Computer system requirements for CNC programs

Plan of Procedures Template (Will Be Update as a Full Plan of Procedures)

Plan of Procedures
Supply List
Item	Description	QTY	Size	Remarks
S1
S2
S3
S4
S5
Tools and Equipment List
Item	Description	Use
T1	Drill	For making holes in wood for screws
T2	Scroll Saw/Band Saw ?	For cutting wood
T3	Screw Driver	For screws and electric equipment
T4	Router	For cutting wood in the finished product
T5
Material List
Item	Description	QTY	Size	Remarks
M1
M2
M3
M4
M5
Parts List
Item	Description	QTY	Size	Remarks
P1
P2
P3
P4
P5

MP1 Update

Marking Period 1 entails my research into my background, alternate solutions, final solutions, testing procedures, models, and developmental work. As I proceed into Marking Period 2 I will finish developmental work and continue to finalize my drawings and begin to order parts.

Currently I am in the middle of my plan of procedures that consists of the bill of materials and assembly. I will have to finalize this before I complete my exploded drawings.

Possible Parts List with Links to Resources:

• Wood:

• 2’x4’xX” Material Bed
• 1’x4’x2” Gantry side arm panels
• Gantry panel 4’ long 4” high 2” wide
• Screws
• Electronics
• Chassis: Gecko G540 4-Axis Driver Controller 48V/7.3A
• http://www.automationtechnologiesinc.com/products-page/cnc-controller-box/4-axis-7-a-cnc-stepper-motor-driver-controller-duplicate

• Drivers: Gecko G540 4 Axis Driver
• Breakout Board
• E- Stop
• Power Supply
• Power Switch
• Outlet Plug
• Wires: Probably just an extension cord
• Parallel Board port for computer (Amazon)
• Cable carriers (Might make with cnc once completed)
• Motors: Nema 23
• Software
• CAD (Already installed on computer)
• Mach 3
• http://www.machsupport.com/software/mach3/
• Hardware
• Round linear rails and bearings
• Router Mount: Gecko G540 4-Axis Driver Controller 48V/7.3A
• http://k2cnc.3dcartstores.com/Bosch-1617EVS-Router-Mount_p_13.html
• Router (In class)
• Acme Screws or Rack and Pinion

Possible Budget for CNC Router
Linear Rail X	159.99
Linear Rail Y	279.99
Linear Rail Z	119.99
Router Mount	69.95
Chassis	494.95
Mach 3	175
Motors	210
Wood:	200
Total:	1709.87

Web References Found During Systems Class:

Rails

http://www.thomsonlinear.com/downloads/articles/Linear_Systems_101_Basics_for_Design_Engineers_taen.pdf http://www.cncrouterparts.com/standard-cable-track-kit-installation-instructions-p-184.html

http://www.cnczone.com/forums/linear-and-rotary-motion/13851-linear-rails-guides-bearings-size-best.html

http://www.pbclinear.com/Inch-Steel-Linear-Shafting---NIL-NIPDL

http://www.pbclinear.com/Download/DataSheet/Simplicity-60-Plus-Shafting.pdf

http://www.pbclinear.com/Inch-Open-Linear-Ball-Bearing-Pillow-Block-(IPPN)

http://www.pbclinear.com/Linear-Shafting-Aluminum-Rail---SR?tab=Specifications

http://www.skamar.com/quick_quote/

http://www.cncshop.com.au/index.php?main_page=product_info&cPath=22_31&products_id=39

http://krazatchu.ca/2012/04/23/on-the-cheap-supported-linear-rail/

Bearings:

http://www.cncshop.com.au/index.php?main_page=index&cPath=20_28

Spindle Mounts

http://www.cncrouterparts.com/router-and-spindle-mounts-c-43_30.html

http://www.woodcraft.com/product/0/46928/velox-cnc-3piece-router-mount-for-bosch-model-1617evs.aspx

http://www.cncrouterparts.com/gantry-rail-clamp-p-136.html

http://www.cncrouterparts.com/dl/cad.pdf/CRP142-02.pdf

http://k2cnc.3dcartstores.com/Bosch-1617EVS-Router-Mount_p_13.html

Wire Cables

http://www.cnczone.com/forums/diy-cnc-router-table-machines/120309-diy-cable-carrier-works-great-cheap.html

