Automated drilling machines

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Revision as of 12:23, 26 May 2021 by Tim (talk | contribs)
Project: Automated drilling machines
Tools: Wrenches
Parts: Frames, Nuts, Bolts, Plates, End caps
Techniques: Shelf joints, Tri joints

Introduction

Challenges


Frames can be manufactured by hand, with careful measurement and drilling. While meditative, this work is repetitive and laborious. Time studies of the hand production process using a drill press reveal that positioning the undrilled frame stock for precise drilling consumes the majority of effort. Automating the process in an affordable manner will reduce cost, increase availability, and free time for creative effort.

Approaches

Drill guide

Gang drill

Dual gripper drill

Challenges

Reducing cost and improving availability of replimat frames requires decentralized manufacturing.

Approaches

A frame drill built from standardized and widely available industrial automation components allows anyone to source the parts they need anywhere to build more frame drills.

This frame drill design makes use of two independently controlled and actuated industrial grippers to move and hold square stock for drilling on all four sides by independently actuated high speed spindles.

Parts

Flat pack frame drill

The frame drill automatically drills regularly spaced holes in square raw material to produce reusable Replimat frames. It is constructed of a number of custom plates, motors, a controller, and several 3D printed parts.

Tools

Parts

Part Quantity Supplier
Plate - drill machine
 2 OpenSCAD File
Plate - spindle
 1 OpenSCAD File
NEMA-17 stepper motor 3 Link
roller-raw-material 12 CAD File
Spindle 1 ER16 500W High Speed DC 48V Air Cooling Brushless Spindle Motor + Driver
LM8UU Bearing 1 - pack of 2 Amazon
Drive belt
Drive pulley
Controller
Neoprene foam w/ adhesive backing Amazon
Drill bit
Rail Guide Support for 16mm Diameter Shaft 1 - pack of 4 Amazon
Rail Guide Support for 8mm Diameter Shaft 1 - pack of 4 Amazon
350mm 8mm T8 Lead Screw Set Lead Screw+ Copper Nut + Coupler + Pillow Bearing Block 2 Amazon
Oilite drill bushing 2 Mcmaster

Avid CNC 60120 Pro

Fully automated production development kit

20mm Parts

Quantity Part Rationale Unit cost Total cost
50 20x20x40mm (2 hole) frames standard length frame 250 total meters of 2020, covering the full quantity needed for all lengths $697
50 20x20x60mm (3 hole) frames standard length frame "
50 20x20x80mm (4 hole) frames standard length frame "
50 20x20x100mm (5 hole) frames standard length frame "
50 20x20x200mm (10 hole) frames standard length frame "
50 20x20x300mm (15 hole) frames standard length frame "
50 20x20x400mm (20 hole) frames standard length frame "
50 20x20x500mm (25 hole) frames standard length frame "
50 20x20x600mm (30 hole) frames standard length frame "
50 20x20x800mm (40 hole) frames standard length frame "
50 20x20x1000mm (50 hole) frames standard length frame "
50 20x80x1000mm (4x50 hole) frames standard length, 4x width frame $452.18
500 90 Degree Corner Connector For strengthening corners, attaching linear axes, shimmed mounts $400
20 Cable Drag Chain 15x20mm keeping wires tidy - quantity provisioned for two 4 axis machines plus maintenance and experimentation $69.80
2000 Spring Loaded M5 T-Nuts for 2020 V-Slot The only T nuts worth using $160
1000 Spring Loaded M4 T-Nuts for 2020 V-Slot The only T nuts worth using $80
1000 Spring Loaded M3 T-Nuts for 2020 V-Slot The only T nuts worth using $80
4 HPV6 Linear module ballscrew SFU1204 with Linear Guides HGH15 HIWIN 100% same size with NEMA23 2.8A 56mm stepper motor 200mm Linear motion system for spindle $79 $316
4 HPV6 Linear module ballscrew SFU1204 with Linear Guides HGH15 HIWIN 100% same size with NEMA23 2.8A 56mm stepper motor 400mm Linear motion system for spindle $109 $436
4 HPV6 Linear module ballscrew SFU1204 with Linear Guides HGH15 HIWIN 100% same size with NEMA23 2.8A 56mm stepper motor 600mm Linear motion system for spindle $126 $504
4 HPV6 Linear module ballscrew SFU1204 with Linear Guides HGH15 HIWIN 100% same size with NEMA23 2.8A 56mm stepper motor 800mm Linear motion system for spindle $142 $568
4 HPV6 Linear module ballscrew SFU1204 with Linear Guides HGH15 HIWIN 100% same size with NEMA23 2.8A 56mm stepper motor 1000mm Linear motion system for spindle $169 $676
4 HPV11 Linear module ballscrew SFU1204 SFU1210 with Linear Guides MGN12 NEMA23 2.8A 76mm stepper motor for CNC milling machine 200mm Linear motion system for carriage $157.60 $630.4
4 HPV11 Linear module ballscrew SFU1204 SFU1210 with Linear Guides MGN12 NEMA23 2.8A 76mm stepper motor for CNC milling machine 400mm Linear motion system for carriage $189.50 $758
4 HPV11 Linear module ballscrew SFU1204 SFU1210 with Linear Guides MGN12 NEMA23 2.8A 76mm stepper motor for CNC milling machine 600mm Linear motion system for carriage $211.99 $847.96
4 HPV11 Linear module ballscrew SFU1204 SFU1210 with Linear Guides MGN12 NEMA23 2.8A 76mm stepper motor for CNC milling machine 800mm Linear motion system for carriage $230.99 $923.96
4 HPV11 Linear module ballscrew SFU1204 SFU1210 with Linear Guides MGN12 NEMA23 2.8A 76mm stepper motor for CNC milling machine 1000mm Linear motion system for carriage $255.99 $1023.96
10 1.5kw air cooled aquare spindle motor 24000rpm HQD factory $1860
10 VFD for spindle
6 Pumps
4 Barrels
4000 M5 nylock nuts
1000 M5 1 hole bolts
2000 M5 2 hole bolts
1000 M5 3 hole bolts
Total $10,190

