CNC DIY 7x7 2008 Assembly Instructions

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After you receive the package, the first thing is to check whether there is any damage to the box during the shipping. If you found any, please inform us as soon as possible. The shipment is insured through UPS.

When you open the package, you will need to count the parts according to the content list below. For this model, we have engraved the part number directly on the PVC frame to make it easy for you to identify.

Contents


Packaged Frame Parts

1Clamp (Not used in machine construction)2
2Motor Support3
3End Ball Bearing Holder 4
4Z Axis Slide Support, Upper 1
5Z Axis Slide Support, Lower 1
6X Axis Slide Support, Near Motor Side 1
7X Axis Slide Support, Far Motor Side 1
8Z Frame Support, Far Motor Side 1
9Z Frame Support, Near Motor Side 1
10Y Axis Slide Support, Near Motor Side 1
11Y Axis Slide Support, Far Motor Side 1
12Motor Side Support 6
13Y Axis Frame Support, Far Motor Side 1
14Y Axis Frame Support, Near Motor Side 1
15Y Axis Side Frame 2
16Cutting Mounting Plate 1
17X Axis Vertical Frame, Left Outter 1
18X Axis Vertical Frame, Left Inner 1
19X Axis Vertical Frame, Right Outer 1
20X Axis Vertical Frame, Right Inner 1
21Z Axis Back Support 1
22X Axis Back Support1
23Working Table1

24. (No longer included in the package) Cutter holder bracket (If you have Fordom Flex Shaft Handpiece, 1 inch diameter, you can use, otherwise, you will need to make you own holder). 2

Packaged Hardware

1Step motor flex coupling 3
2XY Axis Glide Rod 4
3Z Axis Glide Rod 2
4XY Axis Lead Screw 2
5Z Axis Lead Screw 1
6Anti Backlash Assembly(Front, Rear and Spring combo)3
7Stepper Motor (2 Phase, 6 wire) 3
8Stepper Motor Connection Wire 3
9Linear Ball Bearing X,Y and Z 12
10Leadscrew end support ball bearing6

Packaged Screws

  • A - M3 x 10 Pan Head Machine Screw (12) (Between motor support and motor)
  • B - M4 x 20 Hex Machine Screw (See instruction below)
  • C - M6 x 15 Hex Machine Screw (8) (For Y, Z Axis guide rod to the frame)
  • D - M6 x 24 Hex Machine Screw(4) (For X Axis guide rod through double frames)
  • E - M6 x 30 Hex Machine Screw(4) ( For attach X Axis assembly to the base)
  • F - M3 x 20 Wood Screw (For those small holes you find)

Install Y Axis

STEP Y-01

STEP Y-01
First of all, let's lay out all parts for the Y Axis.
Front and side frame, slide support frams, lead screw, guide rods, linear ball bearings and screws.
Screws Used
A - 4 (Motor & #2)
6 (#3 & #14; #3 & #13, Anti Backlash Nut $ #10)
4 (Guide Rod & #13, Guide Rod &#14)
16 (#13 & #15, #14 & #15, #14 & #12)


STEP Y-02

STEP Y-02
Here is a close up photo of the parts.


STEP Y-03

STEP Y-03
Here is another close up photo:


STEP Y-04

STEP Y-04
A close up on far motor side


STEP Y-05

STEP Y-05
A close up on the near motor side


STEP Y-06

STEP Y-06
The shorter shaft of the lead screw will be pushed into the end ball bearing holder (3). It is a tight fit. Hope you will have a long clamp to do this job. I am using a drill press so that I can align them properly before the push. You need to apply the pressure straight into the hole, be very careful not to bend the lead screw. This probably the most critical part of the entire installation. The longer shaft of the lead screw has a loose fit with the ball bearing.


STEP Y-07

STEP Y-07
Here is how I push the linear ball beaing into the slide support frame. A bench vise will do the job very well. Make sure you push the bearing to the bottom of the hole. Don't use a hammer here, no matter how skillful you are with hammers.


STEP Y-08

STEP Y-08
After four linear bearings get installed into the sliding support frame, you can assmeble the guide rod. Sorry, this photo came in early, a few more steps before this.


STEP Y-09

STEP Y-09
This picture shows all linear bearings have been installed onto slide support frame. Notice the orientation of the parts. Two bearings must be on the same side of the frame. Which side does not matter.


STEP Y-10

STEP Y-10
Now, slide the lead screw through the Y Axis frame support, far motor side, as shown below. No need to install screws at this moment.


STEP Y-11

STEP Y-11
Get parts aligned now. It is better do this every step. Sometimes mistake you made is not very obivious, and when you find it, you will have to roll back a few critical step. Slow down and check often.


STEP Y-12

STEP Y-12
Now, let's put anti backlash nut together. First, screw the small end into the lead screw half way. Then put the spring on. After that, put the bigger on and apply some pressure to the spring. How much pressue to apply? Leave the gap between two parts about 1/8 inch will be fine. You need to check whether you can turn the lead screw easily in the nuts. Too much pressure will help remove the backlash, but it will cost the lift time of the leadscrew and nuts because of the extensive friction. Apply some lube to the lead screw before you operate the machine.


