In 2006, I purchased a working SuperMax YCM-30 milling machine from a machine shop in Ann Arbor, Michigan. The milling machine was built for CNC and outfitted (back in 1985) with an Anilam Crusader 2 CNC Controller. The controllers were state of the art in 1985, complete with 386 microprocessors. It reminded me a lot of the AertoTech retrofitted Bridgeport that I used at the University of Pittsburgh, except the SuperMax did not have a tool changer. The SuperMax milling machine soon became lovingly known as "Annie". (I'm not the only guy that names his machines after women, am I? ) Truth be told - Annie was a bitch on wheels...
The milling machine was very robustly built, and had seen little use over the years (even the chrome and the scrapings were still on the ways). The machine weighs in excess of 2500# (~1 135 kg). The Machine Shop owner stated that it was the first machine he had purchased when he went into business for himself, and it earned enough money on jobs to allow him to purchase a 20" x 40" Mazak with an automatic tool changer. After the Mazak was in place - the SuperMax was used for small jobs not requiring a tool change, etc.
So I purchased BobCAD because it had a Post Processor for this machine, and I could get it at a reasonable price.
Additionally - I also knew people that were machining fairly intricate things with BobCAD.
My experience: I had nothing but a lot of trouble getting even the smallest G-code file from BobCAD into the Anilam Crusader 2 via an RS-232 serial cable and sending/receiving method.
Sometimes - it would work!
Most times - it was at least a 2 day struggle to get the code into the Crusader and working properly.
It was obvious, If I wanted to really use this machine - then I needed to upgrade the controller on Annie, so that I could use any CAM program I chose to create the G-code. (such as VCarve and Cut3D - which are truly awesome software packages.)
I looked around the market, and settled in on Larken Viper200 Servo controllers - due to the fact that they could handle the high DC Voltage and amperage that was already in the machine (the Anilam Power Supply was still good and very high power - running at 125 volts DC). I really didn't want to lose any of the power in moving the milling table around.
This blog is to give others a loook into how to do this type of conversion.
Warning: If you know nothing about electronics or working with what are truly lethal levels of electrical voltage - DON'T DO THIS!!! You will Die! Let me repeat - You WILL DIE!
Disclaimer: I am not an electrician nor am I an electrical engineer - I am a HACK. I live dangerously.
Disclaimer: Don't do what I do - You Will Die!
Disclaimer: This project is not for someone that is not tenacious!
Disclaimer: Ok, now that we have the necessary warnings and disclaimers out of the way, let's take a look at how to upgrade this puppy.
Larken Viper200 High Voltage/High Current Servo Controllers.
CNC4PC C1 Break Out Board (aka "BOB").
US Digital E5 Differential Rotary Encoders, 1000 CPR.
US Digital shielded cables and latching connectors.
An old IBM NetVista Computer, with a parallel printer port and running Windows XP.
Mach3 Controller Software (the best controller software in the Galactic Universe!).
American Rotary 3-Phase Converter.
Some miscellaneous hand tools (e.g. terminal connector pliers, soldering iron, voltmeter, etc.).
Total Material Cost: Approx $1,500 US (in 2009) - and a lot of sweat equity.
Moving Annie the Milling Machine Home
Rotary 3-Phase Converter:
Rotary Encoder Installation:
Hooking up Larken Viper200's, and CNC4PC BOB:
A lot of people have asked me "How the heck did you move that massive thing?", after they see Annie.
Annie weighs over 2500# (1 135 kg)
I called a couple of rigging companies - and they all wanted in excess of $2000 to move the machine and set it in place in the garage.
I figured - heck, I move a 3500# car around all day by driving it - why is this so tough?
Here is how I did it - I am not saying that it is safe to do it this way, nor am I recommending it - but...:
I over-pressurized my truck tires to 60 psi, the maximum inflation pressure of the tire. This was done to accommodate the additional weight, and I de-pressurized it back to 35 psi after this adventure was over.
