Tech Stuff by Johan

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Summer update
2009-07-05 14:07:00
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
2009-04-14 18:07:00
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
2009-04-07 05:03:00
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
2009-02-26 00:18:00
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
2009-01-20 16:00:00
Great conditions for some ice racing last weekend! I have also been working on the indexing table design.

Last weekend... 14.1.2009
2009-01-14 15:27:00
...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!

Machining
2008-12-30 22:41:00
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
2008-12-18 18:56:00
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
2008-12-14 23:41:00
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
2008-12-11 14:19:00
Here is a video by Hoss: Endmill Sharpening with 4th AxisVery impressive machining!Read more about his machine here:http://www.hossmachine.infocnczone threadI found the link here

Painted the tube bender 8.12.2008
2008-12-10 08:58:00
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
2008-12-07 16:46:00
If you are a student you can buy cheap software from studica. I bought Solidworks from their webshop.

Electrical cabinet 4.12.2008
2008-12-07 16:46:00
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.

bookmarks
2008-12-07 16:46:00
Bookmarks Hämta Opera Operavänner Opera Web Mail Användarstöd Aftonbladet Sveriges nyhetsportal MSN.com rejsa.nu Det är kul när det svänger! zatzy racing community Wccc.fi Index MiniBuggy.Net Svenska ElektronikForumet -- Index 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 ...

New CNC parts 28.11.2008
2008-12-03 16:34:00
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 DevicesDetails 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/ODetails about the BL70-300 servomotor:-Rated power 300...

Crosscart by Bob 24.11.2008
2008-12-03 16:34:00
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
2008-12-03 16:34:00
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 sometimeAs 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...

Vertical Milling Machine 22.11.2008
2008-12-03 16:34:00
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.) ...

Geared Head Bench Lathe 22.11.2008
2008-12-03 16:34:00
Geared Head Bench Lathe - 13'' Swing 40'' Centers, 2Hp, 1 Ph, 230VIn 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....

Some pics of the Tube bender 18.11.2008
2008-12-03 16:34:00
Click on the pics to view in detail

The crosscart project 15.11.2008
2008-12-03 16:34:00
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
2008-12-03 16:34:00
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
2008-12-03 16:34:00
Feel free to comment on the blog or to contact me by email: nygard.johan@gmail.com