Zoltar 2012-NC -- Prototype build --

[Chris@home]

The first step has been made, and the 12mm ballscrews (1204) did
arrive this afternoon with FedEx from China.
Amazingly within two weeks, ready machined for assembly.

As this is one of the major components, I wanted to check them out,
and be sure these items are usable before continuing ordering the laserparts.

Quality:
Overall these ballscrews & nuts look OK, but really are in need for a cleanup.
Initial the nuts run like these are assembled with dust(?) or some other crap.
So, thats just what Ive done right away, and now they are fine!
Can't feel any backlash so that seems sorted.

Laserparts may now take a longer period as its now vacationing season overhere.
That give me the time to get the 2D drawings organized.

More later-on presented in this topic.

-chris-

[OldRaven]

nice one Chris!

Who knows..  maybe a nice small machine for next to my IGUS one 

You have an estimate of what a kitset would cost..  laser set with most parts..  and the ballscrews?

[Chris@home]

Peter,

Its been designed to remain under 1000 â,¬
Looking at the past this effort should be possible, but now with ballscrews.
Achieving similar or even much better results than the 1000â,¬ machines
the competion offers.

For those who never build a Zoltar Kitset before or never worked with metal
its also a great learning experience.

Peter, you did build similar sized Classic Zoltar before so you know how it performs...
And this one does it even better using dual driven ballscrews on X

Hopefully enough people are interrested in this machine.

-chris-


_____________________________________________________________________________

<sub>>Uses a Proxxon/Dremel or similar 150W tool (not included).

>Ballscrews can be ordered directly from China, ready machined to size.
A China 1204 ballscrewset would set you back about 200â,¬ (incl transport from China!)
>The design is modified to use dual drive on X preventing any uneven movements of the bridge

>The all stainless-steel plano kitset/laserset itself is estimated to sell at 385â,¬ (laserset & assemblyset)
(ex tax & shipment)

>Optional a very nice machined Isel tabletop plate can be installed.

>Support via the dedicated member section on this forum.

Total price well under 1000â,¬  - yes!!!</sub>
_____________________________________________________________________________

[Chris@home]

Development / progress on the 2012-NC

After some request for, if it would be possible to mount a Kress to the 2011-NC machine....
I figured out - looking at the basic structure- that this was no real option as its designed for 200W.
My advice was (and still is) to get or just build a light capable rotary around 200W sufficient enough.
Something I use myself overhere, a converted RC motor:


http://members.home.nl/zoltar/CNC/classicsystem/HF.pdf

Its not so much the weight that is a problem but the bigger cuttertools
that fit the KRESS (or similar 500-800W rotary tools)
A bigger cutter can cause vibrations easier and the higher torque-
momentum having an effect on the cuttingresult.
Had some feedback with other Classic 2001 Zoltar users/owners
who actual did ad kress like tool and being confronted with this extreme:




I thought to create and add the 43MM mount an option to consider/test and give it a chance.



Next to the visible change to Z with the 43mm mount and LED-ARC (as with the 2011-CL),
also the internal structure of the bridge-Y did get a reinforcement to improve its total torsion stiffness.
_{As these modifications will raise the cost of this kitset it will only be available as an separate option to order with the kitset.}

Just got a message from the lasercutter and he found time to cut prototype parts next.....YeY!



Still haven't got enough preorder request yet, so please do let me know
if you wish to own one of these gems some day in the near future.

-chris-

[Chris@home]

Short update.....

It took a long time to have a kit lasercut as a small order.
This is very inefficient for a busy lasercutting company.

The good news is that the needed parts will arrive today
or by tomorrow so this weekend I can start this build

YeY!

Stay tuned.

-chris-

[Chris@home]

Had a quick trialfit and its looking good sofar.

I hope to assemble and finish the mechanics this weekend.

-chris-

[Chris@home]

Finishing the mechanics in one day was a little high fetched,
but could have succeeded if I would have brought the loctite 330 into the shop.

