1000mm x 1500mm Shapeko 2 Upgrade

discussion of design changes / improvements / suggestions
LouisV
Posts: 316
Joined: Fri Dec 13, 2013 3:41 am

Re: 1000mm x 1500mm Shapeko 2 Upgrade

Post by LouisV » Mon Mar 03, 2014 9:46 pm

Looking cool so far. I'm eager to see more of your progress. :)

samc99us
Posts: 269
Joined: Mon Nov 11, 2013 5:20 pm

Re: 1000mm x 1500mm Shapeko 2 Upgrade

Post by samc99us » Tue Mar 04, 2014 7:31 pm

Progress has been fast, but not fast enough. I'm basically doing a lot of things twice. For example, last night I replaced all the screws on my NEMA23 motors with low-profile button head screws, because stock M5 button head screws would impact the Openrail fasteners (8mm low profile button head screws) if the carriage was at all off-nominal. This also afforded the HFS5-4060 X-axis rail more clearance on the motor mount carriage. Of course, this issue has been posted elsewhere, but since there isn't one giant document to detail it, I didn't pick up on it: http://www.shapeoko.com/forum/viewtopic ... 1&start=70

One big failure, that has cost me several hours, is I didn't update my Solidworks model with the longer bed rail I ordered. I used the numbers in Solidworks to align the two y-axis using a pair of calipers and a machinist square, referencing off the edge of my bed rail, but the two axis were roughly 1/2" too far apart!! I will have to re-align everything tonight, aiming for first moves tomorrow.
2014-03-03 23.43.43_small.jpg
2014-03-03 23.43.43_small.jpg (313.54 KiB) Viewed 3510 times
Modified Shapeoko 2: 1500mm fully supported y-axis, 1000 mm 4060 x-axis, ACME Belt Drive Z-axis, Dewalt DNP611, full aluminum t-slot table, 4x NEMA23 180 oz/in stepper motors driven by a G540

samc99us
Posts: 269
Joined: Mon Nov 11, 2013 5:20 pm

Re: 1000mm x 1500mm Shapeko 2 Upgrade

Post by samc99us » Mon Apr 14, 2014 3:04 pm

Been a while, very busy with the real job.

Machine has moved and is nearing completion:
Aluminum_bed_small.jpg
Aluminum bed
Aluminum_bed_small.jpg (198.5 KiB) Viewed 3424 times
LinuxCNC moves (without pen): https://www.youtube.com/watch?v=uXBb1mJymAE
Modified Shapeoko 2: 1500mm fully supported y-axis, 1000 mm 4060 x-axis, ACME Belt Drive Z-axis, Dewalt DNP611, full aluminum t-slot table, 4x NEMA23 180 oz/in stepper motors driven by a G540

megeshg
Posts: 91
Joined: Sat Mar 22, 2014 6:08 pm

Re: 1000mm x 1500mm Shapeko 2 Upgrade

Post by megeshg » Tue Apr 15, 2014 8:33 am

May i ask what the torque on your motors are?

samc99us
Posts: 269
Joined: Mon Nov 11, 2013 5:20 pm

Re: 1000mm x 1500mm Shapeko 2 Upgrade

Post by samc99us » Tue Apr 22, 2014 2:47 pm

The motors on all 4 axis are the #23-130-DS8 from HobbyCNC.com. See here for details: http://www.hobbycnc.com/products/stepper-motors/

As used, they are 130 oz-in stepper motors. If I replaced the HobbyCNC driver board with a Gecko 540, for example, they will generate 185 oz-in in bi-polar mode. I think this is plenty for now, as I machined aluminum with 65 oz-in stepper motors previously.
Modified Shapeoko 2: 1500mm fully supported y-axis, 1000 mm 4060 x-axis, ACME Belt Drive Z-axis, Dewalt DNP611, full aluminum t-slot table, 4x NEMA23 180 oz/in stepper motors driven by a G540

megeshg
Posts: 91
Joined: Sat Mar 22, 2014 6:08 pm

Re: 1000mm x 1500mm Shapeko 2 Upgrade

Post by megeshg » Tue Apr 22, 2014 7:49 pm

samc99us wrote:The motors on all 4 axis are the #23-130-DS8 from HobbyCNC.com. See here for details: http://www.hobbycnc.com/products/stepper-motors/

As used, they are 130 oz-in stepper motors. If I replaced the HobbyCNC driver board with a Gecko 540, for example, they will generate 185 oz-in in bi-polar mode. I think this is plenty for now, as I machined aluminum with 65 oz-in stepper motors previously.

