Re: [Emc-users] 3D Printer Mods?

2012-06-01 Thread Joachim Franek
On Wednesday 30 May 2012 09:28:56 Joachim Franek wrote:
 http://www.ethersex.de/index.php/Main_Page

I played with this code (hw: netio).

Results:
- ADC is working (10bit)
- pwm (named Stellalight) works (range 0..255)

Commands: ECMD (http://ethersex.de/index.php/ECMD_Reference)

Interfaces: rs232, tcp, udp

Examples:

rs232:  (with 2,7V)
command: adc get 4
response: 228

command: channel 0 240
response: OK

eth tcp:
$ echo -e adc get 4 | nc 192.168.1.92 2701
227 
$ echo -e channel 0 250 | nc 192.168.1.92 2701
OK

eth udp:
$ echo -e adc get 4 | nc -u 192.168.1.92 2701
227 
$ echo -e channel 0 250 | nc -u 192.168.1.92 2701
OK

Joachim 


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Re: [Emc-users] 3D Printer Mods?

2012-06-01 Thread andy pugh
On 1 June 2012 11:09, Joachim Franek joachim.fra...@pibf.de wrote:

 eth tcp:
 $ echo -e adc get 4 | nc 192.168.1.92 2701
 227
 $ echo -e channel 0 250 | nc 192.168.1.92 2701
 OK

Those looks trivial to make into M100-style custom M-codes

#! bin/bash
ADC = $( echo -e adc get 4 | nc 192.168.1.92 2701)
halcmd setp motion.analog-in-00 $ADC

to get the data into G-code

(Note that the above is guesswork, shell scripting is a closed book to me)

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Re: [Emc-users] Commutating Reactor

2012-06-01 Thread John Thornton
No wonder that file takes so long it makes one pass at the OD then 
rapids to a slot makes one pass then rapids to the next slot... then 
rapids to the holes then rapids to the ID. And wow is it complicated and 
full of neat code. It would make much more sense from a machining view 
point to cut each slot fully then move to the next slot then change 
tools and drill the mounting holes and with a larger end mill cut out 
the center and OD of the part. The beauty of Lawrence's file is that it 
is completely configurable.

How in the world do you hold the material to machine ID, OD, slots, and 
holes at the same time?

If I had to make that part and I might one day, I'd drill the holes then 
mill the ID. Then I'd prepare a mounting plate with a boss the size of 
the ID then bolt the disk down and mill the slots and the OD.

By duty cycle does that mean the  width of the slot verses the width 
between the slots?

John

On 5/31/2012 10:43 PM, gene heskett wrote:
 On Thursday, May 31, 2012 11:29:49 PM John Thornton did opine:

 Are you tapering the slots so the edges are perpendicular to the center?
 That was I believe the general idea, John.

 I have the next one about 1/3rd done, but the run time is nearly 4 hours as
 I had to slow it because I could see the bit flexing a few thou.  When my
 back gave out just now I hit the pause button while the bit was at SafeZ,
 put the spindle controller in manual at zero speed, blew that last passes
 oil  debris off it, its looking great, and turned off the lights for the
 night.

 BTW, 60 slots with the subroutine is a piece of cake. If you can come up
 with the code to do one slot I can paste it in my subroutine and send it
 back.

 John
 There's stuff in it that isn't now used, but I just put a copy of whats
 running right now on my web page, under Genes-os9-stf/eagle/genes-
 encoder.ngc

 Part of the run time is the sheet is warping when I cut off a piece, so I
 have to use a total cut depth that is about 2.5x as thick as the alu, and
 let it nibble on the oil soaked oak sacrificial pad under it.

 Thanks John.

 Cheers, Gene

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Re: [Emc-users] Commutating Reactor

2012-06-01 Thread John Thornton
That is some interesting code for sure and I can understand why it takes 
so long making one pass over the whole thing with a tiny bit and lots of 
rapid moves. It would be better from a machining view to do the OD and 
ID with a larger endmill and drill the mounting holes then switch to the 
tiny one to make the slots.

It appears the slot sides are perpendicular to the center of the disk. 
If your A and B sensors are mounted in a straight line the off and on 
times will be a bit different between A and B if I'm understanding this 
correctly. Of course Z won't matter.

I still think the slots could be done with less than 30 lines of code 
and using rotate. One bad thing I noticed is the arcs are using radius 
which is known to not be perfect in some cases.

On 5/31/2012 10:43 PM, gene heskett wrote:
 On Thursday, May 31, 2012 11:29:49 PM John Thornton did opine:

 Are you tapering the slots so the edges are perpendicular to the center?
 That was I believe the general idea, John.

 I have the next one about 1/3rd done, but the run time is nearly 4 hours as
 I had to slow it because I could see the bit flexing a few thou.  When my
 back gave out just now I hit the pause button while the bit was at SafeZ,
 put the spindle controller in manual at zero speed, blew that last passes
 oil  debris off it, its looking great, and turned off the lights for the
 night.

 BTW, 60 slots with the subroutine is a piece of cake. If you can come up
 with the code to do one slot I can paste it in my subroutine and send it
 back.

 John
 There's stuff in it that isn't now used, but I just put a copy of whats
 running right now on my web page, under Genes-os9-stf/eagle/genes-
 encoder.ngc

 Part of the run time is the sheet is warping when I cut off a piece, so I
 have to use a total cut depth that is about 2.5x as thick as the alu, and
 let it nibble on the oil soaked oak sacrificial pad under it.

 Thanks John.

 Cheers, Gene

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Re: [Emc-users] OT: 3D Printer Mods?

2012-06-01 Thread Ed Nisley
On Wed, 2012-05-30 at 19:29 +0200, Roland Jollivet wrote:
 The thing is, what do you do with these parts?

Some examples of stuff I've designed  build  used...

A case for a GPS+voice amateur radio circuit:
http://softsolder.com/2012/04/13/wouxun-kg-uv3d-gps-interface-functional-case/

Adapter to hold a camera on a microscope, a macro lens holder for that
camera, plus an LED ring illuminator for the microscope:
http://softsolder.com/2011/11/14/canon-sx230hs-microscope-and-close-up-macro-adapters/
http://softsolder.com/2011/04/11/microscope-led-ring-illuminator/

Caliper repair part (no finishing required!):
http://softsolder.com/2011/05/27/thing-o-matic-caliper-repair-perfection/

Bike helmet mirror mount (ugly, but better than commercial units):
http://softsolder.com/2011/07/01/helmet-mirror-mount-first-light/
http://softsolder.com/2011/06/29/helmet-mirror-mount-solid-model/

Blinky light mount for my recumbent:
http://softsolder.com/2012/01/03/planet-bike-superflash-tour-easy-mount/

Cookie cutter:
http://softsolder.com/2011/09/07/tux-cookie-cutter/

Fuzz blocker for a Kindle Fire:
http://softsolder.com/2012/04/10/kindle-fire-power-button-protector/

Simple stepper motor mount:
http://softsolder.com/2011/08/23/nema-17-stepper-motor-mount/

And, of course, improve the 3D printer:
http://softsolder.com/2011/04/20/thing-o-matic-x-axis-rod-follower-installed/

Beyond their hand-knitted appearance, the parts are entirely serviceable
for most of the things I do. Of course, that may just mean I do simple
things that don't involve a lot of stress on either the operator or the
user. [grin]

Now, admittedly, those parts emerged after the better part of half a
year of rebuilding to persuade my Thing-O-Matic to work the way they
claimed it would. That's a whole 'nother story...

-- 
Ed
http://softsolder.com



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Re: [Emc-users] OT: 3D Printer Mods?

2012-06-01 Thread andy pugh
On 1 June 2012 12:31, Ed Nisley ed.08.nis...@pobox.com wrote:

 Beyond their hand-knitted appearance, the parts are entirely serviceable

I am growing to quite like the hand-knitted appearance.

