Tech Stuff by Johan

Summer update

2009-07-05T15:07:00.008+03:00

I have not been very active updating my blog lately...summer you know :P much other things going on. I have also started a business with my friend Simon, check out our website here: Protoparts. The site is still under construction so be patient :). We offer Mechanical and automation solutions and prototypes. We offer custom made tube bending dies. contact me for more info. We also sell Megasquirt fuel injection systems and wiring harnesses. We are also planning to open a webshop soon.

I have also began to reassemble the Mazak lathe. I have changed the ballscrew balls, and the ballscrew bearings.

A few picks:

Removing turret from Mazak lathe 14.4.2009

2009-04-14T19:07:00.013+03:00

I have had great use of the engine lift I made a couple of weeks ago, when disassembling and removing the turret of the Mazak Slant turn lathe. The turret is being removed because the ballscrew balls are going to be replaced, and all the turret parts are going to be checked and cleaned at the same time.

This is a old pic of the turret with the toolholders and tools installed...

I was not fast enough to take a picture before my dad had removed all the tools. :)

Tools and toolholders.

Turret indexer on the right hand side. If you look closer it seems like there is a missing part on the PCB! Need to confirm that...

Left hand side. Removing the center part.

Bearing visible.

Worm gear inside turret. The worm screw is driven by a hydraulic motor on top of the turret.

Removed the worm gear. In my opinion Mazak is really quality stuff, these parts are almost 25 years old and in perfect condition.

Turret housing removed.

Turret removed.

To be continued...

Formula renault 5.4.2009

2009-04-05T19:27:00.005+03:00

Lately me and my friends have been working on our endurance bimmer, in order to get it in shape before the season begins. We have replaced the rear wheelbearings and brakepads. We also installed some gauges. About a month ago I was to a MC exhibition, there was a formula renault that was interesting. Take a look!

Engine lift 24.2.2009

2009-02-24T21:53:00.007+02:00

Lately i´ve been making a engine lift, that will be useful when working with cars. I also have several other projects that it can be useful in. It will be handy to have when removing the turret from the Mazak lathe. I am also going to install a new door to the car lift side. Here are some pics!

Ice Racing 19.1.2009

2009-01-19T14:13:00.004+02:00

Great conditions for some ice racing last weekend! I have also been working on the indexing table design.

Last weekend... 14.1.2009

2009-01-14T16:27:00.001+02:00

...I almost lived in the workshop :P. Me and some of my friends was working on our endurance car, we have had some problems with megasquirt. The main problem was that the VR conditioner circuit was sensitive to noise, so the ignition did not work as supposed. That problem is now solved. I had also soldered one wire wrong, the cranc VR signal from the conditioner circuit was not ment to be connected to the input of the 4N25 optocoupler, which I had assumed. All problems are now solved and the engine runs! Here are some pictures of basic settings that we are using with our m42 engine with megasquirt MS1 extra 029y4 firmware. Use at own risk!

Crosscart movie 7.1.2009

2009-01-07T00:16:00.007+02:00

Machining 30.12.2008

2008-12-30T23:41:00.006+02:00

The past days I have spent some time machining different parts, both own and for friends. We have also been working with our endurance car. Currently we are modifying the megasquirt so we can control the ignition timing with it. We are going to use 4 ignitioncoils, one for each cylinder. We are using transistors and schmitt triggers to convert the VR sensor signal to a decent digital signal. We simulated the VR signal with a gear hooked up in the lathe :) The circuit seems to work, at least the rpm figures of the lathe and megasquirt match!

Indexing table 18.12.2008

2008-12-18T19:56:00.004+02:00

Today I have been drawing parts for the indexing table that I plan to build. I have also had the opportunity to work with it at school as a project with two friends, Joni and Sebastian. Joni has drawn the electrical diagrams and Sebastian has drawn some of the mechanical drawings. When I have built and tested the indexing table, that will be a two-axis cnc controlled one, I might add the plans to my blog if someone is interested to have a look ;) or perhaps build one? As I previously wrote I am going to use BL70-300 servomotors and VSD-E servo drives. Here are some pics:

Weekend update 15.12.2008

2008-12-15T00:41:00.009+02:00

This weekend I had the mill running for about 24h :P due to a very long gcode and slow feedrate. What i machined is a model of a garrett t3 turbocharger in scale 1:1. I am quite satisfied with the result. The surface finish is very good considering that I used a drill bit as tool! The main problem was that I had not set up the plunge settings correct, so the part got some unwanted hits. My friend Simon lightened the flywheel of our endurance bimmers m42 engine. He also welded the oilpan, that was leaking. I also did some small progress with the crosscart. Here are some pics:

4-axis machining 11.12.2008

2008-12-11T15:19:00.004+02:00

Here is a video by Hoss: Endmill Sharpening with 4th Axis
Very impressive machining!