Motors

http://www.buildyourcnc.com/item/electronicsAndMotors-3axis-425-elcombo

http://www.cnczone.com/forums/faq-of-diy-cnc-machine-building/17419-steppers-servos.html

http://www.cncrouterparts.com/380-oz-in-nema-23-stepper-motor-14-shaft-p-151.html

http://www.cnczone.com/forums/diy-cnc-router-table-machines/122350-choosing-stepper-motor.html

http://www.mpja.com/NEMA-23-Stepper-Motors/products/521/

Motor Mounts

https://www.sparkfun.com/products/12989

Controller Boxes

http://www.buildyourcnc.com/item/electronicsAndMotors-3axis-425-elcombo

http://www.cnccookbook.com/CCEnclosureIdeas.html

http://www.automationtechnologiesinc.com/products-page/cnc-controller-box

http://www.automationtechnologiesinc.com/products-page/cnc-controller-box/4-axis-7-a-cnc-stepper-motor-driver-controller-duplicate

Screws or Bolts

http://www.diynetwork.com/home-improvement/nail-vs-screw-vs-bolt-knowing-the-right-hardware-to-use/pictures/index.html?i=1

http://engineerexplains.com/answr/Screw-vs-Bolt1.html

DIY References

http://www.instructables.com/id/How-to-Make-a-Homemade-2x4-Wood-CNC-Router/

http://imgur.com/a/NGbmh

Router Components

http://blog.cnccookbook.com/2012/04/06/cnc-router-cutters-types-and-how-to-use-them/

Wood Types

http://homeguides.sfgate.com/plywood-strengths-99591.html

http://www.woodmagazine.com/materials-guide/lumber/what-you-need-to-know-about-plywood/

Background Information

Self-manufacturing is a difficult and a costly process. Buying industrial machines costs thousands of dollars. A DIY machine greatly decreases cost and allows customization to fit the work environment. Designing a machine allows building a machine to fit niche needs possible.

Systems lab

Hobbyists and home owners represent the population that utilizes machinery in the home and small workshop environment. Factories require industrial made machines due to the workload present. Industrial machines require stronger materials that withstand ware. Home built machines can be made with cheaper parts due to the lack of stress on the machine. This cuts down on costs.

Industrial CNC MachineCited from: http://www.multicam.com/routers.html

The country is deeply engrained in industrialism. The general person buys mostly factory made objects. People want to manufacture within their homes. Home built machinery allows this. The ability to produce goods in the home is new to modern society.

Home work schop
Cited from :http://www.cnccookbook.com/CCHomeMachineShops.html

Hobbyist and small business owners outsource technologically advanced and niche products. People look for the ability to self-produce. People with the intentions to manufacture products individually need machines that work in a small home or business environment. Designers feel innovated and inspired by the possibility of self-production.

            Home built machinery covers a wide range of products. Computers, CNC machines, and 3D printers represent a small portion of home built machinery. The machines allow customization to fit the needs of the users.

Home built computer

Small scale manufacturing requires money and utility space. Home built machines provide a way to make home manufacturing possible. Hobbyists with limited space build within the limit of space at home. Personal designed machines give hobbyists the ability to customize machines to fit needs. Ease of design and assembly concerns potential builders.  

Design Brief

One will design and produce a CNC router that presents the opportunity for students to cut precise material in the systems lab allowing students to create, design, and produce products for assigned projects.

Executive Summary

People are looking to self-produce in homes, schools, and small business environments. A CNC router solves this problem. The non-industrial design allows for easy storage and placement into different work spaces.  The machine’s purpose is to provide a way for people to manufacture wood and other soft material products.  The router can precisely cut materials into finished products or molds. One uses a CNC router by imputing a computer drawing into the controller software. The machine processes the file and cuts out the desired material.

DIY CNC Router
Cited from: http://hackaday.com/2013/10/24/a-very-professional-homemade-cnc-router/

Edited CNC router picture labeling the parts
Original picture Cited from: http://www.craftsmancnc.co.nz/images/craftsman900st/CNC%20900ST%20-%204.JPG

A CNC router consists of a material bed, gantry, linear motion, motors, and computer software. The parts chosen determine how precise the machine cuts. The material bed supports the cutting material and contains the gantry, linear motion, and motors. Linear motion is the rails and bearings along with the motion drivers. Motors attach to the drivers that attach to the computer. The router attaches to the gantry that glides along the rails to change position.  Hinges applied to the material bed allows the machine to fold for storage. This allows the machine to be larger and still fit into a smaller area when not in use. Wheels attached to the table supporting the material bed allow maneuverability.  

Sysytems lab where CNC Router will end up being placed

Storage and maneuverability is important when working in small spaces. People intend to use the machine for personal production. Space is important in limited work environments. Teachers need the ability to produce projects for shop classes. Industrial CNC machines in factories create modern day products. A small-scale machine provides industrial grade products in a small setting.

Many parts make up a CNC router. Teachers and students benefit from a custom router that fits in the systems lab. Students previously learn computer drawing before entering systems engineering. The students can make systems projects using previously taught skills. Teachers benefit from new possible projects that require the router. CNC routers bring production into small working environments. 