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Re: [Emc-users] Commutating Reactor

2012-06-01 Thread John Thornton
Gene,

I used debug to capture the path of the first slot and put it into my 
subroutine. Run the following in sim and see what you think. Even at F2 
and 0.001 DOC one slot only takes a smidgen over 2 minutes to cut in my 
sim.

F2
T1 M6 G43
#z-final = -0.025
#z-step  = 0.001
G0 X1.1 Y0 Z0.05
#current-r = 0
G10 L2 P1 R#current-r
o100 repeat [60]
   G0 X1.15 Y0
   G1 X1.093745 Y-0.003410 Z0
   o110 while [#5422 GT #z-final]
 G1 X1.093745 Y-0.003410 Z[#5422 - #z-step]
 G3 X1.093747 Y0.002728 R1.09375
 G1 X1.183744 Y0.003611
 G2 X1.183744 Y-0.003611 R1.18375
 G1 X1.093747 Y-0.002728
   o110 endwhile
G0 Z0.05
X0 Y0
#current-r = [#current-r + 6]
G10 L2 P1 R#current-r
o100 endrepeat
M2


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Re: [Emc-users] Commutating Reactor

2012-06-01 Thread gene heskett
On Friday, June 01, 2012 07:20:37 AM John Thornton did opine:

 No wonder that file takes so long it makes one pass at the OD

:) To check fixture clearances.

 then
 rapids to a slot makes one pass then rapids to the next slot... then
 rapids to the holes then rapids to the ID. And wow is it complicated and
 full of neat code. It would make much more sense from a machining view
 point to cut each slot fully then move to the next slot then change
 tools

This spindle is #2 morse collets, loosen drawbar about 2 turns, beat it 
loose with a piece of steel. Hard on bearings.  The only fixed length is 
the rings on the drills, so my tool changing z accuracy if I change the 
collet to fit the bigger mill, really needs my autoz code. Unforch, without 
making a melamine jig to insulate the whole thing, that's out.  It uses 
G38.2 for that.  This way its all done with one z home  one bit if I don't 
break it...

 and drill the mounting holes and with a larger end mill cut out
 the center and OD of the part. The beauty of Lawrence's file is that it
 is completely configurable.

Almost, I've added about 6 or 8 more vars so it is considerable more 
adjustable.  Lawrence's original code is also available on the net.  If you 
need that for comparison I'll dig up the bookmark.
 
 How in the world do you hold the material to machine ID, OD, slots, and
 holes at the same time?

Clamps on each of the 4 corners. Because this stuff is so thin, I've 
considered making a jig fastened to the table, then using one of the 
leftovers in 1/16 brass as an overlaying holddown with its own bolts to 
hold the stuff flat while machining.  That could also serve as a dam to 
hold cutting oil in place a bit better, as it is, it creeps away and has to 
be replenished about 2x a loop thru the main loop.  If I see debris stuff 
on the bit when it goes to safeZ, its time for more oil.  I have made a 
mister that could keep the swarf blown away, but even with the shop door 
open, it turns into a glasses fogging fog of oil in there in about 30 
minutes.  And my lungs don't need that safflower oil in them either.

This between the clamps warpage is why I have to start about 15 thou high, 
and run to about 10 thou into the 1/4 oak sacrificial its clamped down to.  
It wasn't near the problem with 1/16 brass, but with a #60 drill it would 
be 2-3 days to carve because the brass tends to work harden.  I've already 
broke about $50 in these bits, but if I don't push them, they'll cut with a 
0.0025 touch forever in alu if I keep an oil film on the work to seal out 
the oxygen.  A higher speed spindle would help, this one is tapped out at 
2500.  Right now the 'touch' is about 0.0032, so I've dropped the feed 
override to about 75% where I don't see the bit flexing as much.  Time I 
have, accuracy is whats needed.  I only have to do it once IF I get it 
right.  Keyword=right...

 If I had to make that part and I might one day, I'd drill the holes then
 mill the ID. Then I'd prepare a mounting plate with a boss the size of
 the ID then bolt the disk down and mill the slots and the OD.

I've considered that. If I was to make them for sale I'd at least make a 
better holddown jig.  In my case, a mini lathe, the mounting holes could be 
dispensed with as the finished disk is trapped between the spindles preload 
adjusting nut, and an identical locking nut.  So the concentricity demands 
means that center hole is -0.000 to +0.002 max.  It's about right when I 
have to fuss a bit to get it over the threads and seated against the 
preload but.  At the diameter of that bolt circle the bolts would interface 
with the locknuts.  So if to actually be used, the bolt circle would need 
enlarged but the limit there is when the bolts or rivets hit the center, 
index pulse generating interrupter.  There isn't a lot of room to play in 
that area. :) 
 
 By duty cycle does that mean the  width of the slot verses the width
 between the slots?

Yes, exactly, in order to get a 50% duty square wave.  Lawrence's original 
cut at 50% with a /2.0 there, no comp for opto aperture.  Besides, mulls 
are quite a bit faster then divides for the computer.  My last attempt was 
at .45, and it was about 60/40 high/low since the opto's don't have an 
infinitely small aperture.  Lawrence's original code also tapered the index 
slot, but the placement of it at the same fixed width made the inner end of 
the AB slot wider at slot 0, big bump in encoder velocity output. Spindle 
goes whump whump as that slot went by the opto's out of time.  Not good.  
Listen to Z going crazy when running a G76, sounds like its being run by 
pink noise!

Thanks John

Cheers, Gene
-- 
There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order.
-Ed Howdershelt (Author)
My web page: http://coyoteden.dyndns-free.com:85/gene
Man's horizons are bounded by his vision.

--
Live Security 

Re: [Emc-users] OT: 3D Printer Mods?

2012-06-01 Thread gene heskett
On Friday, June 01, 2012 08:37:46 AM Ed Nisley did opine:

 On Wed, 2012-05-30 at 19:29 +0200, Roland Jollivet wrote:
  The thing is, what do you do with these parts?
 
 Some examples of stuff I've designed  build  used...
 
 A case for a GPS+voice amateur radio circuit:
 http://softsolder.com/2012/04/13/wouxun-kg-uv3d-gps-interface-functional
 -case/
 
 Adapter to hold a camera on a microscope, a macro lens holder for that
 camera, plus an LED ring illuminator for the microscope:
 http://softsolder.com/2011/11/14/canon-sx230hs-microscope-and-close-up-m
 acro-adapters/
 http://softsolder.com/2011/04/11/microscope-led-ring-illuminator/
 
 Caliper repair part (no finishing required!):
 http://softsolder.com/2011/05/27/thing-o-matic-caliper-repair-perfection
 /
 
 Bike helmet mirror mount (ugly, but better than commercial units):
 http://softsolder.com/2011/07/01/helmet-mirror-mount-first-light/
 http://softsolder.com/2011/06/29/helmet-mirror-mount-solid-model/
 
 Blinky light mount for my recumbent:
 http://softsolder.com/2012/01/03/planet-bike-superflash-tour-easy-mount/
 
 Cookie cutter:
 http://softsolder.com/2011/09/07/tux-cookie-cutter/
 
 Fuzz blocker for a Kindle Fire:
 http://softsolder.com/2012/04/10/kindle-fire-power-button-protector/
 
 Simple stepper motor mount:
 http://softsolder.com/2011/08/23/nema-17-stepper-motor-mount/
 
 And, of course, improve the 3D printer:
 http://softsolder.com/2011/04/20/thing-o-matic-x-axis-rod-follower-insta
 lled/
 
This is all great stuff Ed, thanks for posting it.

 Beyond their hand-knitted appearance, the parts are entirely serviceable
 for most of the things I do. Of course, that may just mean I do simple
 things that don't involve a lot of stress on either the operator or the
 user. [grin]
 
 Now, admittedly, those parts emerged after the better part of half a
 year of rebuilding to persuade my Thing-O-Matic to work the way they
 claimed it would. That's a whole 'nother story...

