The Kitchen Table Project

This project is created by designer & creator of of Mechmate, Gerald.

He is the avovacate of testing out the control electronics & software before the mechanical works were carried out.

The goal AFAIK is to
1) find out if the control panel design one put up will actually work before it is installed on the actual CNC machine.
2) force learning the very basic of the motion controller software (EMC2 in this case) by actually putting you hands on it and not just talk.
3) confirm if the hardware are in working condition as early as possible.

He carried out the assembly & testing of the control panel components in the comfort of his kitchen dinning table, hence the name...

There are a few very detail design which he put up in his plan & discussions in the forum, one can just buy the stuff & follow the "map to complete the whole she-bang. BUT being me, I just have to know the what/why/where/when/how or the system.... so.... took the long way around to do this project ... again...

My design based strongly on Gerald's concept with a twist...
All components are different from his original but they work...
Electrical circuit also varied a little... but still resemble his original concept.

This is my concoction


Software
Motion Control Software :- EMC2 2.3.4 release
O/S : Ubuntu  8.04LTS "Hardy Heron"


Hardware
Computer :- Intel D945GCLF Atom with 2M DDR2 Ram, 8Gb Thumdrive as storage, 15" LCD monitor, keyboard, PS2 mouse
Motor Drive : M860 Leadshine Micro stepping driver, 6A max
Stepper Motor : 98HS9801, 450Ncm, 4.1mL/phase, 4A
Stepper motor Transformer :- EI core 540VA, 0-48VAC
Computer Breakout/ interface board : Sinyu 5-Axis Ver. 1
Breakout board Transformer 0-9VAC, 9VA
Magnetic Coil Contactor : 3 phase, 240V, 18A
other electrical components : Push button, Indicator light,
Control Panel Chassis : Powder coated Metal chassis, 500mm (H) x 400mm (W) x 200mm (D)

Took me over 4 months to get the motors running under EMC2 control.

It had been a huge struggle for me from day one of this kitchen table project. Time, money, sweat, draw a few drops of blood, late night..... frustration come & go....

Some how the moment you hear the motors singing a quartet for you for the first time....  Priceless...........

The CNC Electronics & Electrical Department Happening

I have a confession to make....

I finally did it! I killed ALL the board in my control panel!!! There goes the PMDX-122 breakout board & the Atom MOBO!!! :(

It all happend in that thundering night, wind howling... fist size rain drop pouring.... blue flashing thunder... door banging....... Err.... nothing of that sort, ;p

Over the X'mas holidays, I proceed to wire up the control panel. Individually,  the magnetic coil contactor, E-stop circuit worked out the Mobo worked fine, BUT they don't jive with each other, ...

Wire all the components, press the start button, hear that satisfying "thump" made by the magnectic coil contactor, and a few blink of the monitor & everything went black-out.... Dead! Mati! Kong! & I didn't have the pleasure to seeing smoke!!!

With a puntured ego & coffer, I went back to search for another board as the return shipping charges to send the dead BOB back to the maker is plainly irrational.

Undetered by this set back, I (again) dive into the vast ocean of information- the internet & picked up this SINYU 5-Axis Interface Board. from the ebay.

This chunk of populated electronic component PCB features a Manual Jog function by connecting a home made joy pad, the circuit for the joy pad is given in the manual.
It has 2 Relays which I can switch on larger Magnetic coil relays for auxillary equipment.
Charge pump featured
Unique 10-wire ribbon cable terminal for connection to the Stepper Driver. I have a choice to configure the board for 5 stepper driver connection or 4.
4 sets of powered 3-port terminal with 12Vdc VCC ready for home/limit proximity switch connection.
Takes 9Vac as power which is easy to implement.

AND it is $$$ friendly too.

As for the Mobo, a replacement were sorte.


Total damage?
RM836  = USD 245 = EUR175 = GBP151= ZAR1,860 = 11,360 rupee = HKD 1,907........

ooooooooouuuuuuuccccchhhhhhhh........

 ##PS,
Read the small print

So..... Please support this blog by clicking on the ads.... every cent counts.....

;)

The Atom Mobo is Alive!

The motion constrol system requires a PC to work.... obvious isn't it...

For EMC2, we can use Pentium 4 with 512Mb or more. I had a free P3 donated. but it Ubuntu didn't like it... An used P4 of the correct spec will set me back ~RM400, It is the most economical choice but I have a soft spot for the Intel Atom chip...

Purchased a D945GLF box. Its contained  mobo + the N240 processor at RM215. I need to have a ATX PSU, a 2Mb DDRII RAM, and use salvaged LCD monitor, keyboard mouse,  HDD, CD drive.

Plug in all the necessary connectors, slot in the RAM, power up... then all hell broke loose for the next 3 day trying to figure out what went wrong.... after swapping a new DDRII RAM, IDE cable, BIOS battery, keyboard, mouse, CD drive and even another HDD. Eventually, it was concluded that the mobo is faulty and while waiting for replacement, (warranty claim), I got hold of the Dual core Atom board D945GLF2 as they only have this in stock...

Back to me workbench, slot in the RAM, plug in all neccessary connector, set the bios, insert the EMC live-CD & we have this

Ran the latency Test, 15,801ns max jitter is  just what I hope for.

Here is the screenshot (literally) of EMC2

Lessons learnt? Yes, Murphy Law never fails!!! ....

Apart from that, check your PSU pinout!!!

The D945GLF requires  2x10 +2x2 power connectors.

The D945GLF2 requires  2x12 + 2x2 power connectors

Getting the right PSU at the right price burnt up 2~3weeks of my time....

So you are warned.