Equipment/Dahlgren Wizzard 2000 ST: Difference between revisions

From London Hackspace Wiki
No edit summary
 
(6 intermediate revisions by 2 users not shown)
Line 1: Line 1:
{{EquipmentInfobox
{{EquipmentInfobox
| name = PCB Mill/Micro CNC <!-- Name of the item. -->
|name=PCB Mill/Micro CNC <!-- Name of the item. -->
| image = Hackspace_Unknown.png <!-- Image of the item. Leave with placeholder image if none exists. -->
|image=Hackspace_Unknown.png <!-- Image of the item. Leave with placeholder image if none exists. -->
| model = Unknown <!-- Model -->
|model=Dahlgren Wizzard 2000 ST (heavily hacked) <!-- Model -->
| category = Equipment <!-- Main category. Please leave alone to keep item in this category -->
|category=Equipment <!-- Main category. Please leave alone to keep item in this category -->
| subcat = CNC <!-- Sub-category if one exists. Please check main listing to see other categories contained within the main one -->
|subcat=defunct <!-- Sub-category if one exists. Please check main listing to see other categories contained within the main one -->
| status = Under construction <!-- Set to one of; Good working order, Faulty, Out of order, Under construction, Out of consumables, Scrapped, or Unknown -->
|status=Unknown <!-- Set to one of; Good working order, Faulty, Out of order, Under construction, Out of consumables, Scrapped, or Unknown -->
| consumables = Unknown <!-- Any items used up in normal operation, such as; ink, paper, saw-blades, cutting disks, oil, etc.. -->
|consumables=Unknown <!-- Any items used up in normal operation, such as; ink, paper, saw-blades, cutting disks, oil, etc.. -->
| accessories = Unknown <!-- Any items associated with the equipment but not consumable, such as; drill bits, safety gloves, goggles, etc.. -->
|accessories=Unknown <!-- Any items associated with the equipment but not consumable, such as; drill bits, safety gloves, goggles, etc.. -->
| reqtraining = <!-- Is training required to use this equipment? Yes or no. -->
|reqtraining=Yes <!-- Is training required to use this equipment? Yes or no. -->
| trainlink = Unknown <!-- If training is required, provide a link to training signup or contact page. Otherwise leave blank. -->
|trainlink=Unknown <!-- If training is required, provide a link to training signup or contact page. Otherwise leave blank. -->
| acnode = <!-- Is the equipment ACnode locked? -->
|acnode=<!-- Is the equipment ACnode locked? -->
| owner = LHS <!-- Provide a link to owners members page if other than LHS -->
|owner=LHS <!-- Provide a link to owners members page if other than LHS -->
| origin = Donated <!-- If via pledge, please link to the completed pledge page on the wiki -->
|origin=Donated <!-- If via pledge, please link to the completed pledge page on the wiki -->
| location = Basement, parts storage<!-- Floor, room/zone and location within that area -->
|location=Basement, Robotics/CNC area <!-- Floor, room/zone and location within that area -->
| maintainers = Sci <!-- NO LINKS PLEASE; it currently breaks the template. If someone is nominated as managing the upkeep of this item, please list them here. -->
|maintainers=Martin_p <!-- NO LINKS PLEASE; it currently breaks the template. If someone is nominated as managing the upkeep of this item, please list them here. -->
| template_ver = 1.1 <!-- Please do not change. Used for tracking out-of-date templates -->
|template_ver=1.1 <!-- Please do not change. Used for tracking out-of-date templates -->
}}
}}
This is a project to convert a CNC engraver to also allow it to operate as a CNC pcb drill. The Engraver is a Dahlgren Wizzard 2000 ST. Currently, the engraver is actively worked on by [[User:Martin_p|Martin_p]], and for the time being lives on the floor in the arts/crafts corner. The original roadmap/discussion has been moved to [[Talk:Equipment/Dahlgren_Wizzard_2000_ST|discussion]] for this page.


This is a project to convert a CNC engraver to also allow it to operate as a CNC pcb drill.
This wiki page is not written in a chronological order, and relevant sections will be updated as the work progresses. I am using my phone camera for taking the pictures, so please excuse their poor documentation-only quality. Please feel free to contact me with any suggestions, or correct any errors or omissions.


The Engraver is a Dahlgren Wizzard 2000 ST.


== It needs ==
== Resources ==
All resources, PCB designs and arduino C++ files live on [https://github.com/martin-pr/cnc-router-hack GitHub]. Feel free to look around and/or contribute (but please email me first).