Read more about his machine here:
http://www.hossmachine.info
cnczone thread

I found the link here

Painted the tube bender 8.12.2008

2008-12-08T22:49:00.011+02:00

This weekend i decided to paint my tube bender. This is how it looked before...

and after.

Homemade tube bender dies.

This is a solidworks assembly of my differential. The diff is a torsen differential from a Honda S2000.

This is a test assembly before i make the final welds.

I also did some test machining this weekend. Will add a pic of the final result when it gets ready!

Bonus pic! Recent visitor map. My visitors mostly come from Finland and USA.

Solidworks 5.12.2008

2008-12-05T14:25:00.009+02:00

If you are a student you can buy cheap software from studica. I bought Solidworks from their webshop.

Electrical cabinet 4.12.2008

2008-12-04T21:59:00.009+02:00

Here are some pics of the electrical cabinet of the milling machine. The parts come from quite many different sources :). The only parts that were bought new are the contactors and the granite drivers. All the other parts are reused ones. Perhaps not better, but cheaper.

New CNC parts 28.11.2008

2008-11-28T19:36:00.011+02:00

Today I went to the postoffice to pick up some parts to my CNC project. The package contained 2 BL70-300 servomotors with encoders and 2 VSD-E servo drives. The parts are going to be used to convert my 3-axis mill into a 5-axis! I bought the parts from Granite Devices

Details about the VSD-E servo drive:

-AC/BLDC/DC/linear/stepper motors supported
-True HDRT torque control
-12-80 Vdc supply voltage
-10A cont. 20A peak output for AC/BLDC motors
-14A cont. 40A peak output for brush DC motors
-True unstallable stepper control (servo mode), see manual for more details
-Panel installation, 19" rack compatible. See example.
-Regenerative brake resistor output
-Hard to kill: short circuit, over current, over temperature, I²t, over voltage and --under voltage protections
-Inputs: step/dir, quadrature, PWM, +/-10V analog, SPI, Indexer
-Single ended & differential encoder input + hall sensor inputs
-User configurable general purpose I/O

Details about the BL70-300 servomotor:

-Rated power 300W
-Peak power 900W
-Rated speed 3000 RPM
-Cont. torque 1.0 Nm
-Peak torque 3.0 Nm
-Optimal supply voltage 75-95 Vdc
-Cont. current 6.6 Adc
-Peak current 20.0 Adc
-length (L) 90 mm
-Frame size 70 x 70 mm
-Weight Encoder 2.08 kg
-resolutuon 4000 CPR
-Phase resistance 0.74 Ohm
-Phase inductance 1.5 mH
-Poles 8

Source http://www.granitedevices.fi

Crosscart by Bob 24.11.2008

2008-11-24T12:42:00.018+02:00

Here are some pics of Bobs homemade crosscart with a Kawasaki Ninja 600 engine. Enjoy! Last Saturday I got a testdrive :D and all I can say is that it was a blast.

Strands s32 CNC retrofit 23.11.2008

2008-11-23T20:14:00.026+02:00

This is my Strands s32 CNC milling machine. It has been a hobby project to retrofit it with Mach 3, and I must say it has been interesting and I have learned alot about CNC. I now have some basic knowledge about: G-code, CAD/CAM, PID, servos, and how the control system of a CNC machine works. I forgot to take a picture inside the electrical cabinet...will add a pic of that sometime

As you can see I am using Contraves permanent magnet DC servos rated to max 1,7 Nm and 7,9 amps RMS. They are a good match with granite device´s VSD-A. The position feedback to the controller cards is generated with Heidenhain encoders. The X and Y axis encoders are 2500ppr and the Z axis encoder is 1024ppr. The Z axis was originally equipped with a linear scale, but it was easier to use a encoder. There is also another advantage with the encoder: it is easier to compensate for the backlash in the Z axis worm gear. The encoder was easily installed at the backside of the motor.

