Fadal 4020HT Retrofit

[DojoJoe]

I appreciate the reply and information - I was starting to think you went silent on here.
I've got it mostly running (although I had almost everything mechanical disconnected, I tend to be very anxious with new code until I've tested it thoroughly), I tested the spindle motor without air - that sure startled me (the belt slips like crazy that way, I didn't quite want to go through the trouble of getting my air compressor running [it's running now, it was broken at the time - I'm a little shop that normally doesn't need air]), but I was rather happy my Baldor VFD works. I've yet to make my keyboard as I'm getting buried working on my customer's machines (and unfortunately a few cars), but it's better than not being busy - though I'd like to finish this project to add to what I can do with the business.

As for the tool changer, I've got a Mitsubishi servo on hand and I scanned in the part of the tool changer I needed to see if I could make it fit in there - surprisingly it says I can make a SH QD bushing and L timing belt sprocket fit, but only barely, and by barely I mean less than 1/16" (my scan says I've got room for a sprocket of 3.125" diameter, and I can find them at 3.1" - I'm just going to be concerned with if the timing belt sticks out of the sprocket - I should really see how close the spindle gets before I commit to that now that I'm talking about that though). I've thought of using a helical gear as I'm seeing them on my customer's CNC's (they typically are making cabinets, so these are high end woodworking CNC's with multiple heads and stations operating at once). I'll just have to get a light gearbox for the servo motor to make the inertia ratio good for it (the sprocket on the turret would be so small there's no way I could get a good gear ratio that way).

I'll put a video up eventually when everything is put together, but it'll be a while since I don't make my living machining parts, but instead by making / modifying / programming machines and systems relating to them - so this is what I'm using for filler work when I'm between jobs or waiting on something.

[DojoJoe]

It's been a while since I've posted and it's exciting when things happen so I wanted to share my progress (even if it is rather slow, though that's because I've been involved in other projects - I'm still reluctant to share actual pictures since I haven't finished the operator panel).

I finally made it where I can use Qt Designer to make UI's and got my UI to start talking to Dynomotion (unfortunately these screenshots are from me running it at home without it connected to the KFlop), I don't expect I've got everything talking correctly on these screens - I did tie in a viewer for G-code as well on a screen. I'm looking forward to putting this on the HMI I received today - I haven't yet checked the coordinates for fixture or the absolute coordinates of the machine - I may need to revise the variables and code I have associated with getting those.

Now, I've started machining the operator console to prove out the machine (I found I was off on Z, and corrected both X and Y with it which was a mistake since they were actually correct - I must have programmed the encoder for Z with a different number of pulses per rev or done something else wrong, I'll figure that out eventually).

As for the buttons, I have my PCB's in for making a custom keypad and I designed it to be modular and programmable, so I can make something similar to a conversational interface - unfortunately the keys I had were different than the layout I used on my pcb so I have new keys coming (I was so looking forward to soldering up the boards and being done with the operator console). To go with that I made a couple models of Keycaps and tied them to variables, when changing those variables I change the wording on the Keycap, this should make it easy for me to make the key say whatever I want and then print it with my resin printer. To go with this the keypad is looking at a csv file that tells it what each key is, that's how I'm making keys be G54, or something like: G83 X? Y? Z? R? Q? F? (Enter X and Y coordinates, Z final depth, R - retract amount, Q - peck depth, F - feed rate)

I still need to do some testing to see how this works, but I've got the code roughed out and the boards to test with, I was hoping to do it with a fully assembled PCB though. I admit I don't typically program CNC's or deal with G-code, so this is a learning experience for me - in other words, I'm having fun - even if I am making slow progress.

I'll share pictures, but I'm still embarrassed with how the thing looks currently, and I haven't finalized my wiring harness which could change to just a couple PCB's (it's not neet, my wires are more than just a bit long, but I don't want to touch them since it works, at least mostly, I haven't really done the chiller yet, though I do have a little soldered pcb to interface with it).

[DojoJoe]

It took a couple tries to get the first part to run successfully, but at least here is the first component to my operator console. I'm using a post processor from Fusion 360 to make my g-code, though I really should try to write some from scratch myself.

I did the engraving with a 1/32" end mill, otherwise I'm happy with it and will be well on my way to having a finished operator console after I get back from this service call (and deal with two other jobs).