Good to know! im always concerned the 125oz motors i have are going to be the weak point in my machine but glad it should do an ok job.

cvoinescu
Posts: 4442
Joined: Thu Jul 19, 2012 6:50 pm
Location: Camberley, UK
Contact:

Re: 1000mm x 1500mm Shapeko 2 Upgrade

Post by cvoinescu » Tue Apr 22, 2014 8:35 pm

125 oz in (9000 g cm) is about the maximum holding torque you can make use of with a Shapeoko-class machine. With 18-tooth MXL pulleys, that works out to about 34 lbf (15.5 kgf) applied to the carriage (less friction and other losses), which is way more than the belt is rated for; with the slightly larger 20-tooth GT2 pulleys, it's about 30.5 lbf (14 kgf). However, it's not a waste: the torque decreases at higher speed, so having a lot of it to begin with is useful.
Proud owner of ShapeOko #709, eShapeOko #0, and of store.amberspyglass.co.uk

samc99us
Posts: 269
Joined: Mon Nov 11, 2013 5:20 pm

Re: 1000mm x 1500mm Shapeko 2 Upgrade

Post by samc99us » Tue Jul 29, 2014 6:50 pm

Machine is up and cutting. Getting the spindle aligned with the bed was proving very problematic. It is very very close after some shimming but not perfect, even with CNC cut router mounts (though some of the holes aren't CNC cut and that could be contributing to the alignment issues). I love the bed and flexibility, Misumi P/N HFSQN4-15250-1500 x3 and 2 of the narrower strips, link to the bed material here: http://us.misumi-ec.com/vona2/detail/11 ... SQN4-15250, but I am sticking a MDF bed on top of the aluminum bed and tramming that to get a surface that is perfectly level with the router in the areas I am cutting. It may be more prudent to go with the MDF to begin with, though one could use smaller MDF sections that are the same size as your workpiece, tram them before you put the workpiece on and that will still let you use the T-slot bed.
Modified Shapeoko 2: 1500mm fully supported y-axis, 1000 mm 4060 x-axis, ACME Belt Drive Z-axis, Dewalt DNP611, full aluminum t-slot table, 4x NEMA23 180 oz/in stepper motors driven by a G540

LouisV
Posts: 316
Joined: Fri Dec 13, 2013 3:41 am

Re: 1000mm x 1500mm Shapeko 2 Upgrade

Post by LouisV » Tue Jul 29, 2014 6:56 pm

samc99us wrote:Machine is up and cutting. Getting the spindle aligned with the bed is proving very problematic. I love the bed and flexibility, Misumi P/N HFSQN4-15250-1500 x3 and 2 of the narrower strips, http://us.misumi-ec.com/vona2/detail/11 ... SQN4-15250, but I am sticking a MDF bed on top of the aluminum bed and tramming that to get a surface that is perfectly level with the router, so it may be more prudent to go with the MDF to begin with.
I found that the aluminum extrusions that make up my bed aren't perfectly level. That's why I bolted a big 1/4" thick sheet of HDPE on the aluminum bed and surfaced that. The aluminum bed still serves a purpose, I can still use the slots for my clamps but if I were to redo the bed from scratch I might revaluate my use of using aluminum extrusions. But that's another project, maybe for winter or next spring.

samc99us
Posts: 269
Joined: Mon Nov 11, 2013 5:20 pm

Re: 1000mm x 1500mm Shapeko 2 Upgrade

Post by samc99us » Fri Aug 01, 2014 11:38 pm

Hey Louis,

I found the same thing, surfaced a big sheet of MDF so have a 22" x 47" build area. This cuts into my z-axis by 3/4" and limits my clamping options though. I'm planning to put t-nuts into the MDF to assist with clamping.

How do you retain access to your bed with the HDPE installed? Do you cut a sheet sized specifically for each project? And what's your material source?

Also, doesn't surfacing help with the last bit of spindle tramming? At least it does in my head by machining the surface so it is exactly perpendicular to the end mill, hence a flat object placed on that surface is perpendicular to the mill? Or maybe I am missing some geometry without a sketch.
Modified Shapeoko 2: 1500mm fully supported y-axis, 1000 mm 4060 x-axis, ACME Belt Drive Z-axis, Dewalt DNP611, full aluminum t-slot table, 4x NEMA23 180 oz/in stepper motors driven by a G540

Post Reply