Chuckle.  That is how this stuff always works.  Like doing an engine swap, 
get all the kits together, but bring $500 for the stuff you have to go get 
because the bolts are 3/8 but the holes are 7/16.  BTDT.  :)

Cheers, Gene
-- 
There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order.
-Ed Howdershelt (Author)
My web page: http://coyoteden.dyndns-free.com:85/gene
To YOU I'm an atheist; to God, I'm the Loyal Opposition.
-- Woody Allen

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Re: [Emc-users] Commutating Reactor

2012-06-01 Thread John Thornton


On 6/1/2012 7:28 AM, gene heskett wrote:
 On Friday, June 01, 2012 07:20:37 AM John Thornton did opine:

 No wonder that file takes so long it makes one pass at the OD
 :) To check fixture clearances.

 then
 rapids to a slot makes one pass then rapids to the next slot... then
 rapids to the holes then rapids to the ID. And wow is it complicated and
 full of neat code. It would make much more sense from a machining view
 point to cut each slot fully then move to the next slot then change
 tools
 This spindle is #2 morse collets, loosen drawbar about 2 turns, beat it
 loose with a piece of steel. Hard on bearings.  The only fixed length is
 the rings on the drills, so my tool changing z accuracy if I change the
 collet to fit the bigger mill, really needs my autoz code. Unforch, without
 making a melamine jig to insulate the whole thing, that's out.  It uses
 G38.2 for that.  This way its all done with one z home  one bit if I don't
 break it...
Yea, for multiple tools have multiple G code files, set Z run one to 
completion, change tools set Z ...
 and drill the mounting holes and with a larger end mill cut out
 the center and OD of the part. The beauty of Lawrence's file is that it
 is completely configurable.
 Almost, I've added about 6 or 8 more vars so it is considerable more
 adjustable.  Lawrence's original code is also available on the net.  If you
 need that for comparison I'll dig up the bookmark.
That's ok your rendition was interesting enough to look at...

 How in the world do you hold the material to machine ID, OD, slots, and
 holes at the same time?
 Clamps on each of the 4 corners. Because this stuff is so thin, I've
 considered making a jig fastened to the table, then using one of the
 leftovers in 1/16 brass as an overlaying holddown with its own bolts to
 hold the stuff flat while machining.  That could also serve as a dam to
 hold cutting oil in place a bit better, as it is, it creeps away and has to
 be replenished about 2x a loop thru the main loop.  If I see debris stuff
 on the bit when it goes to safeZ, its time for more oil.  I have made a
 mister that could keep the swarf blown away, but even with the shop door
 open, it turns into a glasses fogging fog of oil in there in about 30
 minutes.  And my lungs don't need that safflower oil in them either.

 This between the clamps warpage is why I have to start about 15 thou high,
 and run to about 10 thou into the 1/4 oak sacrificial its clamped down to.
 It wasn't near the problem with 1/16 brass, but with a #60 drill it would
 be 2-3 days to carve because the brass tends to work harden.  I've already
 broke about $50 in these bits, but if I don't push them, they'll cut with a
 0.0025 touch forever in alu if I keep an oil film on the work to seal out
 the oxygen.  A higher speed spindle would help, this one is tapped out at
 2500.  Right now the 'touch' is about 0.0032, so I've dropped the feed
 override to about 75% where I don't see the bit flexing as much.  Time I
 have, accuracy is whats needed.  I only have to do it once IF I get it
 right.  Keyword=right...

 If I had to make that part and I might one day, I'd drill the holes then
 mill the ID. Then I'd prepare a mounting plate with a boss the size of
 the ID then bolt the disk down and mill the slots and the OD.
 I've considered that. If I was to make them for sale I'd at least make a
 better holddown jig.  In my case, a mini lathe, the mounting holes could be
 dispensed with as the finished disk is trapped between the spindles preload
 adjusting nut, and an identical locking nut.  So the concentricity demands
 means that center hole is -0.000 to +0.002 max.  It's about right when I
 have to fuss a bit to get it over the threads and seated against the
 preload but.  At the diameter of that bolt circle the bolts would interface
 with the locknuts.  So if to actually be used, the bolt circle would need
 enlarged but the limit there is when the bolts or rivets hit the center,
 index pulse generating interrupter.  There isn't a lot of room to play in
 that area. :)

 By duty cycle does that mean the  width of the slot verses the width
 between the slots?
 Yes, exactly, in order to get a 50% duty square wave.  Lawrence's original
 cut at 50% with a /2.0 there, no comp for opto aperture.  Besides, mulls
 are quite a bit faster then divides for the computer.  My last attempt was
 at .45, and it was about 60/40 high/low since the opto's don't have an
 infinitely small aperture.  Lawrence's original code also tapered the index
 slot, but the placement of it at the same fixed width made the inner end of
 the AB slot wider at slot 0, big bump in encoder velocity output. Spindle
 goes whump whump as that slot went by the opto's out of time.  Not good.
 Listen to Z going crazy when running a G76, sounds like its being run by
 pink noise!
Pink Floyd noise! The subroutine I cobbled up could be done in the same 
way with all the variables. The radius of the arcs at the end of the 
slot is 

Re: [Emc-users] Commutating Reactor

2012-06-01 Thread gene heskett
On Friday, June 01, 2012 08:50:05 AM John Thornton did opine:

 Gene,
 
 I used debug to capture the path of the first slot and put it into my
 subroutine. Run the following in sim and see what you think. Even at F2
 and 0.001 DOC one slot only takes a smidgen over 2 minutes to cut in my
 sim.
 
 F2
 T1 M6 G43
 #z-final = -0.025
 #z-step  = 0.001
 G0 X1.1 Y0 Z0.05
 #current-r = 0
 G10 L2 P1 R#current-r
 o100 repeat [60]
G0 X1.15 Y0
G1 X1.093745 Y-0.003410 Z0
o110 while [#5422 GT #z-final]
  G1 X1.093745 Y-0.003410 Z[#5422 - #z-step]
  G3 X1.093747 Y0.002728 R1.09375
  G1 X1.183744 Y0.003611
  G2 X1.183744 Y-0.003611 R1.18375
  G1 X1.093747 Y-0.002728
o110 endwhile
 G0 Z0.05
 X0 Y0
 #current-r = [#current-r + 6]
 G10 L2 P1 R#current-r
 o100 endrepeat
 M2
 
Printed.  I'll likely put in some named vars if I use it, but I'll give it 
a shot as is after the current one is finished.

Thanks a bunch, John.

Cheers, Gene
-- 
There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order.
-Ed Howdershelt (Author)
My web page: http://coyoteden.dyndns-free.com:85/gene
Absolutely nothing should be concluded from these figures except that
no conclusion can be drawn from them.
-- Joseph L. Brothers, Linux/PowerPC Project)

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Re: [Emc-users] Commutating Reactor

2012-06-01 Thread gene heskett
On Friday, June 01, 2012 08:59:21 AM John Thornton did opine:

 On 6/1/2012 7:28 AM, gene heskett wrote:
  On Friday, June 01, 2012 07:20:37 AM John Thornton did opine:
  No wonder that file takes so long it makes one pass at the OD
  
  :) To check fixture clearances.
  :
  then
  rapids to a slot makes one pass then rapids to the next slot... then
  rapids to the holes then rapids to the ID. And wow is it complicated
  and full of neat code. It would make much more sense from a
  machining view point to cut each slot fully then move to the next
  slot then change tools
  
  This spindle is #2 morse collets, loosen drawbar about 2 turns, beat
  it loose with a piece of steel. Hard on bearings.  The only fixed
  length is the rings on the drills, so my tool changing z accuracy if
  I change the collet to fit the bigger mill, really needs my autoz
  code. Unforch, without making a melamine jig to insulate the whole
  thing, that's out.  It uses G38.2 for that.  This way its all done
  with one z home  one bit if I don't break it...
 
 Yea, for multiple tools have multiple G code files, set Z run one to
 completion, change tools set Z ...
 
  and drill the mounting holes and with a larger end mill cut out
  the center and OD of the part. The beauty of Lawrence's file is that
  it is completely configurable.
  
