AL-54B CNC Conversion

[aussiejoeblow]

Hi all,

As per this thread http://www.woodworkforums.com/f65/h-f-al-54b-lathe-special-132769/ I have purchased an AL-54B for a CNC conversion. For the money I paid I think it is a good starting point. Let me just say that I am no CNC expert. This is a learning curve for me and I will be drawing on the experience from other more 'cluey' members.

The main aim for me is to do it neatly and properly. I am not shy to spend money on the righ gear if I know its going to do what I want. Here are some pics straight out of the packaging. And yes, the motor was toast right away.

http://i70.photobucket.com/albums/i86/jmleban/P1010300.jpg

http://i70.photobucket.com/albums/i86/jmleban/P1010299.jpg

I have ordered the electronics through EZ CNC, or Yuntat as they are known also. During the weekend I had stripped the lathe of basic components in preperation of the conversion. Today the goodies arrived from Hong Kong.:2tsup:

http://i70.photobucket.com/albums/i86/jmleban/P1010302.jpg
I ordered one Nema 34, which will be sitting in place of the q/change gearbox, and two Nema 23 motors. The extra Nema 23 will be for the tool turret which I am currently drawing up. All the electronics will be mounted in a new panel replacing the one joining the two legs on the stand. It will feature a hinged panel to make access easier.

http://i70.photobucket.com/albums/i86/jmleban/P1010305.jpg
New .55 kw 3 phase motor which will be driven by a Hitachi VFD.

http://i70.photobucket.com/albums/i86/jmleban/P1010304.jpg
All the gear train removed. I will make a laser cut plate to flange mount the new motor to the lathe.

http://i70.photobucket.com/albums/i86/jmleban/P1010303.jpg
The stand for the LCD screen and a 6inch keyboard. Another laser cut panel will screw onto this holding the keyboard and a spot for a mouse.

All bracketry will be laser cut and or machined........lets see how I go.:C

[wheelinround]

I read your other post and have been waiting in the wings to see this, after speaking to one of the fellows at H&F last Saturday they assure me there is nothing wrong with the lathes only the motor. So following with much interest.

Ray

[neksmerj]

Aussie,

I reckon you will have a captive audience with your project.

Documentation so far is great, it will be interesting to follow your plight. CNC is something I would love to get into, but just don't know where to start.

Basically, what do you place under computer control? Spindle speed, lead screw speed and cross slide speed?

Ken

[Dave J]

Your not mucking around. :o
I will be watching this thread to see how you go about it.

I just thought I would copy and paste this from the other thread.
I saw a lathe that had the stepper/servo motor down on the right side of the apron instead of sticking out the front which I thought was a good idea as it kept it out of the way. It ran off a belt up to the cross slide screw.

Did you contact H&F's about the damage?

Dave

[aussiejoeblow]

Don't let not knowing too much stop you. The net is a wealth of information. I must also add that the PDF from Mach3 is fantastic reading. Not only from the programing side but also the advice they give for setting a lathe up.

Dave, the plan is to have the Nema 34 where the grearbox was. This will be covered by a panel and sitting in that panel will be the hand controller for that stepper. The cross slide Nema 24 will be sitting under or off to the side of the 16mm ball screw with a 2 to 1 reduction via a timing belt. One thing I have noticed when lathes of this size are converted is the poor look and finish of the conversion. I only want to do this once. The saddle wil also be machined so I can run a full length screw cover. The very last bit, when and if it all goes well, will be a lift up lid that covers the chuck and saddle.........but this is way down the track.



My main concern at the moment is finding wiring schematics for these particular steppers and drivers, something they don't come with.(you know.....a diagram for simple folk!)

I'm not too fussed about the damage. I can see the removal of that panel and a replacement made from stainless housing something......not sure yet......but something.

[Ch4iS]

My main concern at the moment is finding wiring schematics for these particular steppers and drivers, something they don't come with.(you know.....a diagram for simple folk!)


Does the supplier give you the color coding for the phases? if you know that it should be simple to wire up.

I see they are all 8 wire, and I gather the drivers are Bipolar, just means you'll need to pair the wires and then each pair goes to A+, A-, B+, B- on the driver.

[RayG]

Hi aussiejoeblow,

Nice to see you are getting stuck into it. Mach3 and steppers is a nice way to get it up and running quickly. I spy a Macson lurking in the background :) so you shouldn't have too much trouble making the parts you need.

I've been chasing small diameter unjacketted anaconda for running cables around the mill, you might be interested also. Lawrence & Hansen appear to be the agents.
Product Range (http://www.anacondasealtite.com/products.htm#Unjacketed%20Conduit)


Watching with interest.

