have been built to a C4 wind rating covering winds of around 310 km/hr.
Extensive research into cyclone damage has been undertaken by our James Cook University and their finding have been progressively included into the building codes.
Garage doors (Roller doors) are looking to still be a weak point in our current building regs as many of these failed allowing subsequent damage to some homes.

Our North Queenslanders are very cyclone savy as most long term residents have experienced numbers of cyclones and know their potential.
This rat cunning and the smarts to evacuate saved the day.
One might think that they would all live in concrete bunkers but this is definitely not the case. Whole towns literally packed up and left and
that is why the loss of life was so low.
None one sits still just waiting to get hit, they batten down then the moment it is over they chip in and help each other well before any emergency people even get there.
The classic was as the SES were literally cutting their way into a town through fallen trees, a local whizzed past clearing the road with a tractor from the opposite direction, like it is done every day :)

Attached is a pic on one of the older homes in the heavily damaged town of Tully that literally exploded once the building envelope was breached.
Enough said as I'm sure all will agree.

Attachment 11181

Regards
Ross

Rewiring and Auto Zero Screenset
 

Spent the last few days rewiring my machine (all of them days !!).
It has been a very circular exercise with only slight modifications from where I started :o

Anyhow, finally in position to put a few more cables into the machine and try to put the zero plate to bed.
Not content with just a bit of zeroing, I am trying to implement the 2010 screenset on the Mach3 site see http://www.machsupport.com/screens.php
The screen does a two point zero, moves automatically to a tool change position and also can park the gantry out of the way when the job is done.
The author is trying to achieve semi automatic tool changing for those of us who will probably never actually have an ATC.
There is a bug with the latest lockdown version of Mach3 but as the screenset is so new, you have to accept some issues along the way.
They are working on a fix by the way.
Here is the Youtube Video if you are interested, I know I was ... http://www.youtube.com/watch?v=7np99...layer_embedded

I see Skippy and Tony now have their machines in their respective homes.
Gentlemen start your machines :D.

Also I had no idea Pete (tangocharlie) was so helpfull, if I had known that, I would have had him around doing stuff for me ages ago :)

Regards
Ross

Zero Plate Testing
 

Hi All

After a slow weekend progress wise, I was able to rough in my touch plate and install the Mach3 2010 screenset.
My soldering skills get a tick as the 4N25 optocoupler survived the heat and works well.
The little blue LED on the control box also lights up nicely when an electrical contact is made.

The Mach3 2010 screenset (simple) touch routine does two approaches to the plate once at speed, the next very slowly, to get an accurate reading.
It then retracts 30mm or so to give a clearance plain.

Two videos show the solution in action.
http://www.youtube.com/watch?v=X2lYnlm2Pq4
http://www.youtube.com/watch?v=1V4BK6DCExo

Thanks again Ries for the circuit.

Regards
Ross

Need some Good Quality Vector Files for Free? - Read on
 

A Short note to let you know that Google have been indexing SVG (Scalable Vector Graphics) files for a while now.
From the advanced image search choose filetype SVG and the vectors arrive from the web to you on command.

Attachment 11275

SVG does not seem to be widely supported in the CNC software world just yet.
Inkscape will do the format conversions for you to something like EPS or your preferred format.
http://inkscape.org/

This a useful combo of search and conversion and sure beats the labour-intensive search of the vector graphics haunts on the web.

Enjoy
Ross

Zero Touch Plate(s)
 

Through a combination of luck and persistence, I now have two working touch plates.
One plate is plugged into the Y car control box when needed.
The second plate is for the moment fixed to the table to the near LHS of the Y axis travel.

I'm pretty sure I did it the hard way but as any plate is touched the little blue LED in the Y car lights.
The optocoupler in the Y car control box electrically protects the Break Out Board from static from both of the plates.