Machining a prototype part for a intake manifold. The real part will be made in aluminium. In the other pics some various tests :)

Vertical Milling Machine 22.11.2008

2008-11-22T23:18:00.003+02:00

If you don´t have a mill check it out!

Description:

• Meehanite® casting
• Precision bored and honed milling head
• Large diameter quill is chromed
• High precision Class 7 spindle bearings
• Chrome plated motor shaft with lower bearing support
• Spindle head is internally cooled
• Satin chrome finished dials
• Heavy-duty splined motor drive
• One-piece quill pinion and shaft
• 3-stage power downfeed with automatic stop
• Heavy-duty spindle brake
• Locks on all movable surfaces
• Precision hardened and ground ways and table
• Adjustable gibs throughout
• Internal coolant tank built into casting base for use with coolant system (Coolant pump not included)
• Tolerance test sheet included

Standard Equipment

• One-shot lubrication system
• Way covers
• Draw bar
• Tool box with tools

Specifications

• Table Size (in.) 9x49
• Spindle Taper R-8
• Diameter of Quill (in.) 3-3/8
• Number of Spindle Speeds Variable
• Range of Spindle Speeds (RPM) 60 - 4,200
• Downfeeds of Spindle (per/rev./in.)
0.0015 - 0.003 - 0.006
• Spindle Travel (in.) 5
• Head Movement 90°R&L45°F&B
• Distance Spindle to Table (max/in.) 17-1/2
• Distance Spindle to Column (min./in.) 6-3/4
• Distance Spindle to Column (max./in.) 19
• Collet Capacity (in.) 1/8 - 7/8
• Longitudinal Table Travel (in.) (X-axis) 36
• Cross Travel (in.) (Y-axis) 12
• T-slot Number & Size (in.) 3 and 5/8
• T-slot Centers (in.) 2-1/2
• Maximum Weight of Workpiece (lbs.) 660
• Travel of Knee (in.) (7-axis) 16
• Travel of Ram (in.) 12-1/4
• Motor 3HP, 3Ph230/460V Prewired 230V
• Dimensions 65-1/2"W x 63"D x 80"H
• Net Weight (lbs.) 2,420

Vertical Milling Machine - you can find it here

jettools

Geared Head Bench Lathe 22.11.2008

2008-11-22T22:37:00.011+02:00

Geared Head Bench Lathe - 13'' Swing 40'' Centers, 2Hp, 1 Ph, 230V
In my opinion this would be a good hobby lathe suitable for small parts.

Specifications:

• Swing Over Bed (in.) 13
• Swing Over Cross Slide (in.) 7-25/32
• Swing Through Gap 18-3/4
• Length Of Gap (in.) 8
• Distance Between Centers (in.) 40
• Hole Through Spindle (in.) 1-3/8
• Spindle Mount D1-4
• Spindle Taper (with Sleeve) MT-5(MT-3)
• Number Of Spindle Speeds 8
• Range Of Spindle Speeds (RPM) 70-2,000
• Number of Longitudinal and Cross Feeds 40
• Longitudinal Feeds range (in./rev) .0036 - .1005
• Range of Cross Feeds (in./rev.) .0012 - .0345
• Number Of Inch Threads 40
• Range Of Inch Threads (T.P.I.) 4 - 112 T.P.I.
• Number Of Metric Threads 27
• Range Of Metric Threads (mm) 0.2 - 6
• Max. Tool Size (in.) 5/8 x 5/8
• Compound Slide Travel (in.) 2-11/16
• Cross Slide Travel (in.) 6-5/16
• Carriage Travel (in.) 35
• Tailstock Spindle Travel (in.) 3-3/4
• Taper in Tailstock Spindle MT-3
• Steady Rest Capacity (in.) 2-5/8
• Follow Rest Capacity (in.) 2-3/4
• Width Of Bed (in.) 7-3/8
• Dimensions w/Stand: 71"L x 32"W x 47"H
• Main Motor 2HP, 1Ph, 230V Only
• Net Weight (lbs.) 1,015

Geared Head Bench Lathe - you can find it here

jettools

Some pics of the Tube bender 18.11.2008

2008-11-18T15:53:00.012+02:00

Click on the pics to view in detail

The crosscart project 15.11.2008

2008-11-15T13:24:00.013+02:00

This is my crosscart! I am designing it in solidworks, in my opinion the best CAD program available.

the engine is from a Honda CBR 1100 Blackbird -98, so it´s with carburettors. The newer ones are with fuel injection, but the ones with carburettors have got higher peak HP, 164 HP!! I´m considering to convert to megasquirt, but that´s a future project...have to get it running first.

