CNC_Workstation

CNC Workstation

The development of a computerized numeric control workstation and related equipment, which are to be used to research and develop blades and other components for an Intermeshing, and perhaps Interleaving, helicopter for the emerging 600+ Kg GW rotorcraft categories.

See the database Access database ~ [CNC - Workstation] for bill of materials.

The G-code for the filament winding is being developed on Access database ~ [CNC - Winding Generator]; not from DXF drawings converted to G-code.

	Name	Item
	MAKE: Controller	CNC_A006
	MAKE: Workbench	CNC_A001
	MAKE: Core Cutter	CNC_A009
	____________________
	BUY: Attachment Stock	CNC_A010
	BUY: Bearing	CNC_A011
	BUY: Electrical	CNC_A012
	BUY: Electronic	CNC_A013
	BUY: Fabricated Part	CNC_A016
	BUY: Instrument	CNC_A017
	BUY: Linear Device	CNC_A003
	BUY: Metal	CNC_A014
	BUY: Power Transmission	CNC_A015
	___________________
	OTHER: Converter	CNC_A004
	OTHER: Converter -.dxf to g-code	CNC_B014
	___________________
	OTHER: Generator	CNC_A007
	OTHER: Generator - Routing (Access to g-code )	CNC_B044
	OTHER: Generator - Routing - Airfoil Profile	CNC_0071
	OTHER: Generator - Winding (Access to g-code )	CNC_B017
	OTHER: Generator - Winding to g-code - Program Code	CNC_0025
	___________________
	OTHER: Simulator	CNC_A018
	___________________
	OTHER: Interpreter - g-code to Controller	CNC_A005
	OTHER: Interpreter - g-code to Controller - Mach 3~Artsoft	CNC B015
	OTHER: Information Build Your Own CNC Machine Book Reference site: http://buildyourcnc.com/default.aspx Download the eBook in a 34Mb. self extracting zip file: http://hotfile.com/dl/62166684/c6d09...chine.exe.html CLICK on the button "REGULAR DOWNLOAD" ....wait for the timer to tick down, click the Download button, then save the file to your folder. (Included is free CAD/CAM software (runs up to 500 lines of G-code) cutting diagrams, how-to documents, and more). File located in removable E-drive ~ Build your own CNC Machine
	OTHER: Information - G-code & Related Codes	CNC_B020
	OTHER: Information - Definitions, Acronyms & Algorithms	CNC_B018
	OTHER: Information - Symbols	CNC_B019

	OTHER: Composite - Special Tools
	UniCopter ~ Special Tools
	SynchroLite ~ Special Tools

A Basic Overview of Computer Numerical Control (CNC):

An Overview of this Specific CNC Machine:
A thought: August 12, 2004.

The conventional method is to draw many parts, Convert and modify them to G-code, then with the Interpreter modify them to the machine (router). Much of this work must be done interactively with the router on the Interpreter. For varied routing type of work, a good off-the-shelf Converter and Interpreter will probably be best.

The winding of the torque tube and spar will be constants once developed. There are few items to be wound, there is no tool to risk destroying and there will be thousands of very similar steps. It is appearing that all of this winding development and tweaking should be done in the Access Winding Generator, then just run the program through the off-the-shelf Interpreter.

I.e. A custom Winding Generator program and a 'somewhat' custom workstation. The rest as standard

Routing:		Filament Winding:
Drafting (CAD) ⁽¹⁾		Winding Generator (Database Basic Program) ⁽³⁾
.dxf file
Converter (CAM) ⁽²⁾
	Tool Path File G&Mcode ~.txt file
	Interpreter (CNC) ⁽⁴⁾
	Control - Electrical
	Controller
	Power - Electrical
	Electrical Devices ⁽⁵⁾
	Power - Mechanical
Router	Workbench	Filament Winder

Current Means:

DeltaCad. Perhaps AutoCad or other program, later for the 3D.

ACE Converter

Access Database ~ CNC Winding Generator

Modifying Stepster (to add A-axis etc.). Currently working in; Access Database ~ CNC Interpreter. Also considering Microsoft C or Basic.

Motors, encoders, limit switches, etc.

Elaboration on the above CNC system:

The personal Computers (PC). One for CAD and the other for CAM.
Programs that allow the users to design their products. (CAD)
Programs that convert the designs into G code instructions; which are then used by G code interpreter programs that in turn run the machine's controller. (CAM)
Programs that interpret the instructions and operate the machine.
The PC parallel port that sends the signals to the machine's controller.
The controller that reads the signals generated by the PC via the program and the parallel port, which operates stepper motors in a controlled manner.
The stepper motors that moves the axes of the machine to the requirement of the instruction sent to the controller.
The machine that moves each axis individually or simultaneously.

Requirements and Applications:

Combined; Can or should one workstation do all?

Chiller Tray (Refrigeration unit(s) & enclosure)

Oven (Old clothes dryer ?)

Lathe with screw for filament winding OTHER: Composite - Special Tool - Filament Winder

UniCopter - Rotor - Blade - NACA 00xx- Torque Tube Winding 1342

UniCopter and SynchroLite - Tail Booms

SynchroLite - Fuselage - Body - Tube Item 0566. For mandrel see 0376

UniCopter - Propeller Blades ??

Landing gear and Skids

Leading and trailing edge bars in the blades.

Device for stringing out pultruded thread for spar DESIGN: UniCopter ~ Special Tool - Rotor - Blade - Spar

Composite Milling

UniCopter ~ Rotor - Blade - NACA 00xx - Spar - Tip; 1345

UniCopter ~ Rotor Blade - Leading and trailing edges

Milling female spar mold halves.

Milling male or female final blade molds

Router; 1360 or Core cutter; 0668

UniCopter & SynchroLite blade cores

UniCopter & SynchroLite Horizontal and Vertical Stabilizers

Core cutter; 0668

UniCopter & SynchroLite Horizontal and Vertical Stabilizers

Vacuum table.

AND??]

Other Possible Uses for Table:

Helicopter Components:

Principal Assembly Components

Blade Components
Rotorhub Components
Flight-control Components
Power-train Components

Braiding

Shims for elastomerics

See; OTHER: Composite - Special Tool - Core Cutter ~ Possible Items

Making Tools which are Used to Make Helicopters:

Female molds for curing blades etc, or male molds of blades etc.
Core holders with half profile for milling or hot wiring other half of profile.

Tools; Some of which will be used with this CNC Workstation:

OTHER: Composite - Special Tools ~ UniCopter - Special Tools ~ SynchroLite - Special Tools

Startup Sequence:

Turn on Computer.

Open Mach3, on computer.

Load desired file (program), in computer.

Switch on 115 VAC, on controller.

To provide 5VDC and 12VDC control voltage to the system

Switch on 48 VDC, on controller.

To provide power voltage to the X, Y, Z and A-axis motors.

The following may be out of sequence or just wrong.

Activate momentary contact [Engage] toggle switch, on controller. Forget - Switch is jumped and will be removed.

Activate momentary contact [Interface Reset] toggle switch, on controller.

To activate the EStop and Limits board. This also opens the motor brakes and closes the safety motor relays.

Press the red [Reset] button on the Mach3 screen to clear "Emergency Mode" message.
Press the momentary contact [Startup] push button, on the controller.

To activate the Safety Charge Pump and let it provide power to the Parallel Port Board if Mach3 is outputting 12.5K Mh.. O yea???

Home all the axes.

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Last Revised; August 17, 2010