My dark 20 years history in making

There are different concepts out there, depends on what you want to do with the device or what you want to spend… would be probably best to check the cad cam channel of RCgroups at this point as they are busy with that stuff for years now… ( Iwas one of the first posting about and this might be more then 10…12 years ago…)

To proceed with the timeline, I produced several 10 models, kits, planes from EPP for buddies and the club before I recognized it to be boring to do all the same process again… For my previous job I had the Idea for a
Device which I call the CNC killer gun. A portable CNC with which I was able to do quick and precise developmental moves at the customers site, and with the customer in a very quick manner. Unfortunately I had a boss which felt in a way unfortunately affected by the idea and so blocked it whereever possible.
So my direct superior liked it, the CEO too, - but the technical director blocked the idea wherever he was able to.

I’m not permitted to show much of that time as the IP is linked to the company I was working for, but some clips linked to the CNC…

40kg including pc and case, and transportable in a wooden box

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Someway paralyzed by the so called blocking I changed my doing and further worked on my CAD , and rendering skills I own a pretty old licens of C4d and so tried myself in character moddeling… ( this should be an Uruk Hai Orc from the Lord of The Ring, (clan of the white hand)

UEBER2 UKO1 URUK8

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Going through all the planes and builts I did over the years should be rather boring for most non RC - addicted persons so I would continue with eqipping the toolshop.
I passed my studies in Black Forrest, in an location which previously was used as a watchmakjng school. And once a year there is a big watch related meet and greet and trade weekend. Went there , wanted to buy a watch making lathe but that one I wanted was off right before my eyes.
So I got frustrated, went home again and built my own lathe…

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From that time I recognized that all my walls were full of planes and there was no space left for more… time to change my direction of making. And as the lathe was just finished it needed some testing…

So I decided to buy a Swiss watch movement and started to make the environmental parts from Nickel free Stainless Steel and Brass and gathered my first experiences in electroplating.


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Success raises ambitions, so I thought about the possibility to get smaller in parts and technologies and tried myself in producing watchparts for my own purposes…

inbetweenb

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From visual to functional parts…

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I know next to nothing about watchmaking. Did you cut all those parts by using the lathe as a milling machine by putting a mill in the spindle and mounting the stock on the cross slide? (Thanks for continuing to share this journey with us!)

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Nope. First I bulit a router , then I built the small portable router with the big one (clip above). If you watch the hot wire CAD picture and virtually remove both the posts for the z Axis but add a gantry instead you have my big router. Then I used the big one to build the lathe.

Most above parts are done with the first big router, a few with the lathe.
Mostly used tool for that parts is a 0.3mm flat tip shaft bit. Some engravers and bigger flat tips for the surface patterns the posts of that tourbillon in the last pic are syringe needle pieces threaded with 0.5mm from both sides. E.g. the gears are made using a 0.3mm shaftmill . The precision plained brass is fixed to a HPL lost stock plate using CA. The part is shaped and afterwards the CA is dissolved over night in Acetone…

thats all…

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WOW! That is truly amazing!

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There is much more “material” left but too much of the same kind might be boring…


This is done in similar way but not from Aircraft grade aluminium but from cold working steel. Conceptual design… too heavy…
Very fancy parts can be done same way, routed half way from stock then refilled with CA (activated with mild tenside as it is an anaerobe adhesive which needs initators to crystallize on)
The dashes have a width of appr 0.08mm the screwhole is 0.5mm still embedded in CA to be dissolved

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Getting closer to today … When buying my Ramps board for my 3D Printer I thought the boards were so cheap that I had to take 2 sets… thinkering about whatfore to use the second set I decided to do something beside p

rinting

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I think I now should break the timeline as we are close to status quo, - but not to bore you I left out many projects over the time…

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Recently: as I have told, I’m currently digging into watchmaking.
The latest challenge are two vintage quarz watches with defective coils of the lavette stepper motors.
Unfortunately those coils are wound with 0.02mm
enamel wire which is not possible to be wound by hand. At least not by n= 1800 .
So I started buliding a coil winder…

!
First part is the wire auto support with someway a constant tension source.
( until now ist just mechanics but the uc boards should arrive by next week)

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28mm Axis with the winding stepper motor

Shafts still have to be fitted / trimmed and the locking screw holes to be threaded …


Done…
Functional test with existing electronics and slightly too high current values ( did not want to adjust those)… done…

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Meanwhile I setup the harnesses of the light barriers… as I try to have a 5 states wire support indicator using an array of light barriers, I recognized that there is too much light emitted so the phototransistors are not fully high impedance. Perhaps I need a comparator PCB to have clear digital signals.
I also did a simple sketch to get the axis moving but recognized a strange thing I will have to check tomorrow.
Each I/O I need is initialized to be an output and pre loaded with the initial state. The sketch consists of two for loops to apply the stepping signals to the polulu driver shields. When the program starts the feeding motor does several steps into the wrong direction before changing to the right one… tomorrow I will have to see if ths would be hardware bound.

But the stepping feed is pretty acurate for the cheapish setup I run. Step width is between 0.03 and 0.05mm
With quite some elastic play under applied load conditions. But how much load can I get from a 0.02mm Copper wire, othogonal to the moving direction. :grin:

But thats it just for today…

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Today is just short, created some code lines for a discrete cheap control and tested… next would be to connect the stepper stage to the arduino instead of changing port levels only.

The screnn of the oscilloscope shows the 5 weightened frequencies which will afterwards feed the stepper to provide wire

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Both boards have a very reduced core loop program not to get the controller too much from telling the steppers.
So display and variable parametrization are just open to be implemented, but will probably be added before the winding process and not during… but until now it seems to work… Test is done with 0.05mm enamel wire but 0.02mm should also work

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Finished the first revision of the dispenser software
With slightly decreasing the smooth characteristics of the stepper. Now with the right buttons pair you select the wire diameter which is shown with the resistance per meter.
Second is to adjust the resistance you want to dispense /apply then press enter and the dispenser counts the length, calculates the resistance and as the adjusted value is reached it shows an alarm.

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First system test on a MIYOTA stator.

Enamel wire 0.05mm Copper diameter.

7Ohm means 7.x m wire…

Wound in rather 35min.

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Finally implemented the teach in function for the winder… now its just the case for the controller

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