I bought the engine from korvanto

workshop

2008-11-12T20:50:00.026+02:00

Behind the crosscart frame you can see the Strands S32 CNC mill that i am retrofitting with Mach3. Originally it has been 3-axis, but I am planning to add two more so that i can machine more complex parts.

On the rigth side of the picture you can see my homemade beltgrinder, made from junk parts.

This is my welding machine, a Wallius LKM 220. I´ve had it for some years now, and it has been working great!

This is my Optimum Opti S 275 G Bandsaw. Nice to have!

Tos FGHE 32 manual milling machine. Old but functional. The electrical control system has been renewed with a Siemens s7-series PLC.

Harrison V390 manual lathe equipped with Heidenhain digital readout. Infinitely variable spindle speeds with digital display.

Mazak slant turn 1000 CNC lathe. In need of some small repair.

Index GS 30 CNC Lathe. A future retrofit?

Home made tube bender. I made this one before i started building the crosscart.

Initial test!

Finally a picture from the electronics corner

contact

2008-11-12T18:29:00.001+02:00

Feel free to comment on the blog or to contact me by email: nygard.johan@gmail.com

bookmarks

2008-11-01T13:37:00.000+02:00

Bookmarks

bil --AutoPower.se - Skandinaviens största oberoende märkesinriktade bilsajt . WWW.DC-ICE.EE . CAR TUNING AND SOUND . TuningStore . 74fuely Gallery Cosworth & RS Club Diesel Performance Club dp vehicle home DUBMODDER Interactive Car Customizer ffp motorsport - Fast Fruit's performance - vw-audi-seat tuning ffp motorsport Fred's TDI Page. TDIClub.com. VW TDI Enthusiast Community HOT CARS Mersuforum - Kanava suomalaisille Mercedes-Benz -harrastajille! OCL-Brorssons Performerz Visa Ämne - MegaSquirt Project EuroTrash - eurotuner Ray Hall Turbocharging - Main Page Styling Kompaniet Syötön säätö eli ruuvaus The ECOdiesel Web Site Toyota Supra mk3 bilforum trimma filmer covers Turbo charged VW diesels VW Diesel Tachometer VWvortex Forums Tuned my MK2 diesel Webbshop www.holysmoke.fi Päävalikko www.savarturbo.se Index Sölves aktiviteter - förr och nu. Ståhlmotor, bilar, motorer. -- h o c k y . s e -- Kristoffers sida Roadster Bil AB hemipanter bmwturbof1engine Motornord - BMW reservdelar, BMW tillbehör, Chipstrim Car Bibles : The Car Suspension Bible suntechmotorsport 50 Dollar Paint NordicAudi.com www.MegaSquirt.se - Home -::Topplocksverkstans 4-Takt::- * * Automotive Programs by Bowling & Grippo * * Anders bra-att-ha-sida för 02-en
bok . . . C a d m u m . . . Amazon.com Böcker och litteratur - AdLibris Bokhandel
CNC cad cam, dnc, cad cam software, cnc software, dnc software, wireless dnc, drip feed dnc CNC-Arena.de + CAM-Forum.de CNCzone.com-Links CNCzone.com-The Ultimate Machinist Community- The best place to discuss diy cnc machine, mill, lathe,EDM, and cad-cam software, Community for Software Engineers http--www.ersatzmonitor.de Order form simatic download Peters CNC-Ecke 2 Peters CNC-Ecke Shop Floor Automations Siemens - Automation and Drives - Service& Support - Automation Service, Automation Support, Simatic Service, Simatic Support, Siemens Automation and Drives - Service & Support - Technical Forum (Guest) SIGBI System AB erbjuder frekvensomriktare, plc, servo, positioneringssystem, stegmotorer, mjukstartare, dc-bromsar och emc-fil Soft Servo Systems, Inc. PC-Based Motion Control Zeilentrafo PLC-programmering Tekniksidan :: Visar forum - Cnc och Nc maskiner Fanuc 5T problem http://www.roboty.fi/ Fanuc [Archive] - CNCzone.com-The