Wooden bridge project that could be done on a CNC Router

Sample Model

Alternative Solutions and Rational

Solution 1:

Concept:
The material bed chosen is a solid bed. This structure consists of either metal or wood and is the table that supports the entire the device. The linear rails, drivers, and the gantry are on top. This design optimized for backlash because the devices are installed directly into the bed rather than placed on top and more material is used as support. The bed is the table that allows the machine to fit any size requirement because suitable tables are required for beds that contain just the rails.

A moving gantry covers the most surface area of the desired cutting material. The gantry moves on the XYZ planes of motion. The gantry attaches to the table by the X-axis rails. The Y and Z-axis rails attach to the gantry. The system minimizes rail usage.

Linear rails and bearings direct the motion of the router. Round linear rails have a lower load capacity compared to profile rails but the rails work. These rails operate at higher speeds due to less friction. Warped structures the rails attach to do not cause the bearings to become unmovable. The X, Y, and Z-axis use these.

Liner drivers attach to motors and linear rails. The motors cause the drivers to move which cause the rails to move. Rack and pinion drivers allow splicing for larger axes. Low torque motors work with rack and pinion drivers and create high efficiency. Larger CNC routers use them for the X and Y-axis. ACME screws are efficient for smaller axes. They are more accurate than rack and pinions but the difference is negligible in larger units. ACME screws are slower than rack and pinions. Larger CNC routers use them for the Z-axis. 

For this design, a solid bed is chosen for stability. The moving gantry allows for more coverage of the router. The round liner rails allow for slight warping of wood. The liner drivers allow for both longer and shorter axes and the efficient use of different types of drivers.

Why:

Solution 1 contains all elements necessary for the specifications.

Solution 2:

Concept:
The material bed chosen is a bed that consists of the linear rails and drivers and gantry. This type of bed allows for minimal building materials and can be supported on any table but the size makes transporting the device difficult without disassembling the machine. The lack of extra materials also makes the machine unsteady as extra metal or wood applied to the frame and gantry reduces backlash from the router. This style of bed suits a smaller CNC router rather than a larger one.

A moving gantry covers the most surface area of the desired cutting material. The gantry moves on the XYZ planes of motion. The gantry attaches to the table by the X-axis rails. The Y and Z-axis rails attach to the gantry. The system minimizes rail usage.

Linear rails and bearings direct the motion of the router. Profile linear rails have a higher load capacity and are ridged. These rails operate at lower speeds due to more friction. Warped structures the rails attach to cause the bearings to become unmovable. The X, Y, and Z-axis use these.

Liner drivers attach to motors and linear rails. The motors cause the drivers to move which cause the rails to move. Rack and pinion drivers allow splicing for larger axes. Low torque motors work with rack and pinion drivers and create high efficiency. Larger CNC routers use them for the X and Y-axis. ACME screws are efficient for smaller axes. They are more accurate than rack and pinions but the difference is negligible in larger units. ACME screws are slower than rack and pinions. Larger CNC routers use them for the Z-axis. 

For this design, a rail only bed is chosen for the use of fewer materials. The moving gantry allows for more coverage of the router. The profile liner rails allow for high load. The liner drivers allow for both longer and shorter axes and the efficient use of different types of drivers.

Why:

Solution 2 meets most criteria but falls behind in the specification regarding efficient parts.

Solution 3:

Concept:
The material bed chosen is a solid bed. This structure consists of either metal or wood and is the table that supports the entire the device. The linear rails, drivers, and the gantry are on top. This design optimized for backlash because the devices are installed directly into the bed rather than placed on top and more material is used as support. The bed is the table that allows the machine to fit any size requirement because suitable tables are required for beds that contain just the rails.

A static gantry is used when the material moves on the rails. This design contains a hybrid design. The router attached to the gantry moves on the X and Y-axis. The gantry is layered to incorporate the two different moving axes. The Y-axis is doubled  to incorporate the size of the cutting material. A static gantry has less interference with wires.

Linear rails and bearings direct the motion of the router. Round linear rails have a lower load capacity compared to profile rails but the rails work. These rails operate at higher speeds due to less friction. Warped structures the rails attach to do not cause the bearings to become unmovable. The X and Z-axis use these. The Y-axis uses drawer slides. Smaller machines use drawer slides because the slide has to move in and out of the slide casing in order to move which causes the machine to displace more space. Slides are not equipped with the ability to use linear drivers. The slides are common and can carry large loads.