Regards
Ray

[Darren_111]

Hi Aussie,
Great to see the quick progress, following with interest!
Darren

[aussiejoeblow]

Thanks for the info Chris and Ray.


More goodies have been arriving so I have been busy mocking things up. Better progress will happen on the weekend when I have my laser cut adaptors.:;

http://i70.photobucket.com/albums/i86/jmleban/P1010298A.jpg

http://i70.photobucket.com/albums/i86/jmleban/P1010299A.jpg

[aussiejoeblow]

Ball screws are mounted as is the motor. It took a fair bit of machining to get the ball screw in the cross slide but the results are looking good.:D


http://i70.photobucket.com/albums/i86/jmleban/P1010298b.jpg

http://i70.photobucket.com/albums/i86/jmleban/P1010302b.jpg

http://i70.photobucket.com/albums/i86/jmleban/P1010300b.jpg

http://i70.photobucket.com/albums/i86/jmleban/P1010299b.jpg

http://i70.photobucket.com/albums/i86/jmleban/P1010301b.jpg

[RayG]

Hi aussie,

Looks nice and neat, :2tsup: I take it the stepper mounting is the laser cut part you were waiting on.

With the ballscrew, I can't see how the ballnut fixes to the saddle, I'm guessing there is another bracket or bearing mounting block.

The bearing closest to the stepper, are they AC bearings? The far end bearing, I think should be just floating, but I think I see a circlip? You need to allow for the ballscrew to expand and contact a little. You probably already know this.

I see H&F still have some of these AL54B's for sale, very tempting, I wish I didn't already have more projects than I can afford. I'd love to be doing one of these... :)

Regards
Ray

PS any pictures of how you got the ballscrew to fit into the cross slide?

[aussiejoeblow]

Hi aussie,

Looks nice and neat, :2tsup: I take it the stepper mounting is the laser cut part you were waiting on.

With the ballscrew, I can't see how the ballnut fixes to the saddle, I'm guessing there is another bracket or bearing mounting block.

The bearing closest to the stepper, are they AC bearings? The far end bearing, I think should be just floating, but I think I see a circlip? You need to allow for the ballscrew to expand and contact a little. You probably already know this.

I see H&F still have some of these AL54B's for sale, very tempting, I wish I didn't already have more projects than I can afford. I'd love to be doing one of these... :)

Regards
Ray

PS any pictures of how you got the ballscrew to fit into the cross slide?

Thanks Ray. I am actually making a new sadle that incorperates the mounting for the ball nut, should be in my hands tommorow. The bearings were supllied with the ballscrews. The end has a circlip but the bearing itself floats in the housing. The circlip is just preventing the bearing from comming out alltogether.

I'll try pull the cross slide off on the weekend to finish some things off and show what I did.

If anyone is keen on doing one of these...........I still have all the DXF's for the laser cutting.:;

[aussiejoeblow]

Better do some updating......



Most of the electronics are done. PC is up and running and the servos work...:D

Lots more bracketry to make and lots more tidying up to do.

http://i70.photobucket.com/albums/i86/jmleban/P1010309.jpg
Stainless lead screw cover.

http://i70.photobucket.com/albums/i86/jmleban/P1010310.jpg

Electronics cabinet.
http://i70.photobucket.com/albums/i86/jmleban/P1010311.jpg

http://i70.photobucket.com/albums/i86/jmleban/P1010312.jpg

PC.
http://i70.photobucket.com/albums/i86/jmleban/P1010314.jpg

http://i70.photobucket.com/albums/i86/jmleban/P1010315.jpg

[wheelinround]

Looking good.

Somehow I missed the update.

Well my chance slipped by :C they say never let a chance go by, I let 2 go by. In waiting for news of a 230x500 similar to the AL50G lathe possibly coming my way through a deceased estate. Hare & Forbes have now removed this lathe from sale and their website. The 230x500 got tied up in legal issues and I passed on it as the cost to retrieve it I could have bought a new one.

[Lister]

If anyone is looking for a lathe to convert I have a new AL54a for sale, see Metalwork Market.

[WillyInBris]

Good work now you have got me thinking about converting my C6 lol this CNC bug really hurts the wallet I was warned many moons ago by Rodm.

So when will we get some videos love to see it ruining even if its not cutting.

[WillyInBris]

If anyone is looking for a lathe to convert I have a new AL54a for sale, see Metalwork Market.

If you were only in Brisbane.

[aussiejoeblow]

I have everything working except spindle drive......I've been too slack to choose a VFD. Will grab some video of the saddle and compound slide moving.:2tsup:

[WillyInBris]

I have everything working except spindle drive......I've been too slack to choose a VFD. Will grab some video of the saddle and compound slide moving.:2tsup:

Ima excited :2tsup: