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December 13, 2017, 07:11:52 am


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Author Topic: Automatic tool changer for the lathe  (Read 1956 times)
Bubba
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« Reply #15 on: October 11, 2017, 13:21:24 pm »

Dave,
You not using Mach Turn to controll the lathe with tool changer?

The plugin looks good.
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dave benson
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« Reply #16 on: October 12, 2017, 10:33:02 am »

HI All

LLoyd you may be right about the tool holders, and I've examined the inserts am they look identical and the way, one of the the inserts fit in the holder, I'd have to have the holder fixed in the tool post at an odd angle.

Bubba I've got a few versions of Mach3 to test with (things changed over time in the software) and the one on the lathe is an older version. so I will test with that version at some stage.

here is a pic of the tool holders.

Dave


* New Lathe tools.png (1348.13 KB, 1000x750 - viewed 22 times.)

* lathe tools 2.png (1310.52 KB, 1000x750 - viewed 19 times.)

* lathe tools 3.png (1123.22 KB, 1000x750 - viewed 27 times.)
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lloydsp
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« Reply #17 on: October 12, 2017, 12:13:15 pm »

Dave,
If the holders are mirror-images of one-another, but the actual inserts are not, then you do have a left-hand threading tool, but they didn't give you any left-hand inserts!

I have and use both, so I'm pretty familiar with their looks and their setup.  What you describe sure sounds like a right-hand (exterior) threading tool in a left-hand (interior) threading holder!

Lloyd
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Bubba
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« Reply #18 on: October 12, 2017, 19:55:15 pm »

I figure, somebody could use this..

Best.


* R_L_HAND_Threading.JPG (104.74 KB, 1071x826 - viewed 55 times.)
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dave benson
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« Reply #19 on: October 13, 2017, 22:21:23 pm »

I went back and had a look at the original invoice for the tools, and you can clearly see that the RH tool that I was sent is a Turning tool and not a threading tool (they are clearly different). Roll Eyes

I decided to do a quick test of the turret to see how well it would cut, so I turned a 19 mm rod down to 11.75 and then threaded it to M12 x 1.75.

Went very well, As I didn't have the stepper motor connected I did the tool changes "Fred Flinstone Style" by hand and pressed cycle start to continue on after the tool change was done.

On the battery front, I friend gave me four 18650's and a charger, so I now seriously have to look at how to squeeze that stuff into the turret.

Dave


* Finish at pass one.png (987.16 KB, 1000x750 - viewed 20 times.)

* Turret setup for turning dia.png (1319.93 KB, 1000x750 - viewed 30 times.)

* finished thread done with turret.png (1512.68 KB, 1000x750 - viewed 20 times.)
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dave benson
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« Reply #20 on: October 21, 2017, 14:11:55 pm »

Another small update and video

In the video a complete G-code program was ran from the start to finish and happily Mach3 and the tool changer
agreed on which tools to use for each operation.
https://www.youtube.com/watch?v=04_8UEFjlZE
Dave

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Bubba
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« Reply #21 on: October 21, 2017, 22:02:09 pm »

Another small update and video

In the video a complete G-code program was ran from the start to finish and happily Mach3 and the tool changer
agreed on which tools to use for each operation.
https://www.youtube.com/watch?v=04_8UEFjlZE
Dave



I tried to look at it and got a message 'This video is unavailable'. Wink
« Last Edit: October 22, 2017, 04:35:15 am by dh42 » Logged

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dave benson
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« Reply #22 on: October 22, 2017, 00:55:49 am »

Hi Bubba try this https://www.youtube.com/watch?v=04_8UEFjlZE&t=16s
(I found that if i wasn't logged in It would not play for me either)
Dave
« Last Edit: October 22, 2017, 01:01:17 am by dave benson » Logged
Bob La Londe
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« Reply #23 on: October 23, 2017, 16:03:04 pm »

Google is getting to be more mercenary with YouTube.  They keep changing rules so their big contributors don't get paid, push ads even on videos that have ads turned off, and constantly seek to get users to buy a subscription to RedTube when using mobile services.  I will probably start using Vimeo for more of my videos or atleast mirroring them to Vimeo and Daily Motion. 
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Bubba
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« Reply #24 on: October 23, 2017, 17:25:11 pm »

Sorry Dave. No Joy.. Grin


* Capture.PNG (12.05 KB, 810x439 - viewed 11 times.)
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Garyhlucas
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« Reply #25 on: October 23, 2017, 18:00:42 pm »

Bob,
You do know that redtube is a porn site?
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dave benson
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« Reply #26 on: October 23, 2017, 23:45:47 pm »

HI Bubba
I went back and a look at the video, and fiddled with the settings, hopefully it'll work now (the first link I posted)
if not just type in "Lathe Auto Tool Changer 3" into youtube and see how you go.

What you see in the video is a G-code program running from start to finish with lots of tool-changes.

It took a while to get here, as part of the "goals" of the project were to have a battery operated wireless Bluetooth connected Auto tool changer That required little maintenance and was easy to set up (software wise).

