CNCCMV2

Categorization Key

• "+1" means increasing category level by one; "-1" means decreasing category level by one.

• For example, the following shortlist means that "Wrenches" are categorized under "Tools", and that "Materials" is a category of the same level as "Tools"

Tools

+1

Wrenches

-1

Materials

• For example, the following shortlist means that "Screws" are categorized under "Metal" under "Fasteners" under "Materials"

Materials

+1

Fasteners

+1

Metal

+1

Screws

-3

Overview

• The CNC Circuit Mill Version 2 is designed for superior ease of sourcing, fabrication, assembly, and disassembly, combined with high performance, scalability, modularity, and lifetime design- all at low cost.

Performance

• X Axis Travel Range = 20cm

• Y Axis Travel Range = 20cm

• Z Axis Travel Range = 5cm

• Step Motor Torque at 12VDC = 3.2kg-cm

• Spindle Max Rotation Speed = 22600rpm no-load

• Spindle Motor Torque at 24VDC = 88.5g-cm at max efficiency

• Workpiece Holding Mechanism = Linear Bolt and Tensioning Nut

Design

• Stock Steel Cube-shaped External Structure

• Stock Aluminum Angle-based Internal Structure

• Step Motor Axis Drive

• Rotary-to-Linear Motion Converting Stainless Steel Leadscrew and Wear-compensating Leadscrew Nut

• Anti-friction Bronze Sleeve Bearings

• Precision Stainless Steel Axis-Supporting Shafts

• Versatile Fastener-based Holding Platform

• Brushed DC Motor Spindle Drive

• Precision Stainless Steel Spindle Shaft

• Computer to Microcontroller to Stepper Driver Electronics Pathway

• Gcode Streamer to Gcode Interpreter Software Pathway

Cost

• Stock Metal = under 150 USD

• Leadscrews and Leadscrew Nuts = under 250 USD

• Precision Shafts = under 150 USD

• Bearings = under 100 USD

• Fasteners = under 70 USD

• Electronics = under 300 USD

• Software = Open Source

Cube-shaped Frame

• Made of Steel Angles; Uses Corner Junctions each with 6 Washers and 3 Bolts and Nuts; Has Asymmetrical Assembly

• Ease of maintenance - cube can lie on any of its 6 faces

• Design for disassembly - each angle can be independently disassembled

• Planar Enclosure - contained components are protected from any planar impact

• Ease of sourcing - uses stock metal and fasteners

• Lifetime Design - all parts replaceable, critical components such as corner fasteners made of 316 stainless steel

• Ease of assembly - identical corner junctions

• Scalability - certain angles can be scaled in unison for different dimension frames

Axis Structure

• Each Uses 4 Aluminum Angles; Uses Bronze Sleeve Bearings; Uses Stainless Steel Shafts; Uses Bolts, Washers, and Nuts

Axis Drive

• Made of Step Motor; Uses Motor-Shaft-to-Leadscrew Setscrew Coupling; Uses Leadscrew; Uses Leadscrew Nut; Uses Screws, Washers, Bolts, and Nuts

Spindle System

• Made of 3 Aluminum Angles and 1 Steel Flat; Uses Brushed DC Motor; Uses Motor-Shaft-to-Spindle-Shaft Setscrew Coupling; Uses Stainless Steel Driveshaft; Uses 2 Ball Bearings; Uses Spindle-Shaft-to-Milling-Bit Setscrew Coupling; Uses Milling Bit; Uses Screws, Washers, Bolts, and Nuts

Sourcing

• Spreadsheet File

LINK HERE

• Prototyping Spreadsheet

• To edit or download the spreadsheet, click on the following link.

https://docs.google.com/spreadsheet/ccc?key=0AlpsBarfpPkzdFk5aDY3dHM0eEhfZHNkWVppdV9EelE

Soldering Stepper Driver Pins

• Insert the short end of the male headers into the stepper driver board from the bottom, then pressfit the headers into the small breadboard for holding.

• Apply flux to all header connections

• Apply solder to the tip of the soldering iron

• Solder header connections at opposite corners of the stepper driver board for stability, reapplying solder to and cleaning the soldering iron tip as necessary; repeat for the remaining header connections.

Getting Git

• Open Terminal and type:

sudo apt-get install git-core

Getting Arduino Integrated Development Environment

• Go to this webpage:

http://arduino.cc/hu/Main/Software

• Download the Linux 32-bit version of Arduino IDE to a directory of your choosing

Compatibilizing Arduino IDE

• The following steps are a summary of the information in this webpage:

http://www.pluggy.me.uk/arduino-ubuntu/

• Open System>Administration>Synaptic Package Manager, then type your password

• In Synaptic Package Manager, search for jre, then mark for installation the item with the following name:

Openjdk-6-jre

• Note: marking these items will bring up other packages also to be marked. Click "mark" during these times.

• In Synaptic Package Manager, search for gcc-avr, then mark for installation the item with the following name:

gcc-avr

• In Synaptic Package Manager, search for avr-libc, then mark for installation the item with the following name:

avr-libc

• In Synaptic Package Manager, click "Apply"

• Restart your computer

Getting RUBY Programming Language

• Open Terminal and type:

sudo apt-get install ruby1.9.1

• Restart the computer for the changes to take place

Getting GRBL Files

• Open Terminal and type:

git clone https://github.com/damellis/grbl.git grbl

Getting Gctrl

• Open Terminal and type:

git clone https://github.com/damellis/gctrl.git gctrl

Getting Processing

• Go to this webpage:

http://processing.org/download/

• Download the latest version of Processing to a directory of your choosing

Moving RXTX files

• Navigate to the Arduino IDE folder>lib.

• Copy RXTXcomm.jar

• Navigate to the Processing folder>modes>java>libraries>serial>library

• Paste RXTXcomm.jar, replacing the existing version

• Navigate to the Arduino IDE folder>lib

• Copy librxtxSerial.so

• Navigate to the Processing folder>modes>java>libraries>serial>library>Linux32

• Paste librxtxSerial.so, replacing the existing version

Modifying Gctrl

• Open the Gctrl folder

• Open gctrl.pde in gedit

• Change a part of the code as annotated in the following:

Serial port = null; //change starts

String portname = "/dev/ttyACM0"; // Linux, Arduino Uno

//change ends

boolean streaming = false;

Modifying GRBL Files

• Navigate to the GRBL folder

• Open "Makefile" in gedit

• Edit the PROGRAMMER line as:

PROGRAMMER = -c stk500v1 -P /dev/ttyACM0 -b 115200

Flashing GRBL

• Open Terminal and navigate to the GRBL folder (ex. by using the "ls" and "cd" commands)

• In Terminal, type:

make clean

make

• Connect the Arduino Uno to the computer via USB cable

• In Terminal, type:

make flash

• Disconnect the Arduino Uno

Running GRBL

• Navigate to the Processing folder

• Open and run Processing, setting the sketchbook folder as the folder in which the gctrl folder exists

• In Processing, open gctrl using File>Sketchbook>

• Connect the Arduino Uno to the computer via USB cable

• In Processing, run gctrl using Sketch>Run

• Note: For certain functions of gctrl, press and hold down the key for the popup windows to populate.

Determining GRBL Configuration Changes Required

• Go to the following webpage:

http://dank.bengler.no/-/page/show/5474_configuringgrbl?ref=mst

Modifying GRBL Settings

• Navigate to the Arduino IDE folder

• Double-click "Arduino" then click "run" in the popup window

• Note: you may want to create a quick launcher for the Arduino IDE

• Connect the Arduino Uno to the computer via USB cable

• In Arduino IDE, open Tools>Serial Monitor

• Note: the Serial Monitor window should pop up and you should see the following:

Grbl 0.6b

'$' to dump current settings

• In the Serial Monitor, change the left drop-down setting to the following:

Both NL & CR

• In the Serial Monitor, type the following in the command line:

$

• Note: you should now see the following:

$0 = 157.480 (steps/mm x)

$1 = 157.480 (steps/mm y)

$2 = 157.480 (steps/mm z)

$3 = 10 (microseconds step pulse)

$4 = 500.0 (mm/min default feed rate)

$5 = 600.0 (mm/min default seek rate)

$6 = 0.100 (mm/arc segment)

$7 = 0 (step port invert mask. binary = 0)

$8 = 25.0 (acceleration in mm/sec^2)

$9 = 225.0 (max instant cornering speed change in delta mm/min)

'$x=value' to set parameter or just '$' to dump current settings

• In the Serial Monitor, type commands as necessary in the following format, where "X" and "Y" are numbers:

$X = Y

Modularity

• Different step motors and drive mechanisms can be mounted onto the axis support angles via mounting holes

• Different frames can be used, provided they have precise mounting holes for the axis support angles

• Different holding platforms can be used, provided they have mounting holes for the X axis moving angles

• Different spindle setups can be used, provided they have mounting holes for the Z axis moving angles

• Different stepper driver boards and power supplies can be used, provided they have compatible performance specifications within the electronics system

Scaling

• Scaling mainly consists of changing the size of the frame (to affect travel ranges) and the type of step motors (to affect travel rates)

• Other discrete components such as fasteners, leadscrews, and shafts need only be scaled if necessary for functionality or certain desired performance specifications

• The travel range calculation for the X axis:

(X Travel Range) = (Distance Between 2 Parallel Frame Angles Along Horizontal Plane) - (Length of Platform Along Axis)

• The travel range calculation for the Y axis:

(Y Travel Range) = (Distance Between 2 Parallel Frame Angles Along Vertical Plane) - (Length of Z Support Angles Along Axis)

Usage

• Circuit Schematic to Gcode File Toolchain

• See following link for list of electronic design suites:

http://en.wikipedia.org/wiki/Comparison_of_EDA_software

• PCB-Gcode Optimizer

http://cnc.goodbits.net/wiki/index.php5/Pcb-gcode_optimizer

http://www.millpcbs.com/index.php?option=com_content&view=article&id=10&Itemid=44

GVCS Product Ecology

CNC Circuit Mill Product Ecology

Uses

• Induction Furnace - Steel

• Aluminum Extractor - Aluminum

• Metal Roller - Fasteners, Metal Angles, and Flats

• Rod and Wire Mill - Wires, Shafts

• CNC Multimachine - Bearings, Leadscrews, Leadscrew Nuts

• Motors - XYZ Movement

• CNC Circuit Mill - Control Circuit Boards

• Universal Power Supply - Power

Creates

• Milled Circuit Boards

See Product Ecologies for more information.