Ultimate Machinist Community Fanuc Fuse: Fanuc drive units, control boards, power supply fuses. JTEK Machinery, Inc. Online Shopping - Daito:P413 Online - Ersatzteillager von Kuhn Industrietechnik - Sicherung 30A 250V PCI30 Online - Ersatzteillager von Kuhn Industrietechnik - Suchen - P413 CNC Fanuc Heidenhain Service parts for industry Teollisuus työstökone osia Camtek - Etusivu R991H High speed servo motor drive - analog output CNC Mill BF20 CNC - Tero's Project Corner Granite Devices | A Servo Drive Company Granite Devices | Products Alströmergymnsiet CNC-teknik introduktionskurs MechMate CNC Router - Build your own with free plans All Motion AB - Elmotorer Växlar Dc Motorer Stegmotorer & Dc Motor 12v Skyko Technologies - Products mach 3 video tutorial Peter Homann Designs modbus Rapid prototyping plast Finsk homemade cnc Motion Control Products Ltd, For all thats in motion...... cnc hembygge CNC Links DrMachines.Com www.solectro.se © Solectro 2008 servomotorer Touch Screen and panel controls using ModIO - MachCustomizeWiki Share Your Files Part or Art - Page 205 - CNCzone.com-The Ultimate Machinist Community SR CNC Brain
crosscart About Changing the Honda Reg-Rect Byggebilleder 2002 - Team Benzon Crosskart crosskart.no Crosskart Duells - Moped MC Reservdelar Tillbehör Cykel Marin ATV JMHKarts.com - Bullfrog Buggy Plans Sporthoj.com - Sveriges Största Hemsida För Motorcyklister - powered by vBulletin Super Blackbird Info Superblackbird.se Forum Index www.drakart.com-images-duneyellow.gif 2.0 PRO SERIES Härvelit Uusitalo Racing - Minibuggy steering The EDGE Products - Introduction Page cad plans harvelit http://www.nmine.com/tras.jpg The Complete Kartbuilding Website : Free Racing Kart Plans Le kart cross monsterkart http://ursa.irk.ru/manual/ Desertkarts Links Page Dune Buggy Parts, Sandrail Parts, VW Parts - MooreParts.com 2.0 12 " TRAVEL, 5/8 SHAFT, EMULSION SHOCK - Etusivu | bull-speed - www.harvelit.com - Home
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projekt johan and simon´s Toyota corolla ke20 Hembyggd bromsbänk! BUILDING A HYDRAULIC DYNO climber's info on AVR programming - Interrupts T.E.A.M. Racing Studica Skills
rita CAD CAM psMetalltechnik Ritningar SolidCAM - the Gold-certified integrated CAM-Engine for SolidWorks SolidWorks library - Oberview SolidWorks Partner Directory Welcome to 3D ContentCentral (SM) Ritningar Vizualtech Animate.se - Det svenska forumet för 3ds max, Viz, Combustion, Maya Car Blueprints Graphic Artist's Resource solidworks --:> 3dsmax problem The Blueprints - Reference Image Database Good-Tutorials / Photoshop Tutorials + Flash Tutorials Machine Design 3D CAD Library CAD software EAGLE CamBam Free Mechanical Engineering: CAD Software Camnetics CAD / CAM - Practical Machinist - Largest Manufacturing Technology Forum on the Web
verkstad http--www.multi.fi-~kkock Industritorget.se är länken mellan inköpare & leverantör - För svensk verkstadsindustri. KDI DIGITALUTRUSTN. Svarv ,Fräs , upp till 1700 mm www.finnmet.fi - Metallportalen i Österbotten www.vossi.fi - Vossi Työstökoneet - Vossi Machine tools Metallituotteiden tukkumyynti - Pietarsaaren Kaupunkiopas Free Home Workshop Plans Compliments of David Lee's Junkyard Projects Tube Bending Machinery, Pipe Benders, Tubing Notchers, Bead Rollers Kullager.se - Kullager, Hjullager, Kilremmar, Motorcykellager, Nållager - Kullager.se har det mesta! Startsida scand tig åmål svets tigsvets tig-svets svetsar slangpaket svetsskärm svetshjälm Metal Meet Forums - Powered by vBulletin Kvarken.com - Hem Nettikone - Vaihtokoneet - Pikahaun tulokset Chronos Ltd Other Milling Vices R.A Tools OY Mekanex AB - Voimansiirto - lineaariyksiköt Steve Bedair's 9x20 Lathe Site kuggteknik.se Practical Machinist - Largest Manufacturing Technology Forum on the Web - Powered by vBulletin