Left to do is applying the loctite 330
Mount the tabletop and steppermotors.
Cableling the motors to the controller.



Here the final adapter to mount a Nema17 into the Nema23 position.
Came originally from the 3D printer but will also be suitable to apply them here.

First trial with the 2012-NC will be with four Nema 17 motors and my standard Bie 1900 controller.
As soon Rik has got his low budget controller sorted, we can check and see how that works out.

Has been fun sofar, minor mishaps.

-chris-

[Chris@home]

Update....

Tabletop did not arrive yet, so that gave me some time to get other things sorted.
All parts are now locked in position with the loctite 330.
The reinforcement inside the bridge works well.



Had to make some adapters to make the 10mm couplers fit the 5mm steppershaft.
Added a box on top of the stepppermotor for a decent electrical connection.



Some comments that these linear guides on my railsystem have a lot of friction.
Here a short videoimpression to prove otherwise.
http://www.zoltar-cnc.nl/media/forum/2012NCXsliding.AVI

Next left to do cables and cablesuport, and the tabletop offcourse
Hopefully this week or next weekend, TESTDRIVE!

-chris-

[Chris@home]

The Alu tabletop arrived last Thursday, and so yesterday evening got time
to measure and drill & tap the mount holes in the underside of the tabletop.
Further assembly of the dual X-screws was not that hard from there.
Now fingers crossed the two Nema 17 motors are up to the job.



Must say the setup does fit together pretty neat!
Next cabling the motors to the controller.

Sadly Ive got other things to do this weekend, so more next week.

-chris-

[Chris@home]

Could not resist trying and give the Nema17 motors a quick test yesterday evening.

To give an idea about their performance check this short video.



http://www.zoltar-cnc.nl/media/forum/2012NC14102012.mp4

Overall these tiny motors are stronger, give more RPM/torque than I did expect.

The best result is delivered at 2,2Amps with the BIE 1900 controller.
Speeds up to 3 meters per Minute seem to be no problem.
The only setback is that these motors get pretty warm or even hot after a 1,5 hour testdrive.
Maybe another brand drivers more suitable for these motors will give better thermal results.
Looking forward testing with Rik's low budged CNC-USB controller,
now giving me the time finishing the cabling and create the first parts.

-chris-

[Chris@home]

Small step ahead trying to get the cables decently running to the backside.
Connectors on the cables from here running to the controller.

Takes a bit of time to figure out these details, but we are getting there.

-chris-

[Chris@home]

Cabling is now almost done.
Not my favorite part of the project,
but this needs to be decently done,
to work as a reliable tool.

Spacers for the X-motors had to be cutup.
When these are installed the cables on X can be finalized.
(top picture shows the temporary mount)


(Trespa 16mm)

First cutting job done!

-chris-

[Chris@home]

Trial in Alu meant for a China brushless rotary as a toolblock for the next 2011-CL demo machine.



Exploring the limit of this 2012-NC setup Alu is always a good way to testdrive.
Toying with the cutting-feed speeds I crossed a line somewhere halfway the process,
stalling the X-motor. I did zero and restart with no problem.
That is the advantage of good reference switches.

The result is not bad at all, but needs further exploring using another cutting strategy.
Some surfaces could get a higher quality.

I have a short video of the machine in process to post next.

-chris-

_{NOTE: Although possible to put to use for occasionally Aluminium cutting ,
this 2012-NC machine aswell as the 2011-CL are basically not designed for cutting this material.}

[Chris@home]

http://www.zoltar-cnc.nl/media/forum/2012NC alutrial.wmv

Just to get a general impression....

These Nema 17 have limits but do function very well in this setup.

-chris-

[Chris@home]

Here how it looks put together with the Z for the 2011-CL.
It does have an excellent fit with the laserparts aswell the rotary tool.
_{(The top supportring was cut on the first 2011-CL demo machine)}

-chris-