174 lines
7.4 KiB
Markdown
174 lines
7.4 KiB
Markdown
# The "Holy Grail" 3040L CNC (PCB Specialist)
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**Project Goal:** A high-precision, desktop CNC machine optimized for PCB manufacturing (0.8mm drilling, isolation routing) and light aluminum work.
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**Architecture:** Raspberry Pi (gSender) via WiFi → **PiBot FluidNC Controller** → External Drivers → Industrial Mechanics.
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---
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## 1. Bill of Materials (BOM)
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### Mechanical Base
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* **Frame Kit:** CNC 3040L (6061/6063 Hard aluminum alloy).
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* **Table material:** 320 * 520mm (20mm aluminum alloy T table).
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* **Engraving area：** 260*380*110mm
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* **Z-Axis Stroke：** 110mm
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* **Drive System:** 1605 Ball Screws (16mm, 5mm pitch) and HG20 Square Linear Rails on all axes.
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* **Coupling:** 3x **Plum couplings**.
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### Spindle & VFD
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* **Spindle:** 1.5kW, 220V, 5A, 24,000 RPM (400Hz) Water-Cooled Spindle (Diameter 80mm).
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* **VFD:** Huanyang HY01D523B (1.5kW, 220V).
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* **Collet System:** **ER11** (Upgrade to AAA-Precision collets recommended for PCB work).
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* **Water pump:** 80W, 6M lift with 8mm OD / 6mm ID piping.
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### Control Electronics
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* **Controller:** [PiBot FluidNC GRBL Laser CNC Controller V4.7](https://www.pibot.com/pibot-fluidnc-grbl-cnc-controller-v4-7).
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* *More info:* [wiki.fluidnc.com](http://wiki.fluidnc.com/en/hardware/existing_hardware#pibot-fluidnc-grbl-cnc-controller-v47)
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* *Schematics/PCB:* [oshwlab.com](https://oshwlab.com/pi3d14/pibot-fluidnc-grbl-cnc-controller-v4-7a)
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* **Stepper Drivers:** 3x **DM542** (Digital External Drivers).
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* **Motors:** 3x **NEMA 23** 57BYGH76 Stepper Motors (3.0A, ~1.5Nm+ torque).
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* **Limit Sensors:** 3x **LJ12A3-4-Z/BX** (Inductive NPN NO).
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* *Note: The PiBot V4.7 features built-in 0-10V analog output and opto-isolated inputs, eliminating the need for separate converter modules and isolation boards.*
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### Power System (Dual PSU)
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* **Motion Power:** Mean Well **LRS-350-24** (24V, 350W) for Drivers.
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* **Logic Power:** Mean Well **MDR-20-24** (24V, 20W DIN Rail) for PiBot Board & Sensors.
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### Safety & Control Box
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* **Main Switch:** Big Rotary Isolator (Cuts L & N).
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* **EMI Filter:** 250V 10A + IEC C19 Socket + T10A Fuse.
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* **Main Contactor:** 4-Pole AC Contactor (24V DC Coil).
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* **VFD Breaker:** Jotta **C10** (2-Pole DIN Rail MCB).
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* **Buttons:** Green (Start NO), Red (Stop NC), E-Stop (Mushroom NC).
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### Cooling & Accessories
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* **Coolant:** Distilled Water (80%) + Automotive Antifreeze G11/G12 (20%).
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* **Flow Sensor:** **HT-30** (G1/2") wired to VFD "External Fault".
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* **Probe:** **GX12-2** Connector + Touch Plate.
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* **Laser (Optional):**
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* **405nm (500mW):** For curing Solder Mask / Dry Film Photoresist.
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* **Buck Converter:** 24V to 12V (if laser is 12V).
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---
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## 2. Wiring Schematics
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### A. Power Flow (Input)
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1. **Wall (230V)** → **IEC Filter** → **Main Rotary Switch**.
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2. **Rotary Switch** → **Small 20W PSU** (Logic Power).
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3. **Small PSU (24V)** → **Start/Stop Buttons** → **Contactor Coil**.
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4. **Contactor (Power Contacts)** → **Big 350W PSU** & **VFD Breaker**.
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5. **VFD Breaker** → **VFD Input**.
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### B. PiBot V4.7 to DM542 Drivers
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The PiBot V4.7 uses 5V logic shifting for axis signals. The following diagram illustrates the **Common Ground (GND)** wiring logic used in this build.
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| PiBot Axis Header | Wire Color | DM542 Input | Function |
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| :--- | :--- | :--- | :--- |
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| **STP** | **Green** | **PUL+** | Step Signal |
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| **DIR** | **Blue** | **DIR+** | Direction Signal |
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| **EN** | **White** | **ENA+** | Enable Signal (Optional) |
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| **GND** | **Black** | **PUL- / DIR- / ENA-** | Common Ground |
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### C. DM542 DIP Switches
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*Settings optimized for **NEMA 23** and **High Precision PCB Work (1/16 Microstepping)**.*
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**1. Current Settings (SW1 - SW3):** Target **2.84A Peak**.
