EMC2 DC-servo controlled minimill

Hi All,

you may find some of my recent videos amusing/interesting.

Servo tuning and test-running
http://video.google.com/videoplay?docid=3321458111477478272&hl=en

Testing the X-axis:
http://video.google.com/videoplay?docid=1864749796574452730&hl=en

Program dry-run:
http://video.google.com/videoplay?docid=-4918805093165248240&hl=en

One of the first cuts:
http://video.google.com/videoplay?docid=-6222166294337898920&hl=en

First 'serious' job, rough and finish cutting a model-yacht keel bulb
out of steel:
http://video.google.com/videoplay?docid=916833244018390029&hl=en

The machine started out life as an Opti BF-20 manual mill, but only
the base and column remain. We've installed linear rails, ballscrews,
a new belt-driven spindle, a new bigger table, and an enclosure to
keep the coolant inside.

It's controlled by EMC2 via an m5i20 pci-card from mesanet. The
servo-amps are from Jon Elson / Pico-systems and the DC-servos from
Dan Mauch / camtronics.

The servos have 1000 count encoders so I get 4000 edges per revolution
and they are direct-coupled to 2.5mm/rev ballscrews. I did the
PID-tuning with rapids set to 4000mm/min and acceleration around
500mm/s and it stays inside +/- 16 counts or around 0.01 mm at all
times. Better than this for actual cutting which we do at around
1500mm/min maximum.

Next we are going to put an encoder on the spindle to enable rigid
tapping.

More about this in my blog: http://www.anderswallin.net/

have fun,

Anders