As the machine will eventually rapid around to touch the second plate for tool changes, a modification to the GND wire position was also needed.
The circuit works well when the GND is alligator clipped to the z axis spring, rather than the spindle itself.
My circuit needs the GND wire in place and unlike some will not work if omitted.

Next is to install the limit switches as per Sergio's diagram.
http://www.mechmate.com/forums/showt...&postcount=120
It is all ready except for the wires to run to the box with my relays in it.
Should take no longer than say 6 months to complete :rolleyes:
The limit switches will use up my last input of pin 11 on my PMDX 122.
If I feel the need to install my cross hair laser, a push switch and a small 3 volt battery pack will be quite adequate for this purpose.
After they go in no more electronics allowed for a while and hopefully I might concentrate on making stuff not making the machine - time will tell !!

Regards
Ross

Ross,
For the tool change touch off plate, you might want to consider a spring loaded landing pad. This is electrically isolated to the touch plate itself and doesn't require any grounding from the Z-side of the system. like this one...

http://www.k2cnc.com/shop/products.asp?cat=30

But, I have used a high quality MOMentary switch for the same too.

Hi Sean

I have already ordered one like this to try after looking at what the pros were using.
Could not find what they had but thought I would try a metal switch with a flat button (great minds hey Sean, haha)

Attachment 11276

Thanks for the tip.

Regards
Ross

Ross,
It takes a bit to get the hysteresis of the switch down pat and figure out what the length of travel is before contact to determine the Zero tool offset. But after that, it works pretty well.

I had to go this route on my multicam after the spindle came back from repair with CERAMIC bearings that left the tool tip non conductive to the rest of the machine.

Have fun!
Sean

Gidday Sean

By no coincidence the multicam Automatic Z Tool Sensor was what I was looking at and trying to replicate !
Had to look up" hysteresis" but it is certainly the correct term for what you describe.

I am a little suspect on my spindle bearings as I have run them at 24k for long periods during my testing of the Commfront USB adapter.
The specs for a steel bearing appear to top out at about 18K RPM and as I have conductivity through the spindle I definitely have a steel bearing setup :eek:.
A ceramic bearing replacement might also be something I would consider if the current set fail, so to plan ahead for this might also be worth my while.

Request for information on Chinese Spindle Bearings

Does anyone know the bearing size for my 2.2 kw water cooled Chinese spindle. It is one of the many sourced from LoveHappyShopping on Ebay.

Secondly has anyone pulled one of these apart, had any experience with bearing changes or can prove a link on the web to someone who has.

Thanks
Ross

Sean, can't you bypass the ceremic bearing by connecting the +ve signal wire direct from the BOB to your tool bit (with a crocodile clip or something...)?

Ross,
The metal bearing works just fine at 24Krpm. No worries.
You should ask LoveHappy for the bearing number... I just couldn't find my record of his reply...

Hi Ken

Thanks for your search on the bearings, I have asked the supplier for the specs.

The alligator clip is fine for the removable plate but the second plate touch is accessed under machine control.
It rapids over to the fixed point and then automatically goes into the probe routine with no user intervention.
The spindle is not spinning at this point but as soon as it gets to the second reference point, it is off to the job and the spindle fires up.
Right about at this point it tears the BOB ground cable from the Y car box if you have not chased it to remove the clip !!!

Regards
Ross

Ross,
The 24K rpm thing is from my operating experinece, I run at that speed a lot.
Thanks for elaborating your scenario of the touch off. Interestingly, I have yet to deal with 2nd plate touch off, would you kindly enlighten me the use & the advantages of doing that?

Ken

http://www.youtube.com/watch?v=7np99wSr9c8

Ross

Ken,
You can and I do this if the spindle is not on a tool changer. When multiple tool bits are considered, I found that the efficiency of the changer was limited if I spent my time manually setting up the changes every tool selection.