40mm Parts

Parts

Quantity Part Rationale Unit cost Total cost
50 40x40x80mm (2 hole) frames standard length frame, quad 2020 200 meters from our least costly supplier, available in sizes up to 1m long, satisfies the need for this material at $2,018
50 40x40x120mm (3 hole) frames standard length frame, quad 2020 "
50 40x40x160mm (4 hole) frames standard length frame, quad 2020 "
50 40x40x200mm (5 hole) frames standard length frame, quad 2020 "
50 40x40x400mm (10 hole) frames standard length frame, quad 2020 "
50 40x40x600mm (15 hole) frames standard length frame, quad 2020 "
50 40x40x800mm (20 hole) frames standard length frame, quad 2020 "
50 40x40x1000mm (25 hole) frames standard length frame, quad 2020 "
50 40x40x80mm (2 hole) frames, second source standard length frame, single channel 170x 2400mm sections from 8020 inc would satisfiy all required lengths of frame for $10,193 from 8020 inc. 102x 4000mm sections from Mitsumi arrive at $7,752.
50 40x40x120mm (3 hole) frames standard length frame, single channel "
50 40x40x160mm (4 hole) frames standard length frame, single channel "
50 40x40x200mm (5 hole) frames standard length frame, single channel "
50 40x40x400mm (10 hole) frames standard length frame, single channel "
50 40x40x600mm (15 hole) frames standard length frame, single channel "
50 40x40x800mm (20 hole) frames standard length frame, single channel "
50 40x40x1000mm (25 hole) frames standard length frame, single channel "
50 40x40x1200mm (30 hole) frames standard length frame, single channel "
50 40x40x1600mm (40 hole) frames standard length frame, single channel "
50 40x40x2000mm (50 hole) frames standard length frame, single channel "
8 SDA40 40mm double acting air cylinder SDA40 brackets, adapters, and accessories
16 SDA40 plasma cut adapter plates
8 MHZ240D Pneumatic grippers - current issue is that gripper size is limited to 60mm max
6 PRO Rack and Pinion Drive, NEMA 34 Linear motion system for 40mm $1,018.5
30 PRO Gear Rack, 39" (1 meter) Linear motion system for 40mm $1950
15 HGR20 HGR15 HGR25 Square Linear Guide Rail 2pc+4pcs HGH20CA/HGW20CC HGH15CA Flang Slide Block Carriages For CNC Router Engraving Linear motion system for 4040 - HGH20CA $136.62 $2049.34
4 Avid CNC X/Y axis adapter plates
80 2" Dual Wheel Swivel Plate Caster w/Brake Casters 20x shop floor items on wheels $1.39 $111.20
40 50pcs Thread M8 T Slot nuts 40-M8 Half Round Elasticity Spring Nut 4040 Series Groove 8 Aluminum Profile Connectors The only T nuts worth using $150
2 4.5KW ATC Air Cooled Spindle Motor Automatic Tool Changer 220V+BT30-ER25 Tool Holder+Pull Stud for CNC Router Milling For complex machining operations $1,546.09 ea $3092.18
20 High-Quality Automatic Tool Changer HSK63 ISO30 ISO25 ISO20 BT30 BT40 Spindle Tool Magazine Hardening Tool holders for ATC $5 ea $100
4000 M8 nylock nuts
1000 M8 1 hole bolts
2000 M8 2 hole bolts
1000 M8 3 hole bolts
6 SB-37 NEMA Steel Enclosure house and protect electronics $97.91ea $587.46
12 DIN rails
6 DIN compatible power supplies
8 1" x 36" Keyed Shafting Power transmission, idle rollers, jack shafts $30.85 ea $246.80
2 1" x 72" Keyed Shafting Power transmission, idle rollers, jack shafts $46.25 ea $92.50
20 1 Single Split Shaft Collar constrain shafts $5.20 ea $104
20 1" Pillow Block Bearing Power transmission, idle rollers, jack shafts $11.55 ea $231
40 1/4 Square Key 1.5 Long Secure power transmission components $1 ea $40
6 6 Pack Universal CNC Controller
Total $19,558

Pneumatic parts

Tools

Electrical

Villagekit Grid-bot

[1]

A multi-spindle single-axis CNC.

For the framing, we'll use 8040 aluminium extrusion since it's fit for purpose and readily available here in New Zealand.

Where possible, we'll try to use motion control components found in "pro" consumer CNC machines (AvidCNC, RoverCNC, QueenBee, etc), e.g. stepper motors, lead screws, linear rails, etc.

Notes

  • double check vfd model
  • contract CAD production w/ OpenSCAD / NopSCADLib

Waste flows

Wood sawdust can be processed by pellet presses for burning in an automatic wood pellet stove.

References

References

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