To load Annie - the machine shop owner lifted it with a forklift and tow strap, and set her down right over the rear axle of my GMC Sierra Truck (a half-ton rated truck).
I had brought some 2x4's and created a truss between the front edge of Annie's base, and the front side of the truck bed. This was done to prevent Annie from sliding forward should there be a panic brake stop.
I lowered the table as far as it would go, to lower the center of gravity.
I then used ten 10,000# rated ratchet straps, tieing four (4) around the middle to the corner bed hooks, and the fifth one to the trailer hitch receiver. I did this at the middle and at the top of the machine, taking up all ten (10) heavy duty ratchet straps.
I chose to move this mid-day on a Saturday - when there were no special events going on to minimize the traffic.
It was an adventure. About 6-7 people almost collided into the side of the truck - gawking at the massive milling machine in the bed (Hey, how can you help but stare at that beautiful baby? :).
I'm sure if I had to make a panic stop - it would be all-over for me, and I'd probably win a Darwin Award for my stupidity.
I'm not sure that the truck was entirely legally loaded either (*blush*).
Once I had Annie at her new home, I had a tow truck with a telescoping boom come out - and pick Annie up 1 inch, while I steadied the mill by hand. The tow truck boom has to be very well centered over the milling machine - or it will swing.
Once Annie was airborne and steady, next we pulled the pickup truck out from under Annie, then the tow truck driver backed Annie into the front of the garage, and set her down on a bed of 0.75 inch diameter solid steel rods I had placed there..
Once Annie was on the steel rods, she could be rolled around the garage by hand at that point. I immediately closed the garage door and started degreasing her (after I paid the tow truck driver, of course).
Sorry that I don't have a picture of this.
My total cost for moving her was around $150. $120 for the tow truck, and $30 for renting the ten heavy duty ratchet straps.
I would NOT recommend moving a large piece of equipment in this way, it could be dangerous. Ok, it WAS Dangerous. If I had it to do all over again, I would have rented a heavy duty open bed trailer, with electric brakes - and moved it that way.
To move Annie around the garage - I use a great big pry bar that I have purchased from Uline: H1452 Pallet Buster Bar ~ $100, and some solid rods or thick walled pipes.
I wanted to keep all the power that was currently in the Anilam Controller - it is impressive how it can move the massive millling machine table - with up to 750# of load on it.
I had seen some upgrades that removed coils from the transformer to lower the voltage - but I definitely did not want to go that route.
I also wanted to keep the upgrade cost at an absolute minimum.
Therefore - I had to re-use the SEMco Servo motors and the Anilam's beefy 120 Volt DC (yes DC, Direct Current) Power Supply
The decision to re-use the existing power supply - necessitated finding a controller that could handle both the voltage and current of the existing power supply (120 V DC, and 15 Amps).
After a market search - I discovered that LarKen had two (2) controllers out that would handle this high voltage - the Viper100 and the Viper200. The Viper100 could handle voltages up to 125 Volts DC, which wasn't much "head room". Therefore - the decision was the Viper200.
Meko and I discovered that the existing Heidehahn glass scale encoder was not compatible with the Larken Viper 200's.. so I had to install rotary encoders onto the servo's that were compatible with the Larken Viper200's - to get the whole system talking to one another.
Meko and I had a discussion with Larry Kenny (CEO of LarKen), and he informed me that to date - people had good results with the US Digital encoders, and he recommended a 1000 Count Per Revolution (CPR) and a differential encoder if runs were over 10 feet (which the X-axis would be close). It made sense from an EMI standpoint to use differential encoders and shielded wiring through out.
Meko and I spoke to US Digital engineering help line - and they also recommended a Differential encoder and shielded cable.
Meko and I looked at the various mounts available at the time - and chose the E5 mounting package,.
A quick look into the end of the servo motor - after removing the tachometer board - found a stout 5/8" diameter armature shaft - beefy enough for me to press in a shaft for holding the encoder disk.