This arrangement also let me trick the machine on occasion to the new tool height. (setting the tool on the new part and "touching the button" set the new Zero TOP height) On some machines, the macro for tool height is not as easy as Mach 3 set up is. In MultiCAM world where this first presented a problem, the macro was driven from the membrane keyboard on the machine and was a one-way street on set up. Do it first, and always first - very little flexibility in it's earlier machines.

VFD Box Changes
 

Hi All

Spent some time this evening finding a tidy spot for everything in my VFD box and adding some terminal blocks for the wiring.
Ever the one for experimentation, I thought I'd test the envelope and put the USB adapter right next to the VFD inside the VFD box.
Capitalised on the DIN rail mount the adapter has to get it out of the way.
The white thing at the bottom RHS of the box is the exhaust port for the positive pressure enclosure.

All worked a treat ... after I plugged the USB cable into the PC :o
Still sprinkled some torroids around on the cables just to be sure.

Attachment 11296

Running, good visibility in my bespoke VFD box window - 1 RPM short though!

Attachment 11297

My luxurious work station, a piece of 4mm ply on a work stand.
Definitely needs improvement but the pic is to show the little self assembled Mini-ITX box that is running Mach3.
The case is tiny, it is an M350 box with a dual core atom inside.

The rest consists of ...
A silicone keypad (got the idea off Skippy). Hong Kong is now selling cordless silicone keypads for around $20 if you are interested.
Logitech Rumblepad 2 cordless game controller.
M505 Logitech cordless laser mouse (tracks very well in comparison to an optical mouse)
17 inch touch screen I made by putting a touch panel into a standard LCD monitor.

That big R2D2 you see on the monitor is displaying on the 2010 screen set I have been playing with.
Attachment 11298

Another job done but still more to do.

Regards
Ross

well done as always. Is that filter from a Chevy or Ford carburetor! :)

I hope its from a Chevy, or the MM will definitely run slower. :)
I like the silicone keyboard. No dust problems there. :)

Ross,

check this out:

http://www.cnczone.com/forums/diy-cn...spindle-2.html

Message #71

Milosh

Here’s the direct link to this #71 on the zone !

Hi All

Hate to disappoint you Sean and Heath, I bought the filter by dimensions only from my favourite old bloke parts supplier that has one of everything that was ever made on the shelf.
Seeing as it is so import though, I am now calling it a Chevy filter and attracting all the reflected glory that comes with the badge :)

Milsoh and Robert thanks for the links, I will have a look at the pics in the forum post.
They look very detailed so that was just what I was after - good stuff.

The more I look into the bearings on the Chinese spindles, the more it seems substitution is the game they are all playing.
True axial bearings that take loads from multiple directions are quite expensive so it is no wonder they slid down the slope to poorer quality bearings.
My only issue is did they have to slide THAT far and play the insider wise guy games.
I guess once a process is started it is hard to stop.
From my perspective it is not the end of the world though, as retrofitting with known high quality bearings is still less than the price of spindles a few years ago.

Cheers
Ross

Hi All

Tought this was allready posted before, but this is the way Chinese manufacturers get there Germany bearings

http://www.tradett.com/germany-bearing-products/

Dust Shoe Version V1.0 and 2.0
 

Hi All

I had my first go at making a Dust Shoe, Foot or Shroud (The names abound).
The machine cut the 12mm acrylic really well.
I am just so surprised by the quality of the cut with no belt reductions and the 24 tooth pinions.

Version 2.0 is already on the drawing board as I broke the clamp part of the dust shoe drilling a hole in it !!
Given how easily it shattered, next time the dust shoe will be made from polycarbonate that likes to flex a bit more.

Attachment 11310

I have redesigned the clamping mechanism completely.
Both of the dust shoes use a bicycle post cam lock mechanism to attach to the spindle.
The new design clamps at the front and the lever lays nice and flat this time.
The piece on the left bolts to the middle section with some 6mm CSK screws.
The two short lines are profiled 3mm deep each to form a 6mm shaft for the quick release bolt.

