[Open Form ArchitectureParticipant]

@Taylor, Sure, go ahead and distribute -with our name of course. I put meta tags on the FlickR photos anyhow… and they’re liscenced as creative commons (or should be by default)! Thanks!

[Open Form ArchitectureParticipant]

@Taylor,

Our problems were mostly with the PINS (as I suspected). We had “All limits” in Pin #10 which seemed to cause all the problems. Following the larger tutorial on the SAIC website (thanks!) I erased the 10-15 pins as “unused” and we inverted the Z-Axis direction. We had to tweak our table limits to a larger dimension, which scares us because there are no limits, and the steppers could just keep going, but we’ll regulate this with actual model.

Screenshot: http://www.flickr.com/photos/darrel_ronald/5405381284/in/set-72157625822258783/

Questions:

a) The motors are always quite hot. We found online (or manuals?) that they should run about 140 Ferhenheit (is this okay)?

b) The steppers are quite loud -did you have this same issue? Are there quieting techniques?

c) How do you change the speed of the steppers depending on which material you’re using (i.e. Wood versus softer Foam?) SHould we overwrite a feed rate somewhere to speed it up?

[Open Form ArchitectureParticipant]

@ALL,

So we have everything working. Here are photos on FlickR: http://www.flickr.com/photos/darrel_ronald/sets/72157625822258783/

And two videos are being converted (as I write) with our first cut run!

http://vimeo.com/architectureopenform/videos

We’ll post more images & videos as we go through the tests!

[Open Form ArchitectureParticipant]

@Chris,

Problem 1:

It turns out that the above Error in the Traceback concerns having the StepConfig open at the same time as the EMC2 software.

http://www.linuxcnc.org/index.php?option=com_kunena&Itemid=20&func=view&catid=16&id=4080&lang=english

Problem 2:

We have everything communicating, but cannot actually SEND or PLOT the cut lines from EMC 2 to our CNC machine. For some reason, the EMC2 software will not recognize the machine, even though the config is setup and everything. We’re able to move the axis forward and backward.

We think it could be related to a couple issues:

a) That our pins are wrong, since we’re using the NON-PRO version of the HobbyCNC driver and steppers. I am trying to find out what the pins should be (or if they’re different from the Pro version).

b) That for some reason we’ve incorrectly configured that StepConfig -but we’ve followed everything pretty closely.

Otherwise, we’re pretty stumped as to why the machine isn’t recognized. I’ll try to get some screenshots and other photos and post them soon.

[Open Form ArchitectureParticipant]

@All,

All of the sudden, after having our machine working yesterday, where we were able to test movements, we’ve started to get problems while in the StepConfig of EMC2:

Traceback (most recent call last):

File "/usr/bin/stepconf", line 1911, in on_jogplus_pressed

self.update_axis_params()

File "/usr/bin/stepconf", line 1900, in update_axis_params

halrun.flush()

IOError: [Errno 32] Broken pipe

This appears when we’re modifying the stepconfig file in the X, Y or Z axis screens. I cannot find anything helpful online, and am debating whether to create a new config file and see if that works.

The only other help I’ve found suggests that you “deselect” the options when creating a stepconfig file on the first screen (such as send a copy to the desktop, etc.).

[Open Form ArchitectureParticipant]

@Chris,

Question concerning the “Home Location” and “Table Travel” for the X, Y and Z coordinates:

I cannot find decisive information about how to configure the “Home Location” or “Table Travel” parameters of the EMC 2.4 Stepconfig. What did you guys do? Did you locate the “Home Location” at all – for example at the front-left of the table with the Z-axis at the highest point?

I saw in another post that you’ve found the real cutting zone to be around 12″ x 12″ x 2″. I’ve also read that the “Table Travel” cannot be the same dimensions as the “Home Location”.

Along the same lines: If I load a cutting file into EMC2′s interface, and define the 0,0,0 for that model, will the machine know where to begin based on the 0,0,0 point given in the EMC2 StepConfig?

Thanks!

[Open Form ArchitectureParticipant]

@ALL – Canadian Builds

We’re almost done our build! I’ve been testing the X,Y and Z movements today! We’re working out the configuration of the EMC2 and how to locate the 0,0,0 location of the steppers versus the cutting board. In the end we’ve gone with the non-Pro HobbyCNC kit because it was causing problems. We’ll hopefully have some cutting tests produced this week, and then post some images and videos.

We’ve also updated to Ubuntu 10.04 + EMC 2.4 instead of the older release of Ubuntu 8.04. Another modification we did was to house the driver board in an old UPS box (google images for Uniterrupted Power Supply) which has metal housing and is therefore fire-resistant. We’ve created a small room for the machine, but will have to work out a cover for the excess material flying around.

[Open Form ArchitectureParticipant]

@ Taylor:

Thanks for doing the “Demo File” – I’ve had a chance to test it, and what happens is that Illustrator (when I export from Illustrator to either DWG or DXF) is that Illustrator creates a series of blocks within blocks, none of which are parametric.

I tried to edit the “symbol definition” in Illustrator CS4 and it seems to update without too much problems. I was also planning to go slightly bigger with the holes – from 0.24″ to 0.26″ instead -in the case of 1/4″ MDF (with a real uniform thickness of 0.25″). This way the holes won’t be too snug.

Perhaps send me the Illustrator file to test, or I will just do it from scratch in the AutoCAD file I’ve already modified… It’s probably as quick.