  Almost, I've added about 6 or 8 more vars so it is considerable more
  adjustable.  Lawrence's original code is also available on the net. 
  If you need that for comparison I'll dig up the bookmark.
 
 That's ok your rendition was interesting enough to look at...
 
  How in the world do you hold the material to machine ID, OD, slots,
  and holes at the same time?
  
  Clamps on each of the 4 corners. Because this stuff is so thin, I've
  considered making a jig fastened to the table, then using one of the
  leftovers in 1/16 brass as an overlaying holddown with its own bolts
  to hold the stuff flat while machining.  That could also serve as a
  dam to hold cutting oil in place a bit better, as it is, it creeps
  away and has to be replenished about 2x a loop thru the main loop. 
  If I see debris stuff on the bit when it goes to safeZ, its time for
  more oil.  I have made a mister that could keep the swarf blown away,
  but even with the shop door open, it turns into a glasses fogging fog
  of oil in there in about 30 minutes.  And my lungs don't need that
  safflower oil in them either.
  
  This between the clamps warpage is why I have to start about 15 thou
  high, and run to about 10 thou into the 1/4 oak sacrificial its
  clamped down to. It wasn't near the problem with 1/16 brass, but
  with a #60 drill it would be 2-3 days to carve because the brass
  tends to work harden.  I've already broke about $50 in these bits,
  but if I don't push them, they'll cut with a 0.0025 touch forever in
  alu if I keep an oil film on the work to seal out the oxygen.  A
  higher speed spindle would help, this one is tapped out at 2500. 
  Right now the 'touch' is about 0.0032, so I've dropped the feed
  override to about 75% where I don't see the bit flexing as much. 
  Time I have, accuracy is whats needed.  I only have to do it once IF
  I get it right.  Keyword=right...
  
  If I had to make that part and I might one day, I'd drill the holes
  then mill the ID. Then I'd prepare a mounting plate with a boss the
  size of the ID then bolt the disk down and mill the slots and the
  OD.
  
  I've considered that. If I was to make them for sale I'd at least make
  a better holddown jig.  In my case, a mini lathe, the mounting holes
  could be dispensed with as the finished disk is trapped between the
  spindles preload adjusting nut, and an identical locking nut.  So the
  concentricity demands means that center hole is -0.000 to +0.002 max.
   It's about right when I have to fuss a bit to get it over the
  threads and seated against the preload but.  At the diameter of that
  bolt circle the bolts would interface with the locknuts.  So if to
  actually be used, the bolt circle would need enlarged but the limit
  there is when the bolts or rivets hit the center, index pulse
  generating interrupter.  There isn't a lot of room to play in that
  area. :)
  
  By duty cycle does that mean the  width of the slot verses the
  width between the slots?
  
  Yes, exactly, in order to get a 50% duty square wave.  Lawrence's
  original cut at 50% with a /2.0 there, no comp for opto aperture. 
  Besides, mulls are quite a bit faster then divides for the computer. 
  My last attempt was at .45, and it was about 60/40 high/low since the
  opto's don't have an infinitely small aperture.  Lawrence's original
  code also tapered the index slot, but the placement of it at the same
  fixed width made the inner end of the AB slot wider at slot 0, big
  bump in encoder velocity output. Spindle goes whump whump as that
  slot went by the opto's out of time.  Not good. Listen to Z going
  crazy when running a G76, sounds like its 

Re: [Emc-users] OT: 3D Printer Mods?

2012-06-01 Thread Viesturs Lācis
2012/6/1 Ed Nisley ed.08.nis...@pobox.com:
 On Wed, 2012-05-30 at 19:29 +0200, Roland Jollivet wrote:
 The thing is, what do you do with these parts?

 Some examples of stuff I've designed  build  used...


Awesome!
Thank You very much for sharing!!!

-- 
Viesturs

If you can't fix it, you don't own it.
http://www.ifixit.com/Manifesto

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Re: [Emc-users] 3D Printer Mods?

2012-06-01 Thread Joachim Franek
Andy,

prior to express my question you give the answer.
Thanks. Joachim 

On Friday 01 June 2012 12:36:51 andy pugh wrote:
 #! bin/bash
 ADC = $( echo -e adc get 4 | nc 192.168.1.92 2701)
 halcmd setp motion.analog-in-00 $ADC

BTW: 
which comp to load for testing (without lcnc running)?
Is a signal possible?



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Re: [Emc-users] OT: 3D Printer Mods?

2012-06-01 Thread John Stewart
Ed;

On 2012-06-01, at 7:31 AM, Ed Nisley wrote:
 Some examples of stuff I've designed  build  used…

Like others, I'm very impressed. Thanks for the posting, and the web page.

JohnS.





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Re: [Emc-users] OT: 3D Printer Mods?

2012-06-01 Thread Eric Keller
On Fri, Jun 1, 2012 at 7:31 AM, Ed Nisley ed.08.nis...@pobox.com wrote:

 On Wed, 2012-05-30 at 19:29 +0200, Roland Jollivet wrote:
  The thing is, what do you do with these parts?

 Some examples of stuff I've designed  build  used...

Your parts really show the utility of these machines.  I was originally
skeptical a few years ago because they went on and on about
self-replicating machines which made me doubt the credibility of the whole
enterprise. Now that a lot of people have them working it has become
obvious that anyone that makes things is handicapping themselves if they
don't have this kind of machine available to them.
Eric
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Re: [Emc-users] 3D Printer Mods?

2012-06-01 Thread andy pugh
On 1 June 2012 14:52, Joachim Franek joachim.fra...@pibf.de wrote:

 halcmd setp motion.analog-in-00 $ADC

 which comp to load for testing (without lcnc running)?
 Is a signal possible?

You want to see if you can get values into HAL, but without starting
all of LinuxCNC?

You can probably do it with two terminal windows:
Window 1:
halrun
loadrt and2

Window 2:
ADC = $( echo -e adc get 4 | nc 192.168.1.92 2701)
halcmd setp and2.0.in0 $ADC

Window1:
show pin

I chose almost at random, just to create some HAL pins to write to.
You would need loadrt threads / addf and2.0 thread1 / start if you
wanted to see the output pins update

-- 
atp
If you can't fix it, you don't own it.
http://www.ifixit.com/Manifesto

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Re: [Emc-users] Commutating Reactor

2012-06-01 Thread Greg Bernard
Gene-
You could hold your stock down easily with super glue and then use acetone to 
release it like this: 
http://millpcbs.com/index.php?option=com_contentview=articleid=19Itemid=63 .

 
+++
We are like tenant farmers chopping down the fence around our house for 
fuel when we should be using Nature's inexhaustible sources of energy -- sun, 
wind and tide. ... I'd put my money on the sun and solar energy. 
What a source of power! I hope we don't have to wait until oil and coal 
run out before we tackle that. -Thomas Edison, inventor (1847-1931) 




 From: gene heskett ghesk...@wdtv.com
To: emc-users@lists.sourceforge.net 
Sent: Friday, June 1, 2012 7:28 AM
Subject: Re: [Emc-users] Commutating Reactor
 
On Friday, June 01, 2012 07:20:37 AM John Thornton did opine:

 No wonder that file takes so long it makes one pass at the OD

:) To check fixture clearances.

 then
 rapids to a slot makes one pass then rapids to the next slot... then
 rapids to the holes then rapids to the ID. And wow is it complicated and
 full of neat code. It would make much more sense from a machining view
 point to cut each slot fully then move to the next slot then change
 tools

This spindle is #2 morse collets, loosen drawbar about 2 turns, beat it 
loose with a piece of steel. Hard on bearings.  The only fixed length is 
the rings on the drills, so my tool changing z accuracy if I change the 
collet to fit the bigger mill, really needs my autoz code. Unforch, without 
making a melamine jig to insulate the whole thing, that's out.  It uses 
G38.2 for that.  This way its all done with one z home  one bit if I don't 
break it...

 and drill the mounting holes and with a larger end mill cut out
 the center and OD of the part. The beauty of Lawrence's file is that it
 is completely configurable.

