PROPOSED ROADMAP FOR OPEN SOURCE CNC PLANS

This document offers a roadmap for developing the OpenSource CNC Plans as recently discussed on the forum. It is offered as one person's opinion in draft and certainly open for review and critique. It begins at the general level and hopefully continues into greater detail proposing a path for creating the OpenSource CNC PlanSet. Assumptions: Hobbyist level plans - not for commercial resale Builder using the plans has some level of mechaincal expertise Builder has access to some tools to build the machine Begin small - simple to ensure success of the workgroup effort Keep options open to expand to other plans if desired/warrented Success Criteria: Plans are used - someone builds a machine and it works! Plans should identify: Limitations of the plans: Ability to scale up or down Resolution, precision and accuracy potential of the plan(s) Materials, components, build/purchase options as appropriate Linear motion components and potential sources Proven motor, power supply, controller combination Software and computer options The difficulity in developing a set of "quality plans" has been addressed elsewhere in the forum - directly and indirectly. The major challenge is choosing a course of action -- witness the numerous postings. There is a lot of interest - that needs some focus. I hope this document provides some help. Perhaps the major problem facing the group will be the wide range of options available. Some of the options include: the style (design) of the machine; the size; linear drive components (Allthread, Acme Screw, ballscrew, belts, wires, cogs); and linear motion bits (rails, rod, other). The most critical is the choice of motors (stepper vs servo); controller options (full step, 1/2 step, micro step). [The plans ought to address this as well.] Figure 1. suggests a course based on machine style.

Figure 1. Roadmap Overview

The proposed path is central and seems to reflect the largest number of DIY CNC machines being built. If not the largest number - certainly the most frequently posting! The choice of a moving or fixed gantry

could be addressed in the plans -- offering a bonus! Following the course outlined in Figure 1., the next major choice is. SIZE. SIZE: Size matters. Of course it does, but what is big and what is small? A non-scientific review of the forum and 'net suggest there are at least three major sizes of CNC machines. Small, Medium and Large. (You could super-size too) As a point of reference this roadmap suggests the following criteria for SMALL, MEDIUM, and , LARGE.
SIZE
X Axis Y Axis Z Axis

SMALL MEDIUM LARGE

< 12 inches 12 - 48 inches > 48 inches

< 12 inches 12 - 39 inches > 39 inches

< 4 inches < 12 inches > 12 inches

Table 1. Size

Smaller is easier. Small is a lower investment for the first time builder. An added benefit of building a small machine, s it can provide valuable lessons and be used to "bootstrap" to another larger machine. Then again, SMALL maybe to small for some users, so if the plans offer the opportunity for scaling up, the builder may choose to build a larger machine with some confidence of sucess. MATERIALS: The choice of building materials ranges from the plain to the exotic. Plywood, MDF, other wood products; plastics - Delrin and acrylic; and, metals, aluminium or steel are typical CNC materials. The following charts represent the use of various materials in the several sizes of machines. The move from plastics and wood products is relatively intuitive as the SIZE of the machine increases. The complexity and costs of construction increase as the materials move from the more simple wood products to metals.
metals MDF plastics SMALL metals MDF metals LARGE MDF plastics

plastics MEDIUM Chart 1. Materials

MOTORS:: As the builder succedes, they may discover they want to build a larger machine. It would be real important for the plans to address the integration of the motor, power supply and the controller -- and the relationship to the size of the system. By addressing this critical area, the builder can make informed choices -- even if they build a small system with the plan of migrating to a larger one. If/when the builder discovers they want to move to a larger system - they wouldn't want to be saddled with a set of gear thats too small for the new system - unless of course they want two machines! So again, a non-scientific chart relating motor size to system size:
C A C B SMALL MEDIUM Chart 2. Motor Size D B

B D C

LARGE

The motor sizes have been identified as "A", 'B", "C", and "D". These are meant to represent appropriate oz/in torque values to be developed and recorded during the plan development process.
(sorry - don't yet have the data from the surveys-- else that could point a path here)

LINEAR DRIVE SUBSYSTEM: The next category the plans set should address is the Linear Drive components. Choosing BallScrews certainly affords an increase in system resolution and the potential for creating very accurate parts - but there is a cost associated that the plans could address. By offering the choice of the various options available, Allthread, Acme Screws, or BallScrews, the plans would give the user/builder a range of options. Tips and pointers like how to build your own anti-backlash nuts for allthread/acme screws would be valuable too. A listing of suppliers would be important too. LINEAR MOTION: The plans should identify the variety of linear motion (control) options available. Simple drawer slides; black iron pipe with bearings; 80/20-style slides; drill rod and bearings; Thompson-style and THK style options are typical of the choices a builder must make. If the plan set outlined the differences between the available choices, the builder could make better informed decisions as where to spend their money. For a small system scrounged bits from an old printer might be more than sufficient, but offer little room for later expansion. A clear identification of the opportunities and choices available help identify the builder's path. Here again, catalog or web references to availability would be important too. CONTROL -- SYSTEM INTEGRATION: The plan set would afford some opportunity for the builder to 'learn-as-they-go". But the builder shouldn't have to discover through endless experimentation and expenditure of what works - and what doesn't. So, integrating the motor with the power supply and controller is very important (this section may have to be more specific). A quick discussion of: the merits of servo vs. stepper motors; a description of unipolar and bipolar and the merits of each; full step, 1/2 step and microstep controllers is important too. If the builder is even thinking of migrating to a larger system, they should be cautioned and encouraged to size their motor/controller/power supply sub system based on the desired end size, or else build a second system that is separate from the first. CONTROLLER: The options include DIY for those Builders who have the skill and experience in electronics. Else, plugand-play options ought to be outlined. The integration of power supply and motors is also critical - so examples of what works based on the various motor sizes identified above would be helpful. COMPUTER/SOFTWARE: Left for last, this is an area that is relatively easily described. The choice of software dictates the size and type of computer required. DOS-based applications do not require the same level of performance as other 45,000+ stepping systems might. The builder's choice of software could be ecconomicaly based - as would the selection of the computer. The ROADMAP is offered as an approach to developing the plans for the cnczone.com. It is the opinion of the author - High Seas, and is offered for your consideration, comment, and critique. Thanks - Cheers, Jim