3-axis CNC in Germany

swa

swa
Hello MASSO Community

and greetings from Dresden, Germany. We would like to present you our current CNC project. It is a modified CNC from 1998
that had a Siemens Sinumerik control and now uses a MASSO G3. We bought it from a school near our town for a very decent
price in terms of the components installed. Involved are my good friend Carsten (metal cutting mechanic) and myself, Simon
(electronic engineering technician).
In our workshop we mainly work with wood. We can turn, saw, grind, drill and now also mill.

Axes:

We are reusing the three SIMOSTEP 1FL3061 Drive Units.
Motors are:

2x Berger Lahr VDRM3910/50 LWC (Y-, Z-Axis)
1x Siemens 1FL3061-0AC31-0BG0 (X-Axis)
Those are 3-phase-stepper motors. Seemingly rare.

The IDC connector on the side of MASSO is used to run the 5V optical couplers of the SIMOSTEP Drive Units
directly with the 5V TTL signals.
AxisXYZ
Pulses per Revolution10k10k10k
Distance per Revolution125mm125mm50mm
Resolution0.0125mm/step0.0125mm/step0.005mm/step
Gearingmechanical(10:1); tooth belt(48:22)mechanical(10:1); tooth belt(48:22)ball screw(5mm pitch); tooth belt(1:1)
Feedrate5000mm/min5000mm/min1200mm/min
Acceleration350mm/sec 350mm/sec 300mm/sec
min. Travel-1155mm-745mm-165mm
max. Travel+65mm+65mm+65mm
yet to come(Acceleration must be re-evaluated after installation of the 25kg spindle), Backlash, etc.)

Spindle:

We are simply using the existing hand router that we inherited. As wood is already our preferred medium it works fairly well for now.
In the midterm we want to use a 4.5kW BT30 Air CNC Spindle with ATC support.

Currently, a spindle conversion is taking place from the inherited router to a 4.5kW air-cooled spindle. When the conversion is complete this section will be updated.

Work Area:

1220mmx810mmx230mm (X,Y,Z)

Safety Concept:

Our safety circuit uses a PNOZ Z Category 2 EN 954-1 relay. This simplifies our safety circuit enormously as each
of our axes uses a SCHMERSAL limit switch at both ends. All these end positions are independent of our soft ends.
In series with our emergency stop next to the monitor and the handwheel, they trip the relay and disable the drives
and signal emergency stop to MASSO. If the emergency stop is activated, the cause must be eliminated and the
emergency stop must be acknowledged at a button on the control cabinet. Then the actuators and MASSO are both
released again via the relay. Acknowledging the emergency stop is quite common in our special machines.
The two door sensors (left and front) are also wired in series and connected to the door sensor input.

Future Projects:

-Spindle
-Toolsetter
-Automatic Tool Changer
-Vacuum table, 4x pneumatic cylinders for fast workpiece alignment, integration into our central suction, fourth and fifth axis ;)
 

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keymont

keymont
Very nice! Welcome to the community! This must be the most detailed introduction post of them all! German Engineering, even while just saying hello - awesome!



FYI, both of my machines use a 4KW air cooled spindle and they go through pretty much any wood like a hot knife through butter. Have fun!
 

swa

swa
Thank you @keymont for the kind words! We are also happy about the swift integration of MASSO into our system.
If there are any further questions about our project, please write to us. The project allows us both to escape a little
from our daily work. Hence our affinity for wood ;)

In this forum, it seems that quite often a new thread is opened on the same topic because the machines are very different.
Therefore, we will probably announce our progress mostly as a change in our first post.
 

swa

swa
Here is a brief overview of the upcoming spindle rebuild. The choice fell on a RATTM Motor RTMD120X103-30-24/4.5 BT30 380V 400-800Hz 12000-24000rpm 3,6-4,3Nm 4,5kW(S1) 5,4kW(S6) spindle and a 5.5KW Fuling Brand DZB300 Series VFD.
Initial startup is following @cncnutz's example in the disassembled state without MASSO using a potentiometer. If so far all functions are present the installation takes place. Afterwards we report of course on the first results.

At the top right of the first picture, you can catch a glimpse of the possibly following 4th and 5th axis.
 

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jho

JHO
I will be following this build, i'm thinking about this exact spindle some time now.

Having an ATC spindle would be so nice, it's much more efficient and productive.



are you going to place some sort of review?
 

maxq

MaxQ
Hello SWA,

Should the cable that carries the 3 phase power from a VFD to a motor always be a shielded cable? I ask because I recently wired a VFD to power my manual knee mill and I used unshielded SOOW 10/4 AWG. It is however completely contained in flexible metal conduit which is grounded to the mains. Will this cause interference for my Masso-controlled CNC plasma table?



I like your build and look forward to any updates.



Thank you kindly,

Anthony
 

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swa

swa
Dear JHO and Anthony,

Thank you for your interest in our project.
@jho We have already found some missing and insufficient information in the spindle documentation translated from Chinese. We will be happy to report to you when the installation is completed.
@anthony There are a number of reasons to shield motor cables. But you can also do it wrong by creating loops. Please always connect earth potential and shields in a star configuration at a central point. Or directly at the intended connection on the frequency converter. If you build rings, this can sometimes cause problems.
Please also make sure to use cable suitable for drag chains. There the shielding and isolation is specially made to be flexible. With normal cable it will go wrong sooner or later and then you are looking for the error.
We promise to keep you informed.
 

swa

swa
Please excuse the lack of information in our last post. We are expiriencing some problems with the spindle which mainly affect the quality of the air required for the tool gripping and release mechanism as well as the sealing air. We have considered various oil, water and particle separator solutions and our choice was a central maintenance unit and a membrane filter/dryer. For now we use a 5/2 way valve for the grab and release process and two additional pressure reducers and filters. This part is roughly specified but not explained in the spindle documentation. You have to try the three pneumatic connections, since they are not described, and you will hopefully don't find out that the spindle was saved by the frequency inverter while the tool gripper clamp is slowly opening during operation and the motor is slowly blocking due to wrong pneumatic tubing. In addition the spindle is permanently supplied with overpressure so that no particles can get in. All this now for the time being on our test stand as well as for later. Now the spindle receives air supply in quality that a dentist could work with and we dare to run the spindle.
Please have patience with us. Greetings to the whole MASSO community
 
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