This what I've got so-far, you have to add "three lines to the start script in Mach3",then  plug in the dongle (and pair) run.
start Mach3---> start Plugin----> program as normal.

The turret is autonomous, and can either listen to or command Mach3 and requires no changes to the way you program your lathe with the software you have already.
 
All you do then is to re-define your G53's as they will likely be different to mine.

I've also  looked at using OpenCV to monitor the tool changing and report chipped tools (you can see in the last video the "OpenCv" frame open and capturing the turret moves.

You wont be measuring tool wear, but detecting a complete tool-change or broken or chipped tools are a possibility.


Dave
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Bubba
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« Reply #27 on: October 24, 2017, 00:32:48 am »

See the video. Yep, you got it working. I doubt I will be converting my manual lathe any time soon (Clausing 48" bed). But your posts should be great aid for someone who want to go that route.
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dave benson
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« Reply #28 on: November 12, 2017, 12:56:45 pm »

Another Update and some conclusions.

Overall it was a good project that offered plenty of challenges, but nothing “too” challenging.

As I “MacGyver'ed” it together “scrapheap” challenge style from bits and pieces on hand
It ended up a little too heavily built  for the application (16 mm plate instead of 12 mm)
and would suit a 10 x 40 or something similar.

Mechanically the tricky bits were:-
1.The Ratchet and Pawl.
2.The Tool Platen.

With the ratchet wheel, I had to make it twice, as the finish was a little off, and by the way the mill sounded something was loose. The Y axis was a little lose. So I couldn't trust the dimensions. And started again. The final one did show some “strata” type tool marks but in practice works well.

Everything went well with the pawl.

With the Tool Plattern, I had a power interruption for a couple of hours and had to reset the co-ordinates. There were some depth of cut differences, but I thought I would clean them up with a file later. This was a mistake as I should have done this on the mill while it was still indexed and saved a lot of time.

I also found that the walls of the tool holders were not straight, but had some draft at the bottom of the cut which meant that each and every tool slot had to be reworked on the shaper and then filed perpendicular to the floor of the slot.
I used a 3/8 end mill for this, but should have been ˝ inch at least.

Originally I had the stepper motor and gearbox directly coupled to the turret drive shaft
But had to move it inboard some 30 mm to clear my X axis bearing mount. This involved adding some 1 to 1 gear's  and removing the inline coupling.

Interestingly I lost some high speed  acceleration  (about 20 %)  just by doing this (I had taken some benchmarks when programming the velocity and acceleration curves ) for the inline motor configuration.
I put this down to the now  radial load, canting  the gears a little and adding more friction
to the gear train.


Electrically:-

I'm using 3 18650 batteries (4000 ma)  to power the turret.
The idle current was 285 ma and the tool change current was 628 ma.
I did do a estimation the battery life  using fairly conservative figures and thought 720 tool changes  would be an upper limit.

I set out a test, to see how many tool changes I would get in real life, so I made a short Gcode program with 48 random tool changes that went for 11 minutes and ran this for 3 hours.
I felt a bit nervous about letting the batteries deplete too much and so set a limit on the discharge to 10.5 volts .
By the time  I got around to removing the batteries for recharging (about 10 minutes or so), they had recovered a bit as each cell measured 3.69 volts. The batteries did take the full 80 minutes to recharge.
Those batteries do pack a punch as the total tool changes per battery charge is 864.

I did have trouble with the lm298 driver on the shield as it provided less power to the motor
( I think it's the “on state resistance” perhaps it's a bit higher)  and so went back to the “off board driver” which gave me a reasonable tool change time of 5 seconds.

The turret is “plug'n play” either use it and run the plugin, or use your manual tool post  and don't run the plugin.

I've also accidentally “christened” the turret and tested the safety overload at the same time by running it into the chuck spinning at 600 rpm at full rapids. (Errant G28 in code and I should have set this to the tool change position G53 to be the same values) The tool holder was struck by the chuck jaw but swung out of the way. See picture of tool, there was some paint knocked off, other than that there was no damage.

What I had to do then was, reset the centre height (which is lost when the overload is activated) which took about 10 minutes.

edit spelling









 









* damage after crash.png (1047.25 KB, 1000x750 - viewed 15 times.)

* Lathe Tool Turret Loaded with tools.png (958.8 KB, 1000x750 - viewed 20 times.)

* Lathe Turret in operation1.png (1371.75 KB, 1000x750 - viewed 20 times.)
« Last Edit: November 12, 2017, 12:58:37 pm by dave benson » Logged
EddyCurrent
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« Reply #29 on: November 12, 2017, 16:17:10 pm »

Dave,

What an excellent project and result, you should be proud of it, especially taking into account all the different disciplines required to complete.
Could you have use a timing belt to connect the stepper motor and gearbox ?
Could the batteries be charging in situ when the turret is not in use, or would wires to it spoil the job ?
Edit: Note to self(Eddy), you clown.
« Last Edit: November 12, 2017, 19:00:59 pm by EddyCurrent » Logged
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