Almost, I've added about 6 or 8 more vars so it is considerable more 
adjustable.  Lawrence's original code is also available on the net.  If you 
need that for comparison I'll dig up the bookmark.

 How in the world do you hold the material to machine ID, OD, slots, and
 holes at the same time?

Clamps on each of the 4 corners. Because this stuff is so thin, I've 
considered making a jig fastened to the table, then using one of the 
leftovers in 1/16 brass as an overlaying holddown with its own bolts to 
hold the stuff flat while machining.  That could also serve as a dam to 
hold cutting oil in place a bit better, as it is, it creeps away and has to 
be replenished about 2x a loop thru the main loop.  If I see debris stuff 
on the bit when it goes to safeZ, its time for more oil.  I have made a 
mister that could keep the swarf blown away, but even with the shop door 
open, it turns into a glasses fogging fog of oil in there in about 30 
minutes.  And my lungs don't need that safflower oil in them either.

This between the clamps warpage is why I have to start about 15 thou high, 
and run to about 10 thou into the 1/4 oak sacrificial its clamped down to.  
It wasn't near the problem with 1/16 brass, but with a #60 drill it would 
be 2-3 days to carve because the brass tends to work harden.  I've already 
broke about $50 in these bits, but if I don't push them, they'll cut with a 
0.0025 touch forever in alu if I keep an oil film on the work to seal out 
the oxygen.  A higher speed spindle would help, this one is tapped out at 
2500.  Right now the 'touch' is about 0.0032, so I've dropped the feed 
override to about 75% where I don't see the bit flexing as much.  Time I 
have, accuracy is whats needed.  I only have to do it once IF I get it 
right.  Keyword=right...

 If I had to make that part and I might one day, I'd drill the holes then
 mill the ID. Then I'd prepare a mounting plate with a boss the size of
 the ID then bolt the disk down and mill the slots and the OD.

I've considered that. If I was to make them for sale I'd at least make a 
better holddown jig.  In my case, a mini lathe, the mounting holes could be 
dispensed with as the finished disk is trapped between the spindles preload 
adjusting nut, and an identical locking nut.  So the concentricity demands 
means that center hole is -0.000 to +0.002 max.  It's about right when I 
have to fuss a bit to get it over the threads and seated against the 
preload but.  At the diameter of that bolt circle the bolts would interface 
with the locknuts.  So if to actually be used, the bolt circle would need 
enlarged but the limit there is when the bolts or rivets hit the center, 
index pulse generating interrupter.  There isn't a lot of room to play in 
that area. :) 

 By duty cycle does that mean the  width of the slot verses the width
 between the slots?

Yes, exactly, in order to get a 50% duty square wave.  Lawrence's original 
cut at 50% with a /2.0 there, no comp for opto aperture.  Besides, mulls 
are quite a bit faster then divides for the computer.  My last attempt was 

Re: [Emc-users] OT: 3D Printer Mods?

2012-06-01 Thread Przemek Klosowski
On Wed, May 30, 2012 at 3:51 AM, Roland Jollivet
roland.jolli...@gmail.com wrote:

 Do you mind saying what you are printing, and if you feel the printing is a
 worthwhile exercise? I've been looking at different printers for months,
 but they only seem to be able to produce junk. Cnc'ing it out of a block of
 plastic looks far more effective.

The 3D printer situation today reminds me of the old times when I
first ran into phototypesetters, in the early eighties. They used thin
shiny paper that curled from looking at it, stuck together, and
smelled funny. The quality left to be desired; the output looked
somehow like this:

http://dpnow.com/vintage/Features/Printer_reviews/Canon_s900/Test_results1/Quality1/text1/epson_870_normal.jpg

But, you could write your text and math in TeX and typeset it into a
correct form that, if you squinted a little, looked just as good as
professional books.  And you could do it over and over, whenever you
needed it.

Just have patience and see if you can use the 3D technology today in
spite of its current imperfections.

By the way, I would like to try two tricks with 3D printing:

- inserts: e.g. if you need a tight tolerance or high strength, insert
a brass bushing half way into a part being formed
- post-processing, i.e. CNC the precision part out of a rough 3D
printed shape, just like machining a casting.

It should beat CNCing billets, no?

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Re: [Emc-users] OT: 3D Printer Mods?

2012-06-01 Thread Joachim Franek
On Friday 01 June 2012 16:47:57 Przemek Klosowski wrote:
 - post-processing, i.e. CNC the precision part out of a rough 3D
 printed shape, just like machining a casting.
With a spindel parallel to the extruder head.
Here lcnc has it's advantage.

Joachim 


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Re: [Emc-users] OT: 3D Printer Mods?

2012-06-01 Thread Ed Nisley
On Fri, 2012-06-01 at 08:44 -0400, gene heskett wrote:
 the bolts are 3/8 but the holes are 7/16

In this case, the bolts were 7/16 and the holes 3/8... [grin]

-- 
Ed
http://softsolder.com



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Re: [Emc-users] OT: 3D Printer Mods?

2012-06-01 Thread Ed Nisley
On Fri, 2012-06-01 at 10:10 -0400, Eric Keller wrote:
 anyone that makes things

Unlike folks who use industrial-grade machinery to build exquisite
widgets (you know who you are), mostly, I fix stuff.

Being able to sketch out a solid model and then have it *happen* is
wonderfully liberating. The Sherline CNC mill does great work (I just
made a plug-ugly manual-CNC scabbard for a garden knife yesterday), but
for complex shapes the 3D printer can't be beat.

That radio case was what compelled me to get the printer: I couldn't
imagine carving another case from solid acrylic on the Sherline. It took
a few tries to get the design  sizes right, but now I can build a
second and a third with only a few minutes of finishing  fitting; the
printer can be building a case while I'm making the PCB to go inside.

When we eventually downsize, I know which machine tool is a keeper...

-- 
Ed
http://softsolder.com



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Re: [Emc-users] OT: 3D Printer Mods?

2012-06-01 Thread Drew Rogge
Very nice Ed. And thanks for including the OpenSCAD source code. Will prove an
interesting read.

Drew

On 06/01/2012 04:31 AM, Ed Nisley wrote:
 On Wed, 2012-05-30 at 19:29 +0200, Roland Jollivet wrote:
 The thing is, what do you do with these parts?

 Some examples of stuff I've designed  build  used...

 A case for a GPS+voice amateur radio circuit:
 http://softsolder.com/2012/04/13/wouxun-kg-uv3d-gps-interface-functional-case/

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Re: [Emc-users] Commutating Reactor

2012-06-01 Thread John Thornton
I posted on the C(ommerical)NCZone and a guy there says those drives are 
rated for a 3% inductance wye isolation transformer.

John

On 5/31/2012 3:20 PM, Dave wrote:
 They really don't have to be, but they should probably both be larger
 than 10 KVA.  If you have one that was 30 KVA and another that was
 10KVA, I wouldn't hesitate to hook them together for a test.

 Although if you can trip out your 611 with only the spindle running and
 ramping up slowly,  even a couple of 7.5 KVA transformers would probably
 prove out the situation one way or another.

 Dave

 On 5/31/2012 3:15 PM, John Thornton wrote:
 I might be able to scrounge another 240-480 transformer and put it with
 the one I have to get back to 240... do you think they need to be
 similar in size?

 John

 On 5/31/2012 11:28 AM, Dave wrote:

 Looks to me like it is more like a $1264 question.  ;-)

 I don't know.   That's why I would try and borrow one first.

 Know of any plants where you do work that has a spare transformer lying
 around?

 I've put a couple of them together before to get the right voltage..  IE
 240 to 480 and then 480 to 380 etc.

 Dave

 On 5/31/2012 12:06 PM, John Thornton wrote:

 I just ran another program to drill and tap a slew of holes in a 1/2
 steel plate with no problems except for I picked the 5/16-18 tap and
 drill for the 1/4-20 holes and proceeded to tap all 8 of them at the 20
 TPI pitch... no biggie I'll tap them out to 3/8 and plug them and tap
 them over again.

 $64 question will the isolation transformer do the same thing the 7.5hp
 spindle motor is doing on the Samson?

 John

 On 5/31/2012 9:43 AM, Dave wrote:


 You are probably right. When the drive load surges it is likely faulting
 out on what it thinks is a lost phase or phase undervoltage.

 It might be interesting is to run this test again and put a clamp on
 ammeter on each leg feeding your Mill and see how balanced the currents
 are.

 I have never really had any problem with my phase converter running
 loads so I haven't paid much attention to it, but I think I only have
 run capacitors connected between one phase and the made up phase.   I
 know I don't have any
 between both of the two original phases.   I was always more concerned
 about the current balance between phases than voltages.   The voltages
 have always been  within reason ( as I recall ).   But then this is one
 of those things that I don't pay much attention to unless it isn't 
 working.

 I suspect that the 611 is expecting a stiff power supply - which most 3
 phase services can provide.  If you have a large pulley you can attach
 to your phase converter motor shaft to add inertia to the rotor, you
 might want to attach it.  It would help the motor supply surge current
 to the 611 drive.

 Dave



 On 5/31/2012 10:04 AM, John Thornton wrote:


 A little update this morning after last night's experiments I built on
 that a bit this morning. I upped the MFD's on the B-C and A-C caps a
 little at a time till I got close to what I think I wanted in voltage.
 This is what I ended up with...

 Phase ===   A-BB-CA-C
 Caps   50MFD  100MFD 220MFd
 RFC on 246v   263v   271v
 Samson @440 RPM246v   247v   249v
 611 Drive on   245v   243v   241v
 Engraving @6k RPM  244v   243v   234v

 I grabbed a program at random an it turned out to be engraving my
 company logo at 6k RPM. Now mind you this was not 0 to 6k but 0 to 2k
 with a 0.09 second pause between 100 RPM increases up to 6k. To my
 surprise the program ran to the end without a fault including rapids at
 295IPM on the Z axis. When I go to town I'm going to snatch up a few
 more caps to play with and bump up A-C a bit more to try and even it
 out. This will at least allow me to make parts for the time being until
 I either get an isolation transformer or generator. The interesting
 thing that I discovered is if I start up the Samson lathe with the 611
 on I get a fault and have to reset the drive. This leads my tiny brain
 to think that it is a voltage drop to some degree that is tripping out
 the 611... what do you guys think? When my neighbor gets around to
 showing me how to store the traces in the scope I'll try and capture the
 wave form when this happens.

 Thanks for all the help and ideas.

 John

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[Emc-users] First LinuxCNC machine - picking a computer

2012-06-01 Thread Jason Thorsness
Hi,

I'm setting up a LinuxCNC system to control a Fireball v90 router.  Is
there any way to know if this system from Newegg will work with LinuxCNC
without buying it first?

http://www.newegg.com/Product/Product.aspx?Item=N82E16856119071

I also plan to get a 5I25 plugged into a gecko g540 stepper controller.

Thanks,
Jason
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Re: [Emc-users] First LinuxCNC machine - picking a computer

2012-06-01 Thread andy pugh
On 1 June 2012 18:39, Jason Thorsness thorsn...@gmail.com wrote:

 I'm setting up a LinuxCNC system to control a Fireball v90 router.  Is
 there any way to know if this system from Newegg will work with LinuxCNC
 without buying it first?

 http://www.newegg.com/Product/Product.aspx?Item=N82E16856119071

Not really, I don't think. But
http://www.newegg.com/Product/Product.aspx?Item=N82E16813121442
Definitely will work. You don't necessarily need a case for a CNC
controller, as you can put the MB in the same box as the motor drives,
PSUs etc.

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Re: [Emc-users] OT: 3D Printer Mods?

2012-06-01 Thread doug metzler
I've gone off and started making 3D printers out of 3D printed parts
and extruded aluminum frame.  I have 21 different extruded parts and 7
machined parts (off a CNC sherline and a CNC Taig), a lot of
off-the-shelf parts and a few parts I still have to hand-make, but the
leap to CNCing those isn't that far.

The ability to try different designs at virtually no cost and iterate
your existing designs and have the new part in n hour is incredible.
It allows you to come out with the maturity of a future revision from
the start, and if your design doesn't work, well, a complete redesign
with parts to test is a matter of days.

I happen to be making printers, but if i were making windmills I'd
still use the same process.

If you are a product designer I can't imagine a better tool.  Think of
it as the ultimate in try before you buy - you don't have to commit
anything to injection molding until you've actually held it in your
hand.

Thanks,

DougM


On Fri, Jun 1, 2012 at 8:21 AM, Drew Rogge d...@dasrogges.com wrote:
 Very nice Ed. And thanks for including the OpenSCAD source code. Will prove an
 interesting read.

 Drew

 On 06/01/2012 04:31 AM, Ed Nisley wrote:
 On Wed, 2012-05-30 at 19:29 +0200, Roland Jollivet wrote:
 The thing is, what do you do with these parts?

 Some examples of stuff I've designed  build  used...

 A case for a GPS+voice amateur radio circuit:
 http://softsolder.com/2012/04/13/wouxun-kg-uv3d-gps-interface-functional-case/

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Re: [Emc-users] OT: 3D Printer Mods?

2012-06-01 Thread Joseph Chiu
This telescoping planetary gear was entirely 3D printed except for a
few M3 screws.  My machine's calibration was significantly off at the
time, so I had some clearance issues and I need to do a bit of sanding
to get the pieces to fit.  Otherwise, it was just print, remove part,
print, remove part, print remove part, ... assemble.  The pieces were
done in the office, next to the boys bedroom, while the boys were
sleeping, or during dinner hours.

http://chime.in/user/toybuilder/chime/121492527804276736

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Re: [Emc-users] OT: 3D Printer Mods?

2012-06-01 Thread Tom Easterday

On Jun 1, 2012, at 7:31 AM, Ed Nisley wrote:

 On Wed, 2012-05-30 at 19:29 +0200, Roland Jollivet wrote:
 The thing is, what do you do with these parts?
 
 Some examples of stuff I've designed  build  used...
 

Cool stuff, Ed.   I made a modular box for my ER-25 collets I have laying 
around.  http://www.thingiverse.com/thing:16161
-Tom



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Re: [Emc-users] Commutating Reactor

2012-06-01 Thread Joseph Chiu
Hi,
I'm a complete newb on this particular topic, and may not have read
all the fine details, but it seems like this might be something better
suited to photoresist/chemical etching, rather than using bits to try
to mill out the interruptor disks?  Or perhaps laser cut sheets, like
the kinds used for solder stencils, would also do the job?
Cheers,
Joseph

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Re: [Emc-users] Commutating Reactor

2012-06-01 Thread andy pugh
On 1 June 2012 21:19, Joseph Chiu joec...@joechiu.com wrote:

 I'm a complete newb on this particular topic, and may not have read
 all the fine details, but it seems like this might be something better
 suited to photoresist/chemical etching, rather than using bits to try
 to mill out the interruptor disks?  Or perhaps laser cut sheets, like
 the kinds used for solder stencils, would also do the job?

I can say that solder stencil manufacturers can certainly make very
nice encoders, for a price.
https://picasaweb.google.com/108164504656404380542/CNCUnsorted#5746547530954320162
512 slots, 45mm bore.

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Re: [Emc-users] Commutating Reactor

2012-06-01 Thread gene heskett
On Friday, June 01, 2012 06:18:41 PM Greg Bernard did opine:

 Gene-
 You could hold your stock down easily with super glue and then use
 acetone to release it like this:
 http://millpcbs.com/index.php?option=com_contentview=articleid=19Ite
 mid=63 .

I personally have not had that great an experience at getting superglue to 
let go with acetone.  Once set by the moisture in my skin, a stuck 
fingertip is half an hours work.  And required far more effort than this 
.018 thin alu could stand without bending it up pretty good.