STEP Y-13

STEP Y-13
Here is the anti backlash nuts installed on the lead screw.


STEP Y-14

STEP Y-14
Now you can screw the anti back lash nuts to the slide support frame. Remember, do NOT make the screw too tight at this point, you will need to adjust the alignment later.


STEP Y-15

STEP Y-15
You need to clean the rod before install. It can be cleaned by putting a little bit of WD-40 on to it, and then wipe it off with a paper towel. The WD-40 can also be used as prime lubrication on lead screw.
We are ready to install the guide rod into the linear bearings.


STEP Y-16

STEP Y-16
During this step, be very gentle when you push the guide rod into the bearings. Adjust the direction and turn the rod slowly during the push. If the little ball come out of the bearing, it is no fun to find them on the floor and even harder to put them back in.


STEP Y-17

STEP Y-17
Here is when two guide rods have been installed for Y axis.


STEP Y-18

STEP Y-18
Now, screw the rod and frame together. Remember, not too tight, we will need to adjust the alignment later.


STEP Y-19

STEP Y-19
The screws are now installed.


STEP Y-20

STEP Y-20
Now we are ready to install the near motor side frame and side frames. Layout and double check before continue.


STEP Y-21

STEP Y-21
Slowly ...


STEP Y-22

STEP Y-22
Here comes the end ball bearing holder(3). On this end the lead screw shaft and ball bearing have a loose fit.


STEP Y-23

STEP Y-23
At this step, you should check whether you can turn the lead screw easily with your hand. If you feel too much resistance, check the alignment on linear ball bearings and anti backlash nuts assembly.


STEP Y-24

STEP Y-24
Now you can install side frame.


STEP Y-25

STEP Y-25
Using a powered screw driver will save you a lot of muscle strength, but be sure, don't make the screw too tight or ruin the screw.


STEP Y-26

STEP Y-26
Check the squareness often. Out machine usually aligns itself very well. But double check won't hurt.


STEP Y-27

STEP Y-27
Ready for motor assembly now. Here are two motor side support frame.


STEP Y-28

STEP Y-28
The motor will be mounted onto a motor support frame (2).


STEP Y-29

STEP Y-29
Motor mounted onto the motor support(2) frame.


STEP Y-30

STEP Y-30
HNow, ready for the final motor assembly attachment. Make sure the set screws on the coupling are loosen before put them together.


STEP Y-31

STEP Y-31
Screw the motor support (2) to motor side support frame.


STEP Y-32

STEP Y-32
Now the motor is mounted to the frame. Let's finally check the alignments and make sure the leadscrew can be turned by hand easily.


STEP Y-33

STEP Y-33
Here is your Y Axis assembly, just need to put on the working table.


STEP Y-34

STEP Y-34
Now let's tighten all screws up, remember, not too tight. Some screw holes on the frame are made very tight, you will probably screw the screws into it.


STEP Y-35

STEP Y-35
Time to attach working table to the Y Axis, not much to say here, screw them in. The screws are pretty soft, so make sure do it slowly. You don't need to put the working table on at this time, it will make it easier for your test if you have the access to all moving parts.


Install X Axis

STEP X-01

STEP X-01
Now we can start our X Axis assembly. As before, lay out the parts first. We use two side frames on each side to increase the strength of the machine, the machanism of holding the ballbearings are little different from the Y and Z axis. The ball bearings are directly pushed into one of the side frame, and other frame will close it up. The rest will be pretty much same as the Y Axis.
Screw Used:
A - 4 (Motor & #2)
B - 2 (Anti Backlash Nut & #6)
E - 4 (Guide Rod & #17,#18; Guide Rod & #19,#20)
D - 4 (#17,#18,#19,#20 & #15)
F - 24 (#20 & #12; #12 & #2; #17,#18 & #22; #19,#20 & #12)


STEP X-02

STEP X-02
Motor side close up view.


STEP X-03

STEP X-03
Otherside close up view.


STEP X-04

STEP X-04
Leadscrew, guide rod, linear ball bearing and slide support frames...


STEP X-05

STEP X-05
Here is the method I use to push the leadscrew shaft into the ball bearing. The short shaft has a tight fit with ball bearing. You probably don't have this type of equipment, use some other tool you think will do the job. Again, no hammer during the entire process !!.


STEP X-06

STEP X-06
Pushed half way in.


STEP X-07

STEP X-07
Here it is, the short shaft of the lead screw has been installed onto the far motor side frame. If you found the fit is loose, don't worry, use a center punch slightly make a dent on the shaft and that will make the fit tight again.


STEP X-08

STEP X-08
Put other piece of the frame on.


STEP X-09

STEP X-09
Now ready for the slide support installation. Lay out the parts with correct orientation.