* Cosmetic cleaning & minor surface rust removal.
== Mechanics ==
* 3 x stepper motors (NEMA 14 by the looks of it)
**I've got a nema 17 and may be able to source 2 more. Would that fit ? -artag
***This video shows the vertical motor in use as well as the spindle motor with pulley: http://www.youtube.com/watch?v=0nGC2vyW9VU
**Maybe consider getting 0.9 degree step stepper motors to increase precision -[[User:Senthil Seveelavanan|Senthil Seveelavanan]] ([[User talk:Senthil Seveelavanan|talk]]) 10:34, 5 July 2013 (UTC)
* a way of connecting the steppers to the leadscrews.
**Hipster has some couplers of a type that are now really cheap on ebay
* a drill of some kind.
**Some people are using aero/quadcopter motors. Would the controller handle one ? might need a sensorfull motor
***Liam said it took a straight DC motor. So proably PWM speed control if that's the case.
* a way to fix the drill to the x/y platform.
** Spindle is an interchangable module. Any arrangement with the same OD of housing will fit. Will however need round-profile drive belt and motor pulley. Emco unimat spares may be suitable.
* chuck for the drill.
**Collets are much better than a chuck. An ER12 collet chuck would be better than the cheap dremel style, but needs a decent sized motor shaft. There may be something more suitable for auto toolchange (one day)
* small drill bits.
** As standard does not take drills but "gravers" that go through the whole spindle for precise depth adjustment
** It would be nice for it to actually be able to still engrave/mill rather than just drill holes when repaired.
* some rewireing to fix endstops etc.


At the moment the engraver comes with an embedded computer (386FX!), which powers up and works fine, and is connected to a control board that has 3 x [http://imshome.com/products/im481h.html stepper drivers] and a [http://www.onsemi.com/pub_link/Collateral/MC33035-D.PDF brushless dc motor controller] on it.
[[File:CNC_full_view.jpg|thumb|left|Original state (without cover) - full view]]


== Choices ==
=== Original state ===
Apart from lots of dirt and a bit of rust, the mechanical parts were in a reasonable order. The most important missing bits were:
* 3x NEMA 23 motors
* 2x 6mm flexible coupling
* z-axis pulley (6mm shaft)
* working bed
* main motor and belt between the rotary tool bit and the motor
* bit mounting mechanism (only a torso of it left)


We've got 3 main choices:


# Use the existing controller, but we'd need to give it the steppers and drill that it expects.
<br clear=all>
# Chuck the existing control board and use an arduino or something to talk to the [http://imshome.com/products/im481h.html existing drivers]
== Electronics ==
# Chuck all the electronics and do it all our selves.


The first may be the quickest, but we'd need to get identical parts - the manufacturer may sell them, which might make them more expensive.
=== Original state ===
Electronics was split into 3 boards - driver/power source, a 386 controlling board and a front display/buttons board.  


The second will involve some hardware reverse enginerring to work out the pinouts to talk the existing drivers
===== Driver board =====
The driver board was in a good shape, and seemed to be relatively easy to hack. The power source is 35V (motors) and 5V (electronics, stabilised), and works beautifully. The middle part contains a 6-phase motor driver, and will probably not end up used in the end. The stepper motor drivers are older versions, but fully functional, hardwired to use 1/10 substeps, and 800mA peak current.


The 3rd might also be fairly easy - presumably we can use the reprap style electronics with it??
===== Control board =====
*Solexious' stepper drivers could be used, though not with reprap controls. Might also be a good target for grbl.
The 386 machine refused to cooperate because of the missing main motor, and as it would be very hard to reverse-engineer it anyway, I went with the suggestion from the original discussion and ditched it.  


== Proposed roadmap ==
===== Display/buttons board =====
[[File:cnc front.jpeg|thumb|left|Front panel]]
The front board contains a set of buttons, a HD44780-compatible two lines LCD display and 3 pots, all in a very hackable working order.


It currently seems easiest, and possibly more reliable long-term, to fix rather than hack. I suggest we go with this until proven otherwise.
<br clear=all>
=== Arduino ===


# Check pinout of control board output. Will provide nessesary info on stepper voltages, wiring and spindle motor control, as well as verify controller function.
===== Pin assignment =====
# Presuming control output okay, obtain and fit steppers, wire in stops, test motion.
#* If controls damaged, then move to other controls
#* Check if brass wheel causes any motion difficulty
# Fit new spindle motor (see manual page 26 for stock assembly diagram)
# Make spindle bearing and collet holder (see page 25 of manual - this may be very very tricky. Many precision parts)
#* Alternately make missing parts for existing spindle mount. Not much use for immediate goals though.
# Fit replacement table
#* Pricing is hard to find, but many engraving machine suppliers sell replacement T-slot tables which will provide an optimum mounting solution.
#* A temporary table made of MDF or similar should be enough to test function crudely.


== Pics ==
{| class="wikitable"
!
!pin
!meaning
|-
|rowspan="2"|serial
|D0
|RX
|-
|D1
|TX
|-
|rowspan="5"|X+Y
|D2
|step X
|-
|D3
|dir X
|-
|D4
|enable X+Y
|-
|D5
|step Y
|-
|D6
|dir Y
|-
|rowspan="3"|Z
|D7
|enable Z
|-
|D8
|step Z
|-
|D9
|dir Z
|-
|
|D10
|piezo
!colspan=2|shift reg
|-
|rowspan="3"|LCD
|D11
|clk
|0
|RS
|-
|D12
|data
|1
|R/W
|-
|D13
|strobe
|2
|clk
|-
|
|
|
|3
|(not connected)
|-
|
|
|
|4
|bit 4
|-
|
|
|
|5
|bit 5
|-
|
|
|
|6
|bit 6
|-
|
|
|
|7
|bit 7