I did get the 60 slot wheel done, but its not possible to have 60 slots AND 
a slot narrow enough for a 50% duty cycle output.

And despite a freshly done backlash adjustment for xy, I find this teensie 
bit wanting to crawl in the direction of the side that is cutting, at 
feedrates of 4 to 6 and .0015 DOC.  So I've restarted it after the first 
.014 down with a feedrate of .7.  Properties says it now has a 909 minute 
runtime, but it is gradually straightening out the S curve in what is 
supposed to be a straight line.  Dig cutting, if that doesn't fix it, I go 
to climb cutting I guess.

John T.:  I did a short pass with your code, cutting 2 slots.  Feed way too 
fast, the slots were badly S shaped from bit flex.  It sure looked like a 
good idea though.  Thanks.

Running a .7 feedrate, it is gradually straightening out the bottoms of 
the slots.  I also went down to a 45 cycle wheel with the narrowest slot 
for the one under construction now, but my calipers are telling me I'll 
have to pull the opto's together by at least 50 thou to get good 
quadrature.  Dunno if I can bend then that far or not.  We'll see when this 
one is done.  I'll see what the duty cycle is as I'd druther go up than 
down.

Here is a strange observance though, in halscope, encoder.0.velocity is not 
responding to spindle rotation at all until the spindle is up to at least 
1.5 to 2 rps!  Below that, nothing at any gain.  Weirdsville. I don't 
recall buying a ticket to this sideshow. ;)
 
Cheers, Gene
-- 
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 soap, ballot, jury, and ammo. Please use in that order.
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Re: [Emc-users] OT: 3D Printer Mods?

2012-06-01 Thread gene heskett
On Friday, June 01, 2012 06:45:30 PM Ed Nisley did opine:

 On Fri, 2012-06-01 at 08:44 -0400, gene heskett wrote:
  the bolts are 3/8 but the holes are 7/16
 
 In this case, the bolts were 7/16 and the holes 3/8... [grin]

Your kit of taps is in the bottom drawer of the tool chest I assume? ;)

Cheers, Gene
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 soap, ballot, jury, and ammo. Please use in that order.
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Re: [Emc-users] Commutating Reactor

2012-06-01 Thread andy pugh
On 1 June 2012 23:44, gene heskett ghesk...@wdtv.com wrote:

 I personally have not had that great an experience at getting superglue to
 let go with acetone.

I glued in my encoder disc (see earlier picture) then found I needed
it out again.

Luckily heating to 200C released it, with no damage. And that was only
0.15mm thick.

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Re: [Emc-users] OT: 3D Printer Mods?

2012-06-01 Thread gene heskett
On Friday, June 01, 2012 06:47:42 PM Ed Nisley did opine:

 On Fri, 2012-06-01 at 10:10 -0400, Eric Keller wrote:
  anyone that makes things
 
 Unlike folks who use industrial-grade machinery to build exquisite
 widgets (you know who you are), mostly, I fix stuff.
 
 Being able to sketch out a solid model and then have it *happen* is
 wonderfully liberating. The Sherline CNC mill does great work (I just
 made a plug-ugly manual-CNC scabbard for a garden knife yesterday), but
 for complex shapes the 3D printer can't be beat.
 
 That radio case was what compelled me to get the printer: I couldn't
 imagine carving another case from solid acrylic on the Sherline. It took
 a few tries to get the design  sizes right, but now I can build a
 second and a third with only a few minutes of finishing  fitting; the
 printer can be building a case while I'm making the PCB to go inside.
 
 When we eventually downsize, I know which machine tool is a keeper...

That I have faith will be a long time down the log for you Ed.  At 77, I 
haven't even considered that dreadful thought yet.  He who dies with the 
most toys (is still dead) ;)

Cheers, Gene
-- 
There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order.
-Ed Howdershelt (Author)
My web page: http://coyoteden.dyndns-free.com:85/gene
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Re: [Emc-users] Commutating Reactor

2012-06-01 Thread dave
On Fri, 1 Jun 2012 13:19:24 -0700
Joseph Chiu joec...@joechiu.com wrote:

 Hi,
 I'm a complete newb on this particular topic, and may not have read
 all the fine details, but it seems like this might be something better
 suited to photoresist/chemical etching, rather than using bits to try
 to mill out the interruptor disks?  Or perhaps laser cut sheets, like
 the kinds used for solder stencils, would also do the job?
 Cheers,
 Joseph
 
If I wanted to make a lot of them I'd mill a master out of Cu and then
ECM (electrochemical machine) them. Works rather well. Low
distortion. 
I once saw a portable ecm designed to mill holes (actually cut a disc
out of) the side of unexploded ordnance in S.E Asia. ;-)

Dave

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Re: [Emc-users] Commutating Reactor

2012-06-01 Thread gene heskett
On Friday, June 01, 2012 06:50:05 PM John Thornton did opine:

 I posted on the C(ommerical)NCZone and a guy there says those drives are
 rated for a 3% inductance wye isolation transformer.
 
 John
 
BS alert there John. 3% of what?  Without a frame of reference you may as 
well be shopping for a good used car.

Cheers, Gene
-- 
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 soap, ballot, jury, and ammo. Please use in that order.
-Ed Howdershelt (Author)
My web page: http://coyoteden.dyndns-free.com:85/gene
I can't understand why a person will take a year or two to write a
novel when he can easily buy one for a few dollars.
-- Fred Allen

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Re: [Emc-users] First LinuxCNC machine - picking a computer

2012-06-01 Thread gene heskett
On Friday, June 01, 2012 06:53:16 PM Jason Thorsness did opine:

 Hi,
 
 I'm setting up a LinuxCNC system to control a Fireball v90 router.  Is
 there any way to know if this system from Newegg will work with LinuxCNC
 without buying it first?
 
 http://www.newegg.com/Product/Product.aspx?Item=N82E16856119071
 
 I also plan to get a 5I25 plugged into a gecko g540 stepper controller.
 
 Thanks,
 Jason

Not near as well as a box with a D525MW board in it, its dual core, the 510 
is not.

Cheers, Gene
-- 
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 soap, ballot, jury, and ammo. Please use in that order.
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Re: [Emc-users] Commutating Reactor

2012-06-01 Thread gene heskett
On Friday, June 01, 2012 07:00:33 PM Joseph Chiu did opine:

 Hi,
 I'm a complete newb on this particular topic, and may not have read
 all the fine details, but it seems like this might be something better
 suited to photoresist/chemical etching, rather than using bits to try
 to mill out the interruptor disks?  Or perhaps laser cut sheets, like
 the kinds used for solder stencils, would also do the job?
 Cheers,
 Joseph
 
Unforch, no laser.  But yes it might work.

Thanks Joseph.

Cheers, Gene
-- 
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 soap, ballot, jury, and ammo. Please use in that order.
-Ed Howdershelt (Author)
My web page: http://coyoteden.dyndns-free.com:85/gene
It is only with the heart one can see clearly; what is essential is
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-- The Fox, 'The Little Prince

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Re: [Emc-users] Commutating Reactor

2012-06-01 Thread gene heskett
On Friday, June 01, 2012 07:03:18 PM andy pugh did opine:

 On 1 June 2012 23:44, gene heskett ghesk...@wdtv.com wrote:
  I personally have not had that great an experience at getting
  superglue to let go with acetone.
 
 I glued in my encoder disc (see earlier picture) then found I needed
 it out again.
 
 Luckily heating to 200C released it, with no damage. And that was only
 0.15mm thick.

Yes, that works well at 250C and up, but that is not at all friendly to 
other organics, like skin. :-)

Cheers, Gene
-- 
There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order.
-Ed Howdershelt (Author)
My web page: http://coyoteden.dyndns-free.com:85/gene
It is only with the heart one can see clearly; what is essential is
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-- The Fox, 'The Little Prince

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Re: [Emc-users] First LinuxCNC machine - picking a computer

2012-06-01 Thread andy pugh
On 1 June 2012 23:54, gene heskett ghesk...@wdtv.com wrote:

 Not near as well as a box with a D525MW board in it, its dual core, the 510
 is not.

