rung fu clone RF-45 ZX45 cnc conversion

[jumps4]

This may be a little early to start this because i'm waiting for all the parts but here is what i have so far
I thought this was going to be pretty easy but what I'm finding out is there are really a lot of different versions of this mill with all different z axis column lift configurations so I'm not going to have the luxury of using someone elses plans. Oh well just adds to the fun
I have the mill and I took it apart after a 2 hour check out run, I have never used it it's new.
I have my motors for the 4 axis and power supplies they are 4200 oz/in for z, 1600 oz/in for x and y, and an 800 oz/in for a rotary index. the power supplies (3)will be running 60 volt and the 4200's controller has it's own power supply.
I'm still waiting for the ball screws, bearings, couplers and a 5 axis breakout board with relay.
once I get the mechanical parts I can start on the motor mounts. these will be direct drive and that is why the motors are so big. the gear head on the mill weighs 300lbs and I wanted to use this mass to keep down vibration so I'm not going to use lift cylinders on the head.
here are some pics of what I have so far and i will give my list of parts and cost when I get it all together
I figure starting this now will help remind me to take pictures but I also going to be slow because of my health I cant lift anything or stand for very long, so I'll be waiting for my son and son-in-laws help for a lot of this
steve

 

[jumps4]

Re: zx45 milling machine cnc conversion

these are not in any order but it shows what I'm up to
steve

 

[jumps4]

Re: zx45 milling machine cnc conversion

i'm also waiting on another 4200 motor it got beat up on the junk from china

 

[jumps4]

Re: zx45 milling machine cnc conversion

parts list so far
prices include shipping and tax if any
wholesale tools zx45 mill including tax $1920.65 I picked it up local
3 motors, driver, power supplies ebay#170796217146 $896.00
2 10mm x 14mm shaft couplings ebay 251009617349 $17.98
hand pump oiler ebay 170658580507 $49.95
ballscrew kit with bearings ebay 290649528399 $410.00
large shaft coupling 12mm x 19mm ebay 370594678819 $33.99
5 axis breakout board w/relay ebay 290536178924 $26.99
aviation plugs 10 total ebay 110925099663 $19.50
shield wire 100' ebay 160632659191 $100.00
estop and limits from cnc4pc.com $40.00
I also purchased another motor set 3 axis to use for the 4th axis on this mill and to cnc my 9x20 lathe it's ebay #200740129338 i'm using 1/3 of the kit for this mill so that is 164.00 added to this cost. also this kit had 3- 60v 300watt power supplied not 1 as pictured. the company offered the different kit to me to save them import fees it was in cal.
so total cost so far not including little items like wire connectors terminal strips ect is
$3701.31
here are pics

 

[jumps4]

Re: zx45 milling machine cnc conversion

For the lighted power switch and circuit breaker for the control wiring I have found a new power strip cheap ($3.50) and I'm going to take the parts from it
It is cheaper than trying to buy the parts local and the breaker is 15 amp. I'll post a pic when I take it apart. I'm also looking for a relay to turn on the power supplies since they are 6amp peak each and there is 4 of them. when I power this on all the motors are in braking mode 50% load so I wont want all that on the main power switch I'd prefer it to be on a relay.
steve

 

[jumps4]

Re: zx45 milling machine cnc conversion

another note I'm adding a switch to turn off the 4th axis power supply unless its in use no need to have it running all the time

 

[hq308]

Re: zx45 milling machine cnc conversion

Look's like a good well thought out project so far Steve.

Looking forward to watching you progress on this.

 

[jumps4]

Re: zx45 milling machine cnc conversion

thank you david
after sleeping on this last night I have decided to make this all 220v. this will require me to run a dedicated "4" wire 220 circuit from my breaker box to another breaker panel with seperate breakers for the mill, power supplies and 110 circuits. there will be parts like the cooling fans and ac relay circuit that will still be 110v so I will require a ground circuit (white wire )and an equipment ground circuit (green wire). there is too high of an amp load to have the mill and the power supplies,drivers and motors all on one 110v circuit. plus In the future I'm intending to change this 2hp single phase motor to a 3hp 3 phase motor and vfd for speed control, so the 220 will already be there for that. and there will be a coolant pump also. looks like my son and son-in-law will be digging a ditch for the new wire to the house :thinking: I'll draw this all up from the main home load center out and include it with the control circuit drawings.
steve

 

[brucer]

Re: zx45 milling machine cnc conversion

when do you plan on granite epoxying the base?

 

[jumps4]

Re: zx45 milling machine cnc conversion

I have given that some thought but not yet.
I'm intending on putting the y axis motor on the rear for more room up front and I will be working on the base a lot. dont want it too heavy yet. I cant lift anything so I will be waiting for my son to help me out. also on a lot of the conversions I see they leave the y and z axis ballscrew ends loose. I dont want the screw to whip so I'll be mounting both ends thats going to take careful alignment.
steve