övrigt Evi -metsäkoneet How can I know if my engine will run on Straight Vegetable Oil Skoldatanätet - Lexin Sporthoj.com - Sveriges Största Hemsida För Motorcyklister - RR - Radical Riders Pedersöre kommun http://kartat.eniro.fi/ Jämför hotell - Fritidsresor.se Ayia Napa, Agia Napa, Protaras, Cypern. Semester kan inte bli bättre! Custom T-shirts - Design, buy or sell customized TShirts : Spreadshirt 5GB of free space to upload and share your files, photos, videos and music - eSnips.com Fazer Ögon. Att lyckas med choklad. Sporthoj.com - Powered by vBulletin Foreca Sää - Suomi 5 Bears -turbojet EBAMAN, Digitized manual collection :Gallery
el mittausvirhe BEVI Elektronik - Komplettes Skript Index of /ElektronikForumet All About Circuits : Free Electric Circuits Textbooks Electronics Forum (Powered by Invision Power Board) Comfile Technology Inc. PLC
skola Formulas to solve 3rd degree equations (or Cubics). Area48 - HP48/49 for beginners! - Main Page hpcalc.org - HP48 Software Archive Free Online Course Materials | MIT OpenCourseWare IEA - Lund University ordlista el engelsk Lexin - Svensk-engelskt lexikon Yrkeshögskolan Novia - För studerande
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Misc LM2917 - Frequency to Voltage Converter Charge pump - Wikipedia, the free encyclopedia ::: ALLDATASHEET.CO.KR - Datasheet search site for Electronic Components and Semiconductors, integrated circuits, diodes, triacs, and other semiconductors. L298N datasheet, L298N data sheets, L298N pdf, L298N download STMICROELECTRONICS ::: ALLDATASHEET ::: Stegmotor styr-krets Wave tuning / intake port length question - Speed Talk Resultat av Google:s bildsökning efter http://www.maxracesoftware.com/Reversion_in_Chamber.jpg The 4029 CMOS Counter IC Jones on Stepping Motors Pulse Width Modulation 2 PWM Signal Generators Electronic Tachometer circuit Digital to Analog Conversion DAC - Digital-to-Analog Converter JPmotorsport http://www.bgsoflex.com/cgi-bin/intakeln?length=20
Endurance Finnish Endurance Drivers FED http://www.metsys.fi/ana/ajanotto.html MUT-Palvelu
Megasquirt http://www.diyautotune.com/images/circuit_diagrams/v3-switch-circuit-example.jpg
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Teknik Sam's Laser FAQ - Preface, Introduction, What is a Laser?, Safety Inventgeek.com - Your source for inventing and reinventing projects LimitlessBoredom - Jet Engine Build Log Reaktionsmotor 12 - både vacker och stark - IDG.se
Robot hasseslabb RoboCut RobotShop.ca

Tech Stuff by Johan

Summer update

Removing turret from Mazak lathe 14.4.2009

Formula renault 5.4.2009

Engine lift 24.2.2009

Ice Racing 19.1.2009

Last weekend... 14.1.2009

Crosscart movie 7.1.2009

Machining 30.12.2008

Indexing table 18.12.2008

Weekend update 15.12.2008

4-axis machining 11.12.2008

Painted the tube bender 8.12.2008

Solidworks 5.12.2008

Electrical cabinet 4.12.2008

New CNC parts 28.11.2008

Crosscart by Bob 24.11.2008

Strands s32 CNC retrofit 23.11.2008

Vertical Milling Machine 22.11.2008

Geared Head Bench Lathe 22.11.2008

Some pics of the Tube bender 18.11.2008

The crosscart project 15.11.2008

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