What it is about
What it can do

Progress & updates

 

Published plans and parts

Assembly instructions and software links

On-line suppliers in Europe we like & use



Repairable machines is a timelab project, located in Ghent, Belgium

 

 

 

BIG BLACK 01 BUILD LOG

 

 

DISCLAIMER

This documentation is offered as is, in the hope that you might find it useful. This is however not a build manual, but only documentation on our build process. And though we like our machine and its capabilities, there is a lot we would do differently if we would build a second version today.

 

 

 

 

TOOLS

Some of the design decisions need to be seen in the light of the tools available to us.

At the time we started working on this machine, we had access to:
-a decent drill press
-a 30W lasercutter
-Makerbot 3D-printers

At the time we did not own a lathe or accurate metalworking tools.

If we would start over today, we would have the ends of the screws finished to a smaller diameter on a lathe, and have some critical metal parts cut on a waterjet.

 

 

FRAME

 

 

   
 

The parts for the frame. We had those cut to size for us.

   
 

 

300 kilos of steel....
One design decision we never regretted was not to save on the frame. If you are on a tight budget and need to save on the motors, you can always replace them later with more powerful ones. But you can't change out your frame...

 

   
 

In order to drill accurate holes, we manufactured 'caissons' in MDF on the lasercutter.

These caissons have holes, which allowed to mark the positions with a punch. The holes were then drilled on the drill press.

Each piece of the frame had its orientation marked.

 

 

   
 

 

 

   
 

Punching hole markers.

 

 

 

 

 

 

Drilling holes.

 

 

 

 

     
 

 

 

   
 

Spray-painting the frame.

 

 

 

 

 

 

 

 

   
 

Looking sceptical...

 

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The 'log cabin' system gave us a low-tech way to assemble a straight-and-level frame.

It was inspired by ROGR, a machine from Lumenlabs. Their site no longer seems to be on-line, but I found this video:
http://archive.org/details/Lumenlab-LumenlabCNCRoGRsFirstStepsLiftingRobin835

The basic idea is that, as you gradually tighten the bolts and clamp the square tubing together, they will line up in 90° angles.

We used blocks to space the top beams parallel to the bottom ones while fixing them in place, and the bolt spacing - being hand-drilled wasn't perfect, but it worked remarkably well.

 

 

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BRIDGE

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Lieven next to the portal bridge assembly (this is the X-axis)

 

 

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Detail of printed motor coupling on the X-axis. This is not the final version, we broke these and had to design stronger version.

 

 

 

 

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Detail of the backside of the portal bridge (X-axis)
The block in the middle contains the nut and is mounted to the Z-block.

 

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This is the block before mounting, as you see it in the previous image.
The plastic IGUS-nut is held in place with lasercut MDF panels inside the steel housing.

 

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Printed part, a clamp for the screws. Looks very cute now, the orange plate is the build plate from our very first Makerbot Cupcake.

 

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Backside of the Z-sled, to be mounted on the guide rails of the portal bridge.

 

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The Z-axis came as a pre-assembled partfrom IGUS. This is to be mounted on the part above.

 

 

 

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Detail of the mounted Z-axis, seen from above.

 

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Detail of the side of the portal bridge, showing the nut mounted in the lower beam.

 

And then we moved into a new place....

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... which led to a long break and a half-finished machine in storage:

 

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CABLE HARNESS AND GUIDES

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And when we restarted we forgot to take pictures the first couple of days...

 

 

 

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Mounting cable gutters. The cable glands are general purpose airduct tubing, work really well. Just make sure you get a large enough size so you can get your cables AND their plugs through them.

 

 

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Adding endstops.

 

 

CONTROLLER BOX

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Controller box. To do list: take better pictures of the insides. And we should document the wiring.