[Open Form ArchitectureParticipant]

@ Taylor – Continued:

I forgot to mention, that working from Illustrator > to AutoCAD makes all of the holes individual blocks. This of course means that in AutoCAD I cannot do a quick update of all the blocks. If I redo all the holes as one block, then this should (ideally) be fed to others.

Also: I assume that all the holes for the tabs should be centred according to the centre hole? And if I’m going to redo all the blocks, I guess I have the choice of still doing the masonite, because I’m going to resize everything anyhow. In this case, do you think Masonite is still better than MDF?

[Open Form ArchitectureParticipant]

@ Taylor:

I am looking at doing the panels with 1/4″ MDF, which seems to me the most logical option. However I still fell like I don’t have a clear answer from you about the material. If I understand: MDF is good, even if it is slightly heavier. As you say it (might be) is more expensive -but likely not hugely different.

The major issue seems to be then, that the MDF is not between the 0.21″ to 0.22″ as shown in the other post: http://diylilcnc.org/forum/topic/before-you-get-panels-cut-read-this-post and that we will in ALL cases need to adjust the holes (and tabs) to fit. I measured a piece of 1/4″ MDF here at the studio, and it was exactly 0.25″ = too big for the holes.

* Concerning the drawing set, I did have problems with the extra (missing) panels you added. The updated driver case boxes were SPlines, and caused problems to the Laser cutting machine. I therefore had to redraw the updated parts. I just wanted to let you know. I will look at AutoCAD and the feasibility of redoing (by block) the tab holes so that they can be updated to different thicknesses. I work with AutoCAD 2007 files.

Darrel

[Open Form ArchitectureParticipant]

@ ALL – Canadian Order Update:

We have now ordered all the parts. In the end we ordered most of the components from the USA, and shipped locally to a person we know. This will then be forwarded to us over the border.

McMaster-Carr (Distro through Motion Canada):

We did manage to find the McMaster-Carr products through Motion Canada in Montréal, and I suggest you contact them, their total cost is roughly $530 (incl. tax). Please contact: Alexandre Chaurette (alexandre.chaurette@motioncanada.com). They are one of the McMaster-Carr distributers in Canada, and the price is good.

Drivers, Motors, Cables & Electronics:

We sourced all of these from the American companies, to be shipped to Canada.

Skate Bearings:

We sourced from Kinecor (in Montréal) and bought 3 boxes of 16ct Abec 7, sealed bearings. $57.65 (incl. taxes).

Dremel:

We bought the Dremel #300 from Rona (online) that included a bonus 75-piece bit set. It was cheaper than Home Depot. $79.00 (incl. tax). As you have read in the other forum posts, the Dremel #395 originally specified is no longer on sale. I hope that the z-axis will fit this fairly close, but I know that the body is a different shape (from talking with Dremel).

Gantry Body:

We -like the others- are having initial difficulties sourcing the 1/4″ Masonite sheet (0.22″ – 0.24″ actual thickness). Our laser cutter company has been able to find 0.19″ thickness, but I don’t want to re-dimension the drawings to make the slots fit this. We’re debating going to MDF, but still hesitant about the material change, and further, if we go to MDF, our laser cutter won’t do it because of the burning glue.

Total Costs:

The total is about $1300 CDN and this excludes the computer tower and its accessories. The Linux/EMC2 operating system is of course free.

*If you need names or contacts, I can give them.

Good luck, Darrel

[Open Form ArchitectureParticipant]

@ Chris:

So what is your and Taylor’s final opinion about using MDF 1/4″ (0.25) instead of Masonite 1/4″ (0.22-0.24)? It seems that we’re having difficulties finding the right Masonite (in multiple regions) and a substitute option could be helpful. Ideally we don’t need to re-draw all the holes, etc. given that we’re not entirely familiar with the components.

From my experience MDF is a more robust material (at it’s edges) and less susceptible to chipping and peeling. I have a 1/4″ MDF panel right beside me and it feels fairly light but I have had a harm time finding links to a comparative analysis of Density (Weight:Volume ratio) and whether MDF is much heavier than the Masonite. My fear is that MDF might be heavier and cause increased strain on the motors.

From Wikipedia – “MDF”:

“MDF has a typical density of 600-800 kg/m³ or .022-.029 lbs/in3″

From Wikipedia – “Hardboard” :

“Consequently, the density of hardboard is 31 lbs. or more per cubic foot (500 kg/m³)[1] and is usually about 50-65 lbs. per cubic foot (800-1040 kg/m³)”

But I don’t know if we can go by this.

Darrel

[Open Form ArchitectureParticipant]

@Chris:

I am running into a similar problem with the 1/4″ Masonite sheets, but have been able to source a thickness of 0.19″ – is this too small? Or can I use this?

Thanks, Darrel

[Open Form ArchitectureParticipant]

I noticed that in the DXF file the lines are all exploded and not closed polylines. This could possibly slow down some machines if they don’t complete whole lines in a continuous fashion but rather jump around from one partial line segment to another. I have re-built the polylines in a .DWG / or .DXF file if it is desireable to anyone.

[Open Form ArchitectureParticipant]

@DNA Works:

I cannot say if they will ship, but please feel free to contact them (I posted the information above). Maybe if we all place an order there, it can save us money? But considering that Masonite is a dense (and therefore heavy) material, it would be worth comparing the shipping costs to you versus a price quote from one of your local supplier. It is all worth figuring out and comparing costs. If you contact COOP Techno (above) you can always mention our name: Architecture Open Form.

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