Attachment 11309

Definitely want to have it quick to remove as it restricts Z travel to about 140mm when in place.
Setting the Z to zero at 200mm off the spoil board will have it ripped right off.
Maybe another reason for incorporating flex into the design.:)

Regards
Ross

Dust Shoe V2 Comes to Life
 

The redesigned clamping mechanism on my V2 of the dust shoe worked a treat.
The shoe fits an 80mm Chinese spindle and uses a STD 100mm vacuum hose joiner.

Waiting for some 10 mm diameter x 5mm thick rare earth magnets to epoxy in to finish it off.

Clamp
Attachment 11323

Overall
Attachment 11324

Regards
Ross

Collet Holder
 

Two pieces of scrap form ply morphed into a collet holder.

Attachment 11329

Attachment 11330

Attachment 11331

Attachment 11332

Regards
Ross

The other piece of scrap next to the plwood looks pretty good. :)
Did you V-Carve it?

Jason

Seem a good resolution without belt reductios.

Hi Jason

Yet another experiment, it is cast acrylic that has had a vector graphic carved with a 3mm ball nose bit.
When it was done I rubbed furniture wax into the surface and it gave it an interesting transparency.
Turned out fine but I was actually trying a 1mm end mill with some cutting fluid as well as a bit of silicone spray on the other side.
Was working until I dropped the RPM and broke the bit.

Regards
Ross

Made a Fish
 

While browsing the web for creative ideas I came across this site ...
http://buildyourcnc.com/MarkGottscha...NCMachine.aspx by Mark Gottschalk.
A very creative guy, so if you don't own a CNC machine buy one of his creations from him.

Here is my take on a wooden fish produced by the amazing mechmate.

Attachment 11368

Plantation pine finished with a simple wax mixture I make up myself.

Regards
Ross

Very nice Ross!! I like these fish, so many great designs and fish to choose from.

Cheers
Tony.

Hey Ross,

Are you using your dust foot yet? how did you mount it? is it a fixed mount or can the dust foot travel up and down with the Z axis?
Looks good!! I will need to see this in action.
Nothing much to report here as I have been interstate with work since I got back from leave a week or so ago.

Cheers
Tony.

Greetings Tony

This week I have just finished shaping a new short board for a surf trip.
The garage is now a clean room for glassing until the epoxy coats have been completed - so ABSOLUTELY no dust allowed, not even from the Mechmate !!

The machines next project is already drawn up though, as I am using it to make the fin system router jigs for the board.

The magnets have been a while arriving from the UK but they turned up on Friday for the dust foot.
The darn things are so fiercely strong, I am going to have to glue in only 4 of the six possible first to see if i can actually pull the brush off.
Totally over following the cutter around with the vac so I will pay some attention to that soon.
The dust foot is a fixed mount type and the clamp at the front holds it very firmly to the body of the spindle itself.
The foot limits Z travel to around half of the spec so it is not a one size fits all solution.

Really enjoying making stuff with the MM but as I promised myself one project at a time, my boards need replacement badly due to lack of attention to that side of things over the past year.

Cheers
Ross

I look forward to seeing your boards, not too much call for them here but. . . .

Hi Tim

Apparently at zero degrees C water turns to ice. The only place that happens around here is in the freezer section of the refrigerator !

Regards
Ross

Its - 15 c tonight. A bad night is - 60c with wind chill. Always warm and sunny in the shop :)

Tim

Magnets Installed on the Dust Shoe
 

The epoxy holding the rare earth magnets in place has set and pleased to report the dust shoe fits together as planned.
Four 5mm x 10mm diameter magnets held the removable brush in place very strongly.

Attachment 11431
Attachment 11432

The Mechmate also cut a nice router template for my new surfboard's fin plugs. Such a handy machine to have on hand.

Attachment 11433

As far as putting the board directly under the gantry and let the machine cut the holes - just not up to that stage at present :eek:

Regards
Ross