Nichols Miter Build: Bicycle Framebuilding automation

[ToddFarr]

This is slowly starting to get pretty intense so I figured I would start documenting my Nichols Hand Mill Build. I'm working through a semi-automated tube mitering setup, something that I can set and forget and have it cut the tube and return to the home position. This thread will document the build. If you guys have any questions don't hesitate to ask.

Here is how the mill looked when I picked it up


After some serious Cleaning:


Ripping out all the old wiring and going to be putting in a VFD:


Phase II Rotary Table and Servo Controlled Y-Axis Automation Underway:


I've chosen to use a Panasonic FPe PLC to control the Y-axis. Mostly because I got it for free, and it's a nice little contained unit. My plan is to be able to set the Y-axis Feed Rate in inches per minute, 0.100"/min in this case. The Servo will move the table at this controlled speed either for a set distance or until a proximity sensor is tripped. This will stop the system and the Y-axis will reset to a home position.


More to come.
Thanks - Todd.

[ToddFarr]

Had a few hours to work on this tonight.

Here are some detail shots of the Motor Mount.





Took the Old handle off the Y-axis and repurposed it.



For full build picture here is the Set Link on my flickr Nichols Milling Machine - a set on Flickr

[sam]

Seems like you like to build tools, more then you like to build frames, haha just teasing. Nice work, as far as nichols go you got one of the newer ones,

[ToddFarr]

Yeah it would appear that way! Actually I just bought a ring for my fiancee a few months ago that kinda put me in a financial situation if you know what I mean!!! Don't get me wrong totally worth it and she deserves it. But anyways lugs and tubes cost money, as for aluminum, motors, controllers, and my time, well that's all free thanks to my real job. I'm one of those people that always needs to be doing something, so if I can't build bikes right now I might as well build tooling for bikes!

As far as I can tell it was made in the 80's?

[ToddFarr]

"Black" from Anodizing



And here is a video test of the power Feed, before I wire it all in, add the buttons and make it all pretty!

The Power Feed Test | Flickr - Photo Sharing!

[ToddFarr]

Finally got a VFD and had a chance to Gut the controls box tonight. If anyone is looking for a nice VFD at a good price, this is where I bought mine 2HP 230 Volt -- USE AS A PHASE CONVERTER PLUS GET VARIABLE SPEED, Model JNEV-202-H1, Single Phase Input ONLY, Three Phase Output, variable frequency drive, variable frequency drives, ac drive, vfd, afd, frequency drive, drive, inverter, adjustable sp

The plan:


Control Box


Just have to wire in the remote panel now! I finally feel like this project is getting close! It's been sooooo slow with everything else going on in my life!

[Ken Cameron]

OK, I've struggled with removing the long axis production handle on my machine. IT was replaced with a ugly shop made piece of junk that gets in the way of every thing. How did you get it off? Great work btw. Is the VFD going to control the infeed axis servo (stepper?)?

[ToddFarr]

Hey Ken,
Thanks for the compliment. I would have to take a look at it again, but if I remember correctly the gear on this shaft that is part of the rack and pinion has 1 or two set screws on it. They hold onto the shaft and the key on the shaft. I moved the table until I could access them (or 1 I can't remember of the top of my head) and removed both of those and then use a chunk of aluminum and a hammer to tap the back side of the shaft until it slid out.

The VFD is going to control the Spindle RPM. Here is the CAD I worked up for the new Panel, I'm just waiting for the parts to come in.



The PLC will be sending pulse trains to the Stepper Driver (This stepper has feedback so kinda behaves like a servo in the sense it closes the loop). The PLC will have a protective cover over it, and will be mainly used to display the current feedrate which is adjustable by the momentary 3 position selector switch. To raise or lower the feed rate you will simply turn it to + or -. The feed rate will be on a ramp up ramp down function meaning it will start counting slowly and start counting faster the longer you hold it. The PLC will also receive an output from the VFD which says its running or not. This will make it so the Miter cycle cannot be initiated until the Spindle is running. The middle button will allow jogging of the Y-axis Forward and Back. And then there will be a spindle speed potentiometer in the lower corner of the panel. My plan is to eventually put some sort of tach on the spindle too.

There will also be two proximity sensors on the Y-Axis to prevent movement to far in either direction. A separate E-stop will be mounted in its own housing as well to shut down the complete cycle.

-Todd

[ToddFarr]

If this project has done anything for me, it's made me want to turn in the Bridgeport and buy a CNC Knee Mill.

Had a chance to borrow a friends CNC machine to bust this out on Monday. Now you still have to have the machinist mind set to determine the best way to make a part, but man what a time saver....





I had it lift a bit on me on the backside pocket where it didn't have that center screw, but no one is gonna see that anyways right ;)



Anyways it's off to Anodizing, then back in the CNC for engraving.

-Todd

[mjbabcock]

bad ass iPhone case!