Mine is, as far as I can see.

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Re: [Emc-users] First LinuxCNC machine - picking a computer

2012-06-01 Thread doug metzler
If you can swing it get an SSD for your shiny new machine.  I've got
two 525 machines side by side and the one with the SSD is so much
faster it's amazing.

DougM


On Fri, Jun 1, 2012 at 4:06 PM, andy pugh bodge...@gmail.com wrote:
 On 1 June 2012 23:54, gene heskett ghesk...@wdtv.com wrote:

 Not near as well as a box with a D525MW board in it, its dual core, the 510
 is not.

 Mine is, as far as I can see.

 --
 atp
 If you can't fix it, you don't own it.
 http://www.ifixit.com/Manifesto

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Re: [Emc-users] First LinuxCNC machine - picking a computer

2012-06-01 Thread dave
On Sat, 2 Jun 2012 00:06:43 +0100
andy pugh bodge...@gmail.com wrote:

 On 1 June 2012 23:54, gene heskett ghesk...@wdtv.com wrote:
 
  Not near as well as a box with a D525MW board in it, its dual core,
  the 510 is not.
 
 Mine is, as far as I can see.
 

AFIK,  D510 and D525 are both dual core. 

Dave

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Re: [Emc-users] First LinuxCNC machine - picking a computer

2012-06-01 Thread andy pugh
On 2 June 2012 00:33, doug metzler doug.metz...@gmail.com wrote:
 If you can swing it get an SSD for your shiny new machine.  I've got
 two 525 machines side by side and the one with the SSD is so much
 faster it's amazing.

It needn't be a big one, 8GB is plenty.

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Re: [Emc-users] Commutating Reactor

2012-06-01 Thread dave
On Fri, 1 Jun 2012 19:04:23 -0400
gene heskett ghesk...@wdtv.com wrote:

 On Friday, June 01, 2012 07:03:18 PM andy pugh did opine:
 
  On 1 June 2012 23:44, gene heskett ghesk...@wdtv.com wrote:
   I personally have not had that great an experience at getting
   superglue to let go with acetone.
  
  I glued in my encoder disc (see earlier picture) then found I needed
  it out again.
  
  Luckily heating to 200C released it, with no damage. And that was
  only 0.15mm thick.
 
 Yes, that works well at 250C and up, but that is not at all friendly
 to other organics, like skin. :-)
 
 Cheers, Gene

cyanoacrylics bond to almost anything but are reluctant to unbond
without help. Well, you are cooked at  250 F so another milder method
is recommended. :-)
The stuff will  hydrolyze so very warm water may help. However, be aware
that it makes a good surgical glues. 

Dave

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Re: [Emc-users] Commutating Reactor

2012-06-01 Thread Jon Elson
gene heskett wrote:
 On Friday, June 01, 2012 06:50:05 PM John Thornton did opine:

   
 I posted on the C(ommerical)NCZone and a guy there says those drives are
 rated for a 3% inductance wye isolation transformer.

 John
 
 BS alert there John. 3% of what?  Without a frame of reference you may as 
 well be shopping for a good used car.
   
No, this is actually standard power engineering terminology.  I don't 
recall the
way this is measured, but it has a specific definition to a power EE.
The basic concept is this % inductance tells you what the fault current and
sag will be under particular loads.

But, of course, this refers to running the transformer from a stiff 
3-phase mains
supply, not a saggy rotary converter.

Jon

Jon

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Re: [Emc-users] OT: 3D Printer Mods?

2012-06-01 Thread Mark Cason
On 06/01/2012 01:52 PM, doug metzler wrote:
 If you are a product designer I can't imagine a better tool.  Think of
 it as the ultimate in try before you buy - you don't have to commit
 anything to injection molding until you've actually held it in your
 hand.

 Thanks,

 DougM

   Better than that, you will have a solid model to give the mold maker 
so he can check his work.  There's nothing like ordering a mold, and on 
the first test run, finding out that the company machined it wrong...  
And it'll take another 6 weeks to fix it.

   The molds I'm used to weighed 20 tons, but the idea applies to 
anything being made.

-- 
-Mark

Ne M'oubliez   ---Family Motto
Hope for the best, plan for the worst   ---Personal Motto


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Re: [Emc-users] First LinuxCNC machine - picking a computer

2012-06-01 Thread gene heskett
On Saturday, June 02, 2012 12:17:02 AM andy pugh did opine:

 On 1 June 2012 23:54, gene heskett ghesk...@wdtv.com wrote:
  Not near as well as a box with a D525MW board in it, its dual core,
  the 510 is not.
 
 Mine is, as far as I can see.

Someone on this list told me otherwise, perhaps 10 months ago as I was 
getting ready to buy my first one.  Said it was a single core.  If 
hyperthreading in the bios is on, then it looks like a dual core.  The 
D525MW looks like a 4 core if hyperthreading is on.

Cheers, Gene
-- 
There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order.
-Ed Howdershelt (Author)
My web page: http://coyoteden.dyndns-free.com:85/gene
If it's working, the diagnostics say it's fine.
If it's not working, the diagnostics say it's fine.
- A proposed addition to rules for realtime programming

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Re: [Emc-users] First LinuxCNC machine - picking a computer

2012-06-01 Thread Peter C. Wallace
On Sat, 2 Jun 2012, gene heskett wrote:

 Date: Sat, 2 Jun 2012 00:19:45 -0400
 From: gene heskett ghesk...@wdtv.com
 Reply-To: Enhanced Machine Controller (EMC)
 emc-users@lists.sourceforge.net
 To: emc-users@lists.sourceforge.net
 Subject: Re: [Emc-users] First LinuxCNC machine - picking a computer
 
 On Saturday, June 02, 2012 12:17:02 AM andy pugh did opine:

 On 1 June 2012 23:54, gene heskett ghesk...@wdtv.com wrote:
 Not near as well as a box with a D525MW board in it, its dual core,
 the 510 is not.

 Mine is, as far as I can see.

 Someone on this list told me otherwise, perhaps 10 months ago as I was
 getting ready to buy my first one.  Said it was a single core.  If
 hyperthreading in the bios is on, then it looks like a dual core.  The
 D525MW looks like a 4 core if hyperthreading is on.


The D510 is dual core like the D525:

http://ark.intel.com/products/43098/Intel-Atom-Processor-D510-%281M-Cache-1_66-GHz%29

the D410 (and D425) are single core


 Cheers, Gene

Peter Wallace
Mesa Electronics


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Re: [Emc-users] Commutating Reactor

2012-06-01 Thread gene heskett
On Saturday, June 02, 2012 12:22:59 AM Jon Elson did opine:

 gene heskett wrote:
  On Friday, June 01, 2012 06:50:05 PM John Thornton did opine:
  I posted on the C(ommerical)NCZone and a guy there says those drives
  are rated for a 3% inductance wye isolation transformer.
  
  John
  
  BS alert there John. 3% of what?  Without a frame of reference you may
  as well be shopping for a good used car.
 
 No, this is actually standard power engineering terminology.  I don't
 recall the
 way this is measured, but it has a specific definition to a power EE.
 The basic concept is this % inductance tells you what the fault current
 and sag will be under particular loads.

Sounds like another way to state equivalent series impedance or as applied 
to capacitors, equivalent series resistance, or ESR.  3%, from a solid 3 
phase source wouldn't be so bad, but from a saggy RPC? 1% would be better, 
but would take more copper  higher priced iron.

 But, of course, this refers to running the transformer from a stiff
 3-phase mains
 supply, not a saggy rotary converter.
 
 Jon

Cheers, Gene
-- 
There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order.
-Ed Howdershelt (Author)
My web page: http://coyoteden.dyndns-free.com:85/gene
Much of the excitement we get out of our work is that we don't really
know what we are doing.
-- E. Dijkstra

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