STEP X-10

STEP X-10
Slide the left side onto the lead screw.


STEP X-11

STEP X-11
Same as Y Axis, put anti back lash nuts together on the lead screw.


STEP X-12

STEP X-12
Ready to put on other side of the frame for X Axis.


STEP X-13

STEP X-13
Screws the guide rod into the frame. Do make it tight yet, we need a final alignment check before that.


STEP X-14

STEP X-14
The motor willl be attached to this side of the frame.


STEP X-15

STEP X-15
The motor side support (12) will be inserted into those square holes for X Axis.


STEP X-16

STEP X-16
The motor side supports are installed onto the frame.


STEP X-17

STEP X-17
Same as Y Axis, install the motor to the motor support (2).


STEP X-18

STEP X-18
Here you go.


STEP X-19

STEP X-19
Ready for putting on the motor. Remember, loosen the set screws on the flex coupling first. Be careful push the coupling into the shaft, it might tight. Turn it slowly and don't bend it too much.


STEP X-20

STEP X-20
Now ready for putting on the back support (22) of the X Axis.


STEP X-21

STEP X-21
The back support is on now.


STEP X-22

STEP X-22
Now the time to tighten all screws. Leave the anti back lash nut screws the last. Make sure you can turn the lead screw within the nuts easily before you tighten this screws up.


STEP X-23

STEP X-23
Here is the back suport of Z Axis(21)


STEP X-24

STEP X-24
Screw it on to the X Axis slide support frame.


STEP X-25

STEP X-25
Now, you can put X,Y Axis together see whether they will fit. I am sure they will ;)


Install Z Axis

STEP Z-01

[[Image:7x7 STEP Z-01.jpg|frame|left| STEP Z-01
Here is the lay out of Z Axis parts.
Screw Used:
A - 4 (Motor & #2)
B - 2 (Anti Backlash Nut $ #4;#3 & #8; #3 & #9)
C - 4 (Guide Rod & #8; Guide Rod & #9)
E - 8 (#9 & #12; #2 & #12)

STEP Z-02

STEP Z-02
First, need to push in the leadscrew shorter shaft into the ball bearing, which is already installed into a end ball bearing holder(3).


STEP Z-03

STEP Z-03
Now, we need to slide the lead screw into the far motor end of the Z Axis frame(8)


STEP Z-04

STEP Z-04
Lay out the parts again, make sure the orientation of all parts are correct. The ant back lash nuts will be installed on the slide support (4), which is on the motor side.


STEP Z-05

STEP Z-05
The guide rod linear ball bearing have been pushed into the slide support frame (4,5).


STEP Z-06

STEP Z-06
First step of installing anti backlash nuts. Put the small nut onto the leadscrew, notice the direction.


STEP Z-07

STEP Z-07
Put the sprint on.


STEP Z-08

STEP Z-08
Put the bigger nut onto the shaft.


STEP Z-09

STEP Z-09
Apply pressure and push in the big nut toward the small nuts. A gap between two nuts shold be aound 1/8 inch


STEP Z-10

STEP Z-10
Anti backlash nuts installed onto the slide support frame. The photo didn't show that you should leave the screws loose, prepare for the later alignment adjustment.


STEP Z-11

STEP Z-11
Guide Rods have been slided in. Becareful, turn the rod slowly and don't push hard if it stucks.


STEP Z-12

STEP Z-12
Ready for the motor parts, here are the motor side support (12) and motor side Z frame (9).


STEP Z-13

STEP Z-13
Motor side support frame (12) has been screwed to the Z Axis near motor frame (9).


STEP Z-14

STEP Z-14
Attention!!. In this photo, the orientation of the slide support of motor side is wrong. It is very easy to make this mistake. Fix it now. I didn't do this on purpose, but I want to show you this photo to get your attention.


STEP Z-15

STEP Z-15
Ready for Z Axis motor


STEP Z-16

STEP Z-16
Again, Motor install.


STEP Z-17

STEP Z-17
Motor mounted. You decide the wire connector orientation based on how you want to connect the machine to your stepper motor driver. For Z Axis, I like to face the connector backwards.


STEP Z-18

STEP Z-18
More on motor.


STEP Z-19

STEP Z-19
Now we can put all Z Axis parts together.


STEP Z-20

STEP Z-20
One more...


STEP Z-21

STEP Z-21
Before you tighten up all screws, make sure you check the alignment, and you can turn lead screw easily with you hand. Check often will save you trouble when you start test motor and driver.


STEP Z-22

STEP Z-22
You can attach the cutter plate later after you purchase you cutter. I have included a cutter bracket in the package, which can be used with Fordom Flex Shaft hand piece No. 31. But you can easily make your own with material available to you, like plywood, plastic scraps or even metal.


STEP Z-23


Now, you have completed the most part on X, Y and Z axis. Only a few more steps to put them together. I suggest wait for your driver and cutter to come before you do this. The electrical wiring do challenge us sometime, and leave the mechanical components seperately will help to identify the issues later.






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