Emco PC Turn 55

[Threedj16]

Anyway, since I've been working on PLC code mostly and waiting to use the lathe, finally found a place that was able to work out my timing pulleys and belts for motor, spindle and encoder. Also decided to swap out the 30 year old bearings...LOL...they could probably use it. Hopefully that will all be in next week. That should be really fun getting all that setup. I'll have pics of that setup eventually. Though I still have to design the encoder box for this new timing pulley and will be milling it out of aluminum instead of messing around with 3D printed parts this time around.

If it all works, I'll be happy to post all the pulley and belt info. Just be warned, they all have to be modded to fit.

[ScotY]

Now the fan only runs above 90 degrees. Very neat little temp controller from Amazon for $16 bucks. Loaded with features.

https://www.amazon.com/gp/product/B00OX ... UTF8&psc=1

That’s a neat way to control the fan, thanks for posting that. Are there relays in the controller? My fans are 12v and would like to have them temp controlled...think it will work?

[Threedj16]

Now the fan only runs above 90 degrees. Very neat little temp controller from Amazon for $16 bucks. Loaded with features.

https://www.amazon.com/gp/product/B00OX ... UTF8&psc=1

That’s a neat way to control the fan, thanks for posting that. Are there relays in the controller? My fans are 12v and would like to have them temp controlled...think it will work?

Yup, you have a heat and cool relay built into the controller. It would control 12v just as well as 120v. I can't remember the max current for the built in relays, but it was way more than any fan would pull. It's also a simple panel mount controller too, so easy install. Since I have no reason to see the unit for control, I just mounted it right on top of the fan and ran the RTD probe up higher were there would be more heat generated. They give you a very long probe cord, so you could mount it about anywhere within 10ft and control the fan.

[Threedj16]

Found just enough room to add in a DIN rail mount for my KBIS-240D signal converter.

Anyway, here's a few renderings. I have another model that's just a box without the DIN mount. The lid (which snaps in place) holds the board in along with studs on the base, so no screws needed. Also has holes for the two trim pot adjustments.

[ScotY]

Thanks for that info. I’ll have to order one.

[Threedj16]

Version 1 fit perfectly, but since I went to DIN rail mount, I wanted to trim any excess that I could. So this box is tighter and I want to make sure it fits perfect.

And the guys who recommended the KBIS-240D, thanks, you'll were spot on. I was hard headed in the beginning and tried a standard DIN mount 0-10v to 0-5v signal converter with isolation. But it would not allow a raised output (only a raised input). The wording on their website was misleading. But thankfully I was able to return the FS-33 card and found the KBIS-240D on ebay for $30 shipped. Only thing it was lacking for me was a case and DIN mount. Now this is all covered....LOL. Anyway, hope others find it useful. This thing is a must if using any above ground common motor controller (like the Consew BLDC setup I have).

[DICKEYBIRD]

And the guys who recommended the KBIS-240D, thanks, you'll were spot on.

Yay! I love it when a plan works! I'm not electro-magically swuft enough to truly understand the isolation thing but a few years ago when a knowledgeable kind soul told me about the KB stuff, I listened to him & the magic smoke stayed where its supposed to ever since!

[Threedj16]

And the guys who recommended the KBIS-240D, thanks, you'll were spot on.

Yay! I love it when a plan works! I'm not electro-magically swuft enough to truly understand the isolation thing but a few years ago when a knowledgeable kind soul told me about the KB stuff, I listened to him & the magic smoke stayed where its supposed to ever since!

I've accidentally released it once with a G540 and these stupid non earth referenced grounds with a simple slip of the meter probe....ARGH.

Fit is great. However my timing on changing the freakn filament out wasn't so good. I ran out of filament at 94%, lost one layer and let it keep running. I knew it was screwed, but it allowed me to test the fit. It naturally broke at the one layer where I restarted, and it took 8 hrs instead of 6 (stupid time estimator is never correct). So anyway, having to print another box. But at least it fit the DIN rail great and the tighter inside dimensions worked out good too. Now just have to wait until I have time to print another box....sigh.

Oh well, I'm taking a bit of a break this weekend anyway. Just working out a few small things. Next weekend is spindle bearing change and the new timing pulley/belts should arrive. Not looking forward to designing the encoder mount for it. All the pulleys have to be highly modified also. Couldn't find anything close in the size range with the correct ID. So having to bore 3 pulleys and sleeve the encoder shaft. Face down the hubs on two of them and drill/tap new set screw holes. But in the end, I should have a nice 25% motor to spindle reduction, 1 to 1 encoder and all on timing pulleys instead of v-belts. I put this part off as long as possible. As I hate doing this stuff. The electrical is more fun for me.

Hopefully some pics tomorrow with the new box printed. Doubt I do much more than that this weekend, unless I get a wild hair and decide to play with the PLC code some more.

[Threedj16]

Wow, life happens when your are busy making plans for a chill weekend. Ended up spending most of yesterday tearing apart my 3D printer. Decided it was just fussing at me wanting some routine maintenance. Got it apart, cleaned it up, started putting it back together when I noticed an extruder fan was running at room temps. Then I remembered it started doing that the night before and thought I need to check that out. But was half asleep the night before and didn't even think, crap that is causing my temps to be off (and ended up being off by 40 degrees). Thankfully it's a dual head printer, so finally got it all back together and just used the other extruder. Decided after 1 1/2 years of heavy use, might not be such a bad idea to go ahead and replace both heaters with nicer ceramic heaters and all new thermocouples for it. So now even more added to the plate for next weekend, though this may get put off longer, rather get my lathe drive system installed first.

Anyway, here are some pics of the KBIS-240D DIN rail mount box (renders above in earlier post). It still allows access to both min and max trim pots, nice large wire slot for using any configuration the board allows. Centering bosses hold the board in place on the bottom and studs hold it down from the lid. Lid snaps on nice and tight if you use PETG to print. If you use ABS, might want to tolerance it for such, as PETG is zero shrinkage practically, so I left no fit tolerances in the CAD which leaves a great tight fit.

It ain't purdy, but it works fantastic. I can honestly say now there is zero DIN rail space left. Think there is one more tiny spot in the top of my cabinet if I had anything else to mount (which thankfully, I can think of nothing). The solenoid for the mist/air is sitting on the left ledge, pretty close to where it will mount. Wasn't a top priority to get it mounted yet. Need to grab a few fittings anyway along with a quick connect for the air hose. Can't decide if I'm going to use the water filter deal (with pressurized fluid or just standard setup of letting the air jet pick up the liquid). I never noticed a huge improvement on my mill's mist system by adding pressurized air. Just a lot more work installing.

[Threedj16]

Been slacking a bit lately (actually other stuff came up), but finally finished up my drive pulley conversion today to timing belts and pulleys along with the encoder mount. Working great now, just need to go back and calibrate the signal converter again to the new pulleys.

Getting really close to letting this machine loose on it's first CNC pawn with the turret under CNC control too now.