Unimatic CNC Router

X range (left/right): 530mm
Y range (front/back): 500mm
Z range (up/down):    120mm

X/Y max speed: 3600mm/min
Z max speed:   3000mm/min
Spindle max:   24000 RPM

Collet: ER20

Demo of it cutting plywood: https://www.youtube.com/watch?v=XMiQymoBE04

Machine bed diagram

The CNC router is made up of multiple parts.

• CNC machine frame: made by unimatic - (measurements different)
  • Bed size: X 750mm, Y 860mm, Z 141mm (distance between collet nut and bed)
  • The aluminium T-slot base with 15 slots for normal M6 hex nuts, spaced 50mm apart
• Spindle: water cooled, 3 phase, with a ER20 collet chuck
• Motion Controller: Isel C142 controller, for controlling the stepper motors of the machine
• Computer: Laptop Dell Latitude D600 (?), running LinuxCNC
• Chiller: DN CW-3000 - Manual
• Dust extractor: Mardon dust extractor
• Spindle drive: Huanyang 2.2kW VFD HY02D223B, Single phase to 3 phase - Manual

Connections:
Laptop Parallel Port → Motion controller → stepper motors
Laptop Serial Port → Serial to RS485 converter → VFD → spindle

Emergency Stop loop Connections:
The following are wired in series and power will only be sent to motors and spindle if all are on:

• Main Emergency Stop button
• Tool controller
• Chiller
  • Temperature is not above 60*C
  • Water flow has not stopped
  • Water level in tank is not low

1. Turn on the laptop
   • open the lid and reach the power button, which is located on the back left corner of it's keyboard
   • Note: make sure not to pull out the cables plugged into the laptop while turning it on
     • The cables that are plugged into the laptop include: video cable for monitor, power cable, Serial port to RS485 converter for VFD, Parallel port for motion controller, USB keyboard and mouse
   • Note: make sure the USB stick is not plugged in when booting (it will try to boot from it otherwise)
   • Turn on the monitor above the router
     • the display source should be “INPUT-2” displayed on the screen, press the “INPUT” button on the monitor if it says “INPUT-1”
   • log into the laptop using username: hacklab password: hacklab
2. Pull out the estop (gently) on the motion controller
   
3. Release the estop button on the machine by twisting it
   
4. Log in by tapping your token on the tool controller
   
5. Turn on chiller
   
6. Push green button mounted next to VFD.
   • Note: This will send power to the stepper motors
   • Note: The-Z axis will drop a few centimetres.
     • Unload any fragile tools first, if you are worried about them being damaged.
     • The drop is due to the Z-axis electromechanical break disengaging a little before the stepper motors get power
   • Note: Wait for the laptop to boot before pressing the green button
     • The laptop sends out random signals out on its parallel port when it boots, and would make the CNC mill move around randomly, which is dangerous

1. Home / move the spindle fully up and to the back, for easy access
2. Press the main estop next to the machine - this is done first, the rest can be done in any order
3. Turn off the chiller
4. Log out from the tool controller
5. Turn off the laptop

Note: the motion controller Estop does not need to be pressed

1. Double click the 'Linux CNC' icon on the desktop
2. Make sure the router can safely home - move the spindle up, then to the back left corner, with no obstruction. If the tool is too long, it may have to be removed.
3. Click the red, then the orange icon to enable keyboard control. Do not use the arrow keys to move the motors unless it is necessary to clear an obstruction, as the machine is not yet aware of its endstops and may ram into the end of the axis.
4. Press “Home All”
5. If needed, disable keyboard control with the orange icon, drive the spindle forward and change the loaded tool in the collet. Reenable keyboard control.
6. Position the tool at the origin point of your work piece. Select the radio button for the X axis, and press “touch off”. Repeat for Y and Z axis.

TODO

TODO: photo of pad
There is a touchoff pad plugged into one of the inputs of the motion controller
The spindle + tool are grounded, so the tool contacting the touchoff pad completes a circuit
Gcode: https://marlinfw.org/docs/gcode/G038.html
Example: G38.2 F100 Z-1
Click 'Touch Off' and enter the thickness of the touchoff plate, printed on top.

Dust extractor needs emptied periodically, follow instructions on the dust extractor

Some notes on the CNC's quirks.

The CNC laptop runs Debian 7 and should not be updated as the CNC functionality relies on a special real-time kernel.

Gcode files need to have a “.ngc” file extension. The last line of the gcode should be “M30”; this is a program end signal and Linux CNC will refuse to load any files without it.

It would be nice to get a new set of a M6 T-Slot Clamping Kit for workholding.