Basically:
-Reprap-shield on an Arduino Mega
-4 stepper drivers: X(2x), Y, Z
-2 48V power supplies
-2 Relays, one to switch the tool, one for a vacuum cleaner
-contacts for an emergency switch and endstops
-individual fuses on the stepper motors and the relays.

We used DIN-connectors for the motors and audio-plugs for the endstops.

 

 

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Added a floor. This is just bolted onto the frame.

 

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TOOL CLAMP

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We initially used a printed part to mount the Kress motor, but replaced it with an aluminium piece.

 

 

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Milling the aluminium clamp in Brussels.

 

 

 

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BILL OF MATERIALS

 

ITEM USED IN SUPPLIER # COST/PIECE
DryLin W single rail, square Guide rails on X and Y IGUS 4 54,04 €
DryLin W housing, square   IGUS 6 5,56 €
DryLin W housing, square, floating   IGUS 6 5,56 €
DryLin trapezium spindle 30mm Screws on X and Y IGUS 3 79,05 €
DryLin trapezium nuts (plastic) 30mm   IGUS 3 79,05 €
DryLin linear spindletable compact  Z-axis IGUS 1 197,00 €
         
         
         
         
stepper motor NEMA 34 34SM SB Serie - 2,9A/coil X (double) and Y STAPPENMOTOREN.NL 3 77,31 €
stepper motor NEMA 23 SY42STH47-1684B Z zappautomation.co.uk 1 21 €

stepper drivers HP 5042 4,2A 50V driver 1/128 microstep
http://damencnc.com/en/components/motors-and-drivers/stepperdriver

 

  damencnc.nl 1 55 €

Kress spindle motor (brushed AC motor) http://damencnc.com/en/tools/kress/kress-milling-motor


  damencnc.nl 1 150,00 €
Reprap electronics   www.grrf.de 1 200,00 €

Arduino Mega

 

    1 49,00 €

Power supply 48V 8.3A
http://damencnc.com/en/components/electronic-parts/power-supplies

 

  damencnc.nl 2 75,00 €
endstop switches   rs-components.be 5 1,00 €
         
steel frame - thin walled tube 120x120x3mm Frame Metal GENT 1 312,00 €
         
angular bearings 30mm single-row Screws on X and Y RS-components.be 6 16,00 €
         
Motor couplings and screw clamps were 3D-printed on Makerbots and Ultimakers.        
         
         
         

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

 

 

 
 
 

 


 

MARCH 27th 2013 -TIMELAB - GHENT - On Wednesday March 27th we will be presenting our big black machine. It is a 800x1000mm 3-axial milling machine intended for milling wood panels in the Ghent fablab. See http://www.timelab.org/nl/presentatie-zelfgebouwde-freesmachine

Everybody is welcome for a quiet drink and some loud milling, from 19h at timelab.

 

MARCH 25th 2013 - Way too long since we came back to our milling machines. Both me and Kurt have been busy running our respective labs and haven't been able to put as much time in our machines as we would want.

MARCH 20th 2013 - SHOP UPDATE - For now we are not distributing any kits of the miniCNC. The machine electronics are based around the old Makerbot Cupcake boards, which are no longer available. We are reworking the electronics to run off a set of Reprap electronics and a modified version of Pronterface.

JANUARI 30th 2012 - Lieven will be giving a workshop/presentation of the miniCNC at the Antwerp Hackerspace.on Friday the 10th of Februari, 8PM.
See http://voidwarranties.be/index.php/Mini-cnc_workshopfor details.


SEPTEMBER 27th 2011- Adam W.-Swicizinsky und Ewald Neuhofer from AWS design team are taking the machine to the Vienna design week to engrave furniture, from September 30th to October 3rd, themed "Copyright - Design zwischen Inspiration und Kopie"
You can follow them on their project blog: http://awsdesignteam.wordpress.com

Copyright, Copyleft - aws designteam - Fr 30.09.2011 – Mo 3.10.2011 - stilwerk
viennadesignweek.com - Labor
www.awsdesign.cc