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* **SW1: ON, SW2: ON, SW3: OFF** (Recommended Start).
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**2. Idle Current (SW4):**
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* **SW4: OFF** (Half Current - reduces heat when the machine is idle).
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**3. Microstepping (SW5 - SW8):** Target **3200 Pulse/Rev**.
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* **SW5: ON, SW6: ON, SW7: OFF, SW8: ON** (Result: **640 Steps/mm** with 1605 screw).
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### D. Spindle Control (0-10V Direct)
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The PiBot V4.7 includes an integrated 0-10V circuit.
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**Signal Connection:**
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* Locate the **10V Spindle Interface** terminal on the PiBot.
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| PiBot Output | VFD Terminal | Function |
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| :--- | :--- | :--- |
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| **0-10V** | **VI** | Analog Voltage Control |
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| **GND** | **ACM** | Analog Common |
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| **Spindle Fwd** | **FOR** | Forward Signal |
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| **Spindle Rev** | **REV** | Reverse Signal |
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| **Common** | **DCM** | Digital Common |
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### E. Probe (GX12)
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* **Pin 1 (GND):** Alligator Clip.
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* **Pin 2 (Signal):** Touch Plate (Connect to PiBot Probe Input).
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* *Safety:* Confirm continuity from spindle bit to ground before probing.
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---
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## 3. Cables & Connectors
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Proper shielding is critical to prevent EMI from the VFD from interfering with the limit sensors or stepper signals.
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* **Spindle:** **GX20-4** (Double shielded **TRVVP 4x1.5mm²**). *Note: High-flex, oil-resistant for drag chains.*
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* **Motors:** **GX16-4** (Double shielded **RVVP 4x0.5mm²**).
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* **Sensors/E-Stop:** **GX12-3/GX12-2** (Shielded **RVVP 0.3mm²**).
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| TRVVP (High-Flex Drag Chain) | RVVP (Standard Shielded) |
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| :---: | :---: |
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---
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## 4. FluidNC Installation & Configuration
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1. Download the latest release from [FluidNC GitHub](https://github.com/bdring/FluidNC/releases/latest).
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2. Unzip and run:
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```bash
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./erase.sh
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./install-fs.sh
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./install-wifi.sh
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```
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3. Use `fluidterm.sh` to set your WiFi:
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```
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$STA/SSID=MyWifiSSID
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$Sta/Password=YourPassword
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```
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4. **Configuration:** Upload your `config.yaml` using the Web UI (usually at `192.168.1.xxx` or via `CTRL+U` in terminal).
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* *Note:* Ensure the Pin mapping in `config.yaml` matches the PiBot V4.7 PCB silkscreen (e.g., Step pins, Dir pins, and the 0-10V pin).
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---
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## 5. First Run Checklist
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1. **Unlock:** Send `$X` to clear `<Alarm>`.
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2. **Sensors:** Trigger limit switches manually; verify `Pn:X/Y/Z` in console.
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3. **Spindle VFD:**
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* Program VFD parameters (see Section 7).
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* Check Water Flow
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* Test `M3 S12000` for 50% speed (200Hz).
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4. **Probe:** Test contact with a multimeter/console before performing a Z-zero.
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---
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## 6. Complete VFD Settings List (Huanyang HY01D523B)
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For **1.5kW, 220V, 400Hz** spindle:
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| Parameter | Description | Setting | Notes |
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| **PD013** | Factory Reset | **8** | Clear old data first. |
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| **PD005** | Max Freq | **400.0** | |
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| **PD004** | Base Freq | **400.0** | **CRITICAL:** Do not leave at 50/60. |
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| **PD003** | Main Freq | **400.0** | |
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| **PD141** | Rated Voltage | **220** | |
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| **PD142** | Rated Current | **5** | |
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| **PD143** | Motor Poles | **2** | High-speed CNC spindles are 2-pole. |
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| **PD144** | Rated Motor Revolution | **3000** | As calculated above (3000 @ 50Hz). |
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| **PD002** | Freq Source | **1** | External Terminal (0-10V). |
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| **PD001** | Commands Source | **1** | External Terminal (FOR/REV). |
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| **PD070** | Analog Input | **0** | **0-10V** (Standard for PiBot). |
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| **PD072** | High Analog Freq | **400.0** | Scales the knob so "Max" = 400Hz. |
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*For advanced spindle control, see [FluidNC Spindle Config Documentation](http://wiki.fluidnc.com/en/config/config_spindles).* |