* [http://pointless.net/photos/id/1363117805/ stepper drivers]
|}
* [http://pointless.net/photos/id/1363117840/ other bits on the interface board]
* [http://pointless.net/photos/id/1363120494/ 386 computer + transformer]
* [http://pointless.net/photos/id/1363120499/ top view]
* [http://pointless.net/photos/id/1363120512/ view of the mounting thing for a stepper, NEMA 14?]
* [http://pointless.net/photos/id/1363120524/ the cover]


== Links ==
<br clear=all>
 
== Software ==
All sources live on [https://github.com/martin-pr/cnc-router-hack GitHub], both for [https://github.com/martin-pr/cnc-router-hack/tree/master/arduino Arduino] and for Linux side (not yet implemented).
 
=== Original state ===
Because I decided to ditch the 386-based control board early on, the original state was non-existent.
 
=== Arduino ===
The main part of hard work is done by an Arduino Nano. It is connected directly to the motor drivers, endstops, display and buttons. It receives its data via a USB/RS232 serial port.


* Wizzard ST manual, includes parts numbers (ST High Lift not 2000): http://www.suregrave.com/downloads/manuals/Wizzard%20ST%20Manual.pdf
* Video of an 2000 ST opened up for stepper testing. Shows X/Y spindle motor. http://www.youtube.com/watch?v=0nGC2vyW9VU
* Some raw interfacing info: http://www.vectric.com/forum/viewtopic.php?f=4&t=11920
* Third Party support page.  Some interesting points: http://www.engraversnetwork.com/Dahlgren/wizzard_tip001.htm


[[Category:PCB making]]
[[Category:PCB making]]
[[Category:Projects]]
[[Category:Projects]]

Latest revision as of 11:53, 21 January 2019

PCB Mill/Micro CNC
Hackspace Unknown.png
Model Dahlgren Wizzard 2000 ST (heavily hacked)
Sub-category defunct
Status Unknown
Consumables Unknown
Accessories Unknown
Training requirement Yes
Training link Unknown
Owner LHS
Origin Donated
Location Basement, Robotics/CNC area
Maintainers Martin_p

This is a project to convert a CNC engraver to also allow it to operate as a CNC pcb drill. The Engraver is a Dahlgren Wizzard 2000 ST. Currently, the engraver is actively worked on by Martin_p, and for the time being lives on the floor in the arts/crafts corner. The original roadmap/discussion has been moved to discussion for this page.

This wiki page is not written in a chronological order, and relevant sections will be updated as the work progresses. I am using my phone camera for taking the pictures, so please excuse their poor documentation-only quality. Please feel free to contact me with any suggestions, or correct any errors or omissions.


Resources

All resources, PCB designs and arduino C++ files live on GitHub. Feel free to look around and/or contribute (but please email me first).

Mechanics

Original state (without cover) - full view

Original state

Apart from lots of dirt and a bit of rust, the mechanical parts were in a reasonable order. The most important missing bits were:

  • 3x NEMA 23 motors
  • 2x 6mm flexible coupling
  • z-axis pulley (6mm shaft)
  • working bed
  • main motor and belt between the rotary tool bit and the motor
  • bit mounting mechanism (only a torso of it left)



Electronics

Original state

Electronics was split into 3 boards - driver/power source, a 386 controlling board and a front display/buttons board.

Driver board

The driver board was in a good shape, and seemed to be relatively easy to hack. The power source is 35V (motors) and 5V (electronics, stabilised), and works beautifully. The middle part contains a 6-phase motor driver, and will probably not end up used in the end. The stepper motor drivers are older versions, but fully functional, hardwired to use 1/10 substeps, and 800mA peak current.

Control board

The 386 machine refused to cooperate because of the missing main motor, and as it would be very hard to reverse-engineer it anyway, I went with the suggestion from the original discussion and ditched it.

Display/buttons board
Front panel

The front board contains a set of buttons, a HD44780-compatible two lines LCD display and 3 pots, all in a very hackable working order.


Arduino

Pin assignment
pin meaning
serial D0 RX
D1 TX
X+Y D2 step X
D3 dir X
D4 enable X+Y
D5 step Y
D6 dir Y
Z D7 enable Z
D8 step Z
D9 dir Z
D10 piezo shift reg
LCD D11 clk 0 RS
D12 data 1 R/W
D13 strobe 2 clk
3 (not connected)
4 bit 4
5 bit 5
6 bit 6
7 bit 7


Software

All sources live on GitHub, both for Arduino and for Linux side (not yet implemented).

Original state

Because I decided to ditch the 386-based control board early on, the original state was non-existent.

Arduino

The main part of hard work is done by an Arduino Nano. It is connected directly to the motor drivers, endstops, display and buttons. It receives its data via a USB/RS232 serial port.

Retrieved from ‘https://wiki.london.hackspace.org.uk/w/index.php?title=Equipment/Dahlgren_Wizzard_2000_ST&oldid=52518’