Meko, me, and a skilled machinist center the servo armature, and drill and ream for a 0.25 inch diameter shaft - light press fit.
We stuffed paper towels into the open areas of the servo - to prevent metal chips from entering the windings.
Meko and I pressed in a 0.25 inch diameter drill rod material as the stub shaft to hold the rotary encoder optical disk.
US Digital E5 Rotary Encoder Specifications sheets (right click to download).
Meko and I also used the US Digital CA-FC10-SH-NC 10-Pin Latching Unterminated Shielded Cable. Using the differential rotary encoder - and the shielded cable from US Digital - insured that things like Electro-Magnetic Interferenced (EMI) would not be a problem.
When in doubt - build it stout! (Meko's motto).
Total Cost for E5 differential rotary encoders, shielded cables, and miscellaneous parts - was approximately $300 US. But you will also need a good pair of terminal crimping pliers, and a good (variable heat, good tip) soldering iron to do this properly.
Additionally - Meko and I needed to design and fabricate an endcap for the SEMco Servo motors to position the US Digital rotary encoder sensor body.
Meko and I designed and machined a "temporary" endcap out of tempered hardboard, and installed that on to the servo's to "test" the idea.
I have been using this "temporary" end cap for several years now - and I really need to make a permanent end cap out of aluminum one day soon.
I will place the CAD files for these end caps here in the future.
Sidenote: Did you ever notice that when you're building a CNC milling machine - you really need a CNC machine to make parts for the conversion ???
By the way, SEMco's local office is a great company to work with - and very helpful. I will place the contact information for SEMco here. Even though the SEMco servo motors are original and built in 1985 - they are still going strong!! (Thank Goodness). They still make brushes and what-not for the Servo's and can repair them if necessary. Which reminds me, I need to treat my servo's to some nice new brushes..
First Meko debugged all the wiring on a board - prior to moving it into the cabinet.
The guys at Anilam were super to work with, and gave us an electrical schematic, and that helped a lot (Thank You Jerry Bouvier! You are a walking encyclopedia of information! ).
I will also say that Larry Kenny (CEO LarKen) was great to work with throughout this entire upgrade project, too.
There was a lot of work tracking down every wire from the servo's, the limit switches, etc..., and hooking that up correctly. You can see Meko deep in thought in the picture below.
Meko is one hell of an electrician!!!
I managed to keep enough of the Anilam's circuitry - that I could use the Digital Read Out (DRO) on the Anilam Crusader 2 control panel. This is great news as it enables me to use the mill in a non-cnc / free-hand mode on occasion. Definitely a tribute to how the great engineers at Anilam laid this out as separate circuit structures.
This upgrade has been working flawlessly. The new controllers and hooking everything up to a PC allows me to make massive G-code files in whatever software I want to (e.g. VCarve, Cut3D, etc. etc.).
I highly recommend it to anyone that has a similar machine. You will expand the usefulness of the machine beyond your wildest dreams.
Next Projects: X0-Y0 Edge Finder, and a rotary 4th axis !!!!
Annie's column motor is a 3 Horsepower 220 Volt AC 3-Phase motor.
Meko and I had installed 220 Volts AC in the garage, but the 3-Phase was the issue.
After a bit of reading up on the internet - Meko decided to use a rotary converter (versus a static converter), as it could be used to start other 3-Phase motors
Once the 3-phase converter type was set, a quick look around the internet, and reading various reviews, we settled in on an American Rotary brand. I can't say enough good things about the people and the product at American Rotary. They are always very helpful to those that are newbies (like Meko and me) at this game. They didn't care at all that I was only a one man-one dog shop. I have not had one single problem with that phase converter in the entire time that I've used it. It's quiet, and gets the job done.
Yeong Chin: Maker of SuperMax Equipment: YCM Americas, Inc., 9945 S Pioneer Blvd., Santa Fe Springs CA, 90670 USA, (562) 205-9268
SEMco Servo Motors:
ArtSoft Mach3 Controller Software - the greatest controller software on the planet.