Liner drivers attach to motors and linear rails. The motors cause the drivers to move which cause the rails to move. Rack and pinion drivers allow splicing for larger axes. Low torque motors work with rack and pinion drivers and create high efficiency. Larger CNC routers use them for the X and Y-axis. ACME screws are efficient for smaller axes. They are more accurate than rack and pinions but the difference is negligible in larger units. ACME screws are slower than rack and pinions. Larger CNC routers use them for the Z-axis. 

For this design, a solid bed is chosen for stability. The hybrid gantry allows for more coverage on the Y-Axis and less wires. Drawer slides carry larger loads. The round liner rails allow for slight warping of wood. The liner drivers allow for both longer and shorter axes and the efficient use of different types of drivers.

Why:

Solution 3 does not meet most criteria. The solution falls behind in the support of desired cutting material, efficient use of parts, and size of machine.

Solution 4:

Concept:
The material bed chosen is a solid bed. This structure consists of either metal or wood and is the table that supports the entire the device. The linear rails, drivers, and the gantry are on top. This design optimized for backlash because the devices are installed directly into the bed rather than placed on top and more material is used as support. The bed is the table that allows the machine to fit any size requirement because suitable tables are required for beds that contain just the rails.

A static gantry is used when the material moves on the rails. This design contains a generic static gantry where the router attached only moves on the Z-axis. The material bed is attached to rails that move the material on the X and Y-axis. This design reduces the size a CNC router can support because the machine size is doubled to cover the entire size of one particular piece of cutting material. The material bed is layered because one layer is attached to the x-axis rails and the other layer is attached to the Y-axis rails. A static gantry has less interference with wires.

Linear rails and bearings direct the motion of the router. Drawer slides are used for smaller machines because the slide has to move in and out of the slide casing in order to move which causes the machine to displace more space. Slides are not equipped with the ability to use linear drivers. The slides are common and can carry large loads. These slides are used for the X and Y-axis. A profile linear rail is used for the Z-axis. Profile linear rails have a higher load capacity and are ridged. These rails operate at lower speeds due to more friction. Warped structures the rails attach to cause the bearings to become unmovable.

Liner drivers attach to motors and linear rails. The motors cause the drivers to move which cause the rails to move. Rack and pinion drivers allow splicing for larger axes. Low torque motors work with rack and pinion drivers and create high efficiency. Larger CNC routers use them for the X and Y-axis. ACME screws are efficient for smaller axes. They are more accurate than rack and pinions but the difference is negligible in larger units. ACME screws are slower than rack and pinions. Larger CNC routers use them for the Z-axis. 

For this design, a solid bed is chosen for stability. The static gantry eliminates wire interference. Drawer slides carry larger loads. Profile linear rails are rigid and allow high loads. The liner drivers allow for both longer and shorter axes and the efficient use of different types of drivers.
Why:

Solution 4 does not meet most criteria. The solution falls behind in the support of desired cutting material, efficient use of parts, and size of machine. 

Specification Grid:

Specification Grid
Specifications	Solution 1	Solution 2	Solution 3	Solution 4
The CNC router must be able to cut desired material precisely.	+ The machine is designed to cut wood.	+ The machine is designed to cut wood.	+ The machine is designed to cut wood.	+ The machine is designed to cut wood.
The machine must be able to support 2’x4’ pieces of plywood	+ The machine can support the load and size of the piece of wood.	+ The machine can support the load and size of the piece of wood.	- The machine can support the load but not the size of the piece of wood.	- The machine can support the load but not the size of the piece of wood.
The machine should use the most efficient parts.	+ The solid bed allows for stability. The moving gantry allows surface coverage. The linear rails allow for warping of wood and load. The linear drivers allow for larger and small axes.	- The rail bed does not allow stability. The moving gantry allows surface coverage.	- The solid bed allows for stability. The hybrid gantry does not allow for coverage of surface area. The linear drivers allow for larger and small axes.	- The solid bed allows for stability. The static gantry does not allow for coverage of surface area. The linear drivers allow for larger and small axes.
The machine should be of the smallest size possible to cut a 2’x4’ piece of plywood.	+ The machine is just large enough for 2’x4’ pieces of wood.	+ The machine is just large enough for 2’x4’ pieces of wood.	- The machine is too small for 2’x4’ pieces of wood.	- The machine is too small for 2’x4’ pieces of wood.
Tally of Ratings	4+	3+	1+	1+

Final Solution

I intend to develop solution 1. The solution meets all specifications. The solid material bed allows for stability. The moving gantry allows greater surface area coverage. The only down fall is that the wiring is longer. The linear rails allow wood to settle over time. Since the machine will be in an environment that is close to the ocean, the wood may warp. These rails are not affected by warping and are made from materials that do not rust. The combination of rack and